MODULAR EXTENSION OF FZG-GEAR TEST RIG FOR IN-SITU MEASUREMENT POSSIBILITIES

Noise, Vibration and Harshness (NVH) engineering as well as gear damages are important topics for the usability of electromechanical powertrains in vehicles and for the future use of gears for any application. As part of the DFG-project sensor-integrating gear (german: Sensorintegrierendes Zahnrad (SIZA)) an FZG-gear test rig has been extended in order to allow various possibilities in sensing data close to the gear wheel and inside. The novelty of this approach is a gear that includes vibration sensors and capable of measuring close to the vibration source. FZG-gear test rigs are worldwide in operation and known out from ISO 14635 with their usability and robust design. Starting from a description of the test rig, an overview on the changes of its components for the integration of in-situ measurement is presented here. After a description of the test rig it is explained why parts are changed, which possibilities are not chosen and how the test rig is operating after the integration with the new parts. In order to minimize external disturbances of the signals, to avoid wrong assemblies as well as grant the efficient use of the test rig under the different operating conditions the internal structure, possible influence on sensing and the assembly had been considered. This paper shows how general design techniques like poka yoke had been used. Additionally, simulations and results before and after the new design are planned to show the impact of the constructional changes on the measurement results and on the tooth contact. As an outlook results of previous publications are referenced.