Universal Reducer Test Bench
Universal Reducer Test Bench — Multi-Type Gearbox Testing for Planetary, RV, Worm & Industrial Reducers
The universal reducer test bench is a flexible, high-precision testing platform built to evaluate many gearbox types — including planetary reducers, RV/cycloidal reducers, worm gears, bevel gears and custom industrial gearboxes. Designed for R&D, production verification, quality control and durability testing, this bench gives engineers accurate torque, speed and efficiency data for confident product decisions.
The Key capabilities of Universal Reducer Test Bench
High precision measurement — torque accuracy down to ±0.1% FS and speed accuracy to ±0.1% FS for reliable characterization.
Four-quadrant control — motoring and braking modes support power recovery and negative torque testing.
Programmable inertia simulation — reproduce real-world rotor and driveline inertia for accurate dynamic behavior.
Regenerative energy recovery — reduces facility power use by returning energy to the grid or local storage.
Modular fixturing — fast-change adaptors support concentric/offset shafts and multiple mounting standards.
Automated test sequences & reporting — curve-following control, pass/fail logic and downloadable reports (CSV/TDMS).
| Function Category | Specific Requirements | Note / Key Advantage |
| Speed Regulation | Supports $0 \sim 3000\ \text{r/min}$ stepless speed regulation, ensuring stable operation at any speed point over extended periods. | Wide Coverage:Meets the testing requirements of a broad range of speed reducers. |
| Fixed-Speed Loading | Applies an equal and fixed ratio load for an extended duration at a specific speed (manual or automatic loading). | High Reliability:Allows for reliable assessment of rated load capacity and thermal stability. |
| Variable-Speed Loading | Applies a non-equal load for an extended duration across different speeds. | Durability Insight:Excellent for evaluating the anti-fatigue performance and durability of the gearbox. |
| Bi-Directional Function | The testing machine is adaptable to apply load and measure performance in both forward and reverse directions. | Full-Spectrum Testing: Torque direction does not impact overall system performance. |
| Energy Feedback | The energy consumption (driving) and energy generation (loading) units are integrated to achieve bidirectional energy recovery. | Dual Energy Recovery: Maximizes efficiency in both driving and braking scenarios. |
| Manual Control | Supports manual user operation for minor adjustments and fine-tuning during testing. | User Flexibility:Ensures ease of operation and precise control for specific test cases. |
| Automatic Programming | 1. Multi-Step Speed Setting: Allows for programmed speed settings, automatically applying the corresponding load after reaching the target speed. 2. Step-wise Loading: Supports programmed loading processes: speed-up $\rightarrow$loading $\rightarrow$ speed-down $\rightarrow$ stop. | Unattended Testing:Enables complex, repeatable test cycles with precise control and minimal human intervention. |
| Humanized Design | Automatic control and functional segmentation ensure a stable and reliable control process with minimal human error. | Safety and Stability:Dedicated safeguards against system instability or operator error. |
Typical test modes
Steady-state torque & speed maps — efficiency and loss mapping across torque/speed envelopes.
Dynamic transient & acceleration tests — step loads, ramps and stop/start cycles.
Backdrive & stiffness measurement — quantify backlash, torsional stiffness and hysteresis.
Durability cycles — long run cycles with condition monitoring and automatic alarms.
Temperature & thermal stability tests — coupled with cooling rigs to measure temperature rise under load.
Technical specifications
| Item | Spec (Can be customized) |
|---|---|
| Max torque | 200 000 N·m |
| Max speed | 10,000 rpm |
| Torque accuracy | ±0.1% FS |
| Speed accuracy | ±0.1% FS |
| Inertia sim. range | 0.1 – 30 kg·m² |
| Cooling | Forced air / oil cooled |
| Interface | EtherCAT, Modbus TCP, OPC UA |
| Application Scale | Typical Torque Range | Typical Speed Range | Common Reducer Types & Applications |
|---|---|---|---|
| Small / Laboratory | 10 Nm – 5,000 Nm | 100 – 10,000 RPM | Small servo gearboxes, precision instruments, light automation. |
| Standard / Industrial | 1,000 Nm – 200,000 Nm | 10 – 3,000 RPM | Helical gear reducers, bevel-helical reducers, worm gears. Used in conveyors, mixers, packaging machinery. |
| Heavy-Duty / Industrial | 50,000 Nm – 1,000,000+ Nm | 1 – 500 RPM | Large parallel shaft reducers, heavy-duty worm reducers. For mining, cement, marine, and steel mill applications. |
When we specify a test bench for you, we consider these factors:
Reducer Size and Type: The physical size and gear ratio of the reducer under test (RUT) are the primary drivers.
Test Purpose:
Performance/Endurance Testing: Requires testing at the reducer’s rated torque and speed.
Fatigue/Life Testing: Often requires testing at over-torque conditions (e.g., 150-200% of rated torque) to accelerate failure.
Peak Torque Testing: For applications with high shock loads, you may need to validate a much higher maximum momentary torque.
Industry Standards: Your testing must comply with relevant standards (e.g., ISO 6336, AGMA 6011, GB/T 3480), which define test load levels.
Future-Proofing: We often recommend a design with a 20-30% capacity margin to accommodate future product developments.
Applications & Industries
R&D Centers: Validating new reducer designs and material performance under controlled conditions.
Manufacturing & QA: Production line testing, quality compliance, and end-of-line verification.
Heavy Machinery: Testing gearboxes for mining equipment, cranes, and large industrial drives.
Automotive: Performance and durability testing for transmission systems and vehicle reducers.
Aerospace & Wind Power: High-reliability testing for critical gear drives.
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