1. Overview
The static torsion test bench is a specialized equipment for conducting static torsion stiffness and strength tests on various mechanical transmission components, characterized by high accuracy and good stability. The control computer software of the test bench adopts WINDOWS interface programming and has a good human-machine dialogue interface. Due to the use of variable frequency speed regulation drive, the control is flexible and can meet the testing requirements of various specimens, with good adaptability.
2. Scope of application
2.1 Reference Test Standards
QC/T 29082-1992 Technical Conditions for Automotive Transmission Shaft
QC/T 523-1999 Test Method for Test Bench of Automotive Transmission Shaft Assembly
Internal standards of the enterprise
2.2 Testing Scope
This test bench is mainly used for static torsional strength and rigidity testing of mechanical transmission components or assemblies, such as shafts, coupling components, transmissions, transmission shafts, transfer cases, and other transmission assemblies. Replacing different fixed brackets and connectors can meet the static torsional strength and stiffness tests of most automotive components.
2.3 Test items
Static torsional strength test
Static torsional stiffness test
3. Main technical parameters of the test bench
3.1 Drive Parameters 3.2 Test Range and Accuracy
Drive power: 2.2kw Test angle: Unlimited
Input speed: 100-1000r/min Angle measurement accuracy: ≤ 0.01 degrees
Input torque: 28Nm Angle control accuracy: ≤ 0.05 degrees
Output speed: 0.025-0.25 r/min Speed control accuracy: ≤ 1%
Reduction ratio: 4000:1 Speed measurement accuracy: ≤ 1%
Output torque: 0-80000Nm Torque test range: 0-100000 Nm
Loading method: Continuous loading or intermittent loading. Torque testing accuracy: ≤ 0.5%
4. Test bench system description
4.1 Overview
The test bench consists of three main parts: mechanical system, electrical system, and measurement and control system. These three parts are interconnected to form an organic whole. The electrical system is responsible for providing power to the test bench and collecting test data at all times; The measurement and control system plays a monitoring role to ensure the normal operation of the test bench; The mechanical system is the foundation of the test bench, and it works in coordination with the other two major systems to complete various test projects.
4.2 Mechanical System
The mechanical system mainly consists of driving variable frequency motors, worm gear reducers, planetary gear reducers, torque sensors, angle encoders, connecting flanges, transmission shafts, specialized fixtures, and installation plates. The experiment uses an AC variable frequency motor as the power source, which is driven by a frequency converter and can conveniently adjust the speed. Because the static torsion test requires low-speed high torque output, the reducer adopts a worm gear and planetary reducer with a reduction ratio of 4000:1. The torque sensor is equipped with a calibrated force arm and a standard gauge level tension and pressure sensor. The angle measurement is carried out using a rotary encoder. The structure of the test bench is shown in the following figure.

4.3 Electrical System
4.3.1 Overview
The electrical aspect of the test bench is divided into two parts: control and measurement. The control part includes control of motor frequency conversion and speed regulation. The measuring parts include speed, angle, torque, etc. Both control and measurement are built around industrial control computers.
4.3.2 Control System
The control system of the test bench consists of an AC control unit, a DC control unit, a signal acquisition (measurement part), an analog-to-digital (A/D) and digital to analog (D/A) conversion part, a motor drive system, and a computer control system, which are combined with each other.
4.3.3 Measurement System
The test bench measurement system mainly includes one set of torque sensors and one set of rotary encoders. The torque sensor is mainly used to measure the input torque of the specimen, and calculate and analyze the yield point, maximum torque point, as well as the strength and stiffness of the sample based on the measured value of the rotation angle and curve analysis.