This document describes the design and fabrication of a gear testing rig. The testing rig was designed to find the life cycle of composite gears based on their glass transition temperature under varying torque and RPM. Key steps included benchmarking existing rigs, rough sketches, designing machine elements, modeling and drafting parts, manufacturing elements, assembling the rig, and testing. Sensors include a temperature sensor, RPM sensor, and Arduino board to acquire data and link to Microsoft Excel for analysis. The rig allows testing of spur gears from 40-120mm in diameter under a maximum torque of 34Nm and speed of 500RPM.

1. DESIGN AND FABRICATION OF GEAR TESTING RIG
Presentation by KANDHAN.S
BE Mechanical Engineering ,
Rajalakshimi Institute of Technology
Note : This work of mine showcases an amateur
process of new product development based on
our necessity.

2. INTRODUCTION
• It is a Testing rig designed, controlled by Arduino board via computer interfaced with
Microsoft excel to find the life cycle of the Composite gears on basis of its glass
transition temperature (Tg) using thermal sennsor at given torque and RPM
• The test rig is designed from benchmarking and then fabricated

3. Methodology
Rough iterative sketches of machine
elements
Design of machine elements based
on operating conditions
Modeling and drafting of machine
elements
Manufacturing machine elements
Assembling and testing of gear
testing rig
Benchmarking

4. Benchmarking

5. FZG back-to-back gear test rig
Bernd-Robert Hoehn, Peter Oster,
Thomas Tobie, Klaus Michaelis
ISSN 0350-350X
GOMABN 47, 2,129-152
Strucni rad/Professional paper
UDK 620.22.05 : 621.892.094 : 620.1.05

6. GEAR TEST RIG FOR NOISE AND VIBRATION
TESTING OF CYLINDRICAL GEARS
Mats Åkerblom et al
mats.akerblom@volvo.com
Volvo Construction Equipment Components AB
SE–631 85 Eskilstuna, Sweden

7. Rough iterative sketches of
machine elements

10. Design of machine elements…

11. Design of machine elements…

12. Design of machine elements…

13. Design of machine elements…

14. Design of machine elements…

15. Design of machine elements…

16. Design of machine elements…

17. Design of machine elements…

18. Design of machine elements…

19. Design of machine elements…

20. TESTING RIG SPECIFICATION
TESTING RIG SPECIFICATION
Test gear specification Gear type Spur gear
Minimum diameter 40 mm
Maximum diameter 120 mm
Maximum width 30 mm
Module 2
Maximum loading torque 34 Nm
Maximum rotating speed 500 RPM
Motor specification 2HP, 3 Phase, induction motor

21. Modeling and drafting of
machine elements

29. Test gear
3phase, 2HP
induction motor
Ideal gear
Loading component providing braking torque

30. RPM sensor
Temperature sensor
Canopy

31. Manufacturing machine
elements

32. Key way End milling Gas cutting
Welding
Turning

33. Side milling Tapping
Grindingbuffing

34. Frame sizing
Backbone frame
Column arrangement

35. Painting
Pre-assemblage

36. Assembling and testing of gear
testing rig

37. Pedestal bearing
M10 bolt
M12 bolt
Lever to apply load

38. Loading component providing braking torque
Ideal gear
RPM sensor
Arduino Board
Data from Arduino is linked with MS excel
Test gear
3phase, 2HP
induction motor

39. Usage of Electronic devices..

40. RPM sensor (Hall effect sensor)Wiring terminals to connect ARDUINO

41. Infrared non contact thermal sensor
Arduino board to acquire
temperature data and RPM data

42. TEMPERATURE SENSOR (NON CONTACT TYPE)

43. USB connection
Arduino board to acquire temperature data and RPM data
Connections to LED display

44. TEMPERATURE SENSOR (NON CONTACT TYPE)
Canopy
RPM sensor

45. Ideal gear
Damaged composite gear
composite gear on running condition
Ideal gear on running condition

48. No more slides
THANKS FOR YOUR PATIENCE !