Design Of Test Rig Research Articles

Design of novel test rig for prosthetic finger distal interphalangeal and phalanx strengths.

Testing is one of the most significant phases of any engineering process, the last process followed by conceptualization, designing, and fabricating. If the testing outcomes are not genealogy sensible measurables, then eventually it calls for a redesign overhaul. Existing testing equipment to analyze the load and failures are conventional digital universal testing machines with minimum jigs and fixtures. In addition, the existing fixtures cannot be adapted to the anatomy of a human finger. Consequently, the present work explores the best possible design of a jig for testing the naturally articulated movement of a human finger (prosthetic wear-on). Furthermore, the present jig design checks a wide range of parameters such as freedom of motion, a path along with curvature, load, failures, and intermittent positions of applied load, which is adaptable to existing universal testing machines available for broader applications.

Design selection of experimental test rig for static thrust on micro size propeller using Pugh method

This paper aims to propose a simple, straightforward, yet robust test rig design to measure the static thrust magnitude for small propellers. Although there were advanced tools like multi-axis force or torque sensors, sophisticated equipment and complex mechanisms were required to capture the accurate thrust magnitude. Therefore, providing simple and effective test rig design for small-sized propellers is quite challenging. In this work, Pugh matrix analysis was used to evaluate three new designs of Propeller Thrust Measurement Rig (PMTR) and compare the designs against a benchmark model. The evaluation covered important design criteria during test operation, such as measurement accuracy, stability, ease of development, assembly, maintenance, versatility, electronic integration, airflow interference, adaptability for tilt angle studies, and resemblance to multicopter flight conditions. The results reveal that the PMTR-1 design scored the highest in the analysis and emerged as the most suitable candidate among the proposed designs. It showed potential superior performance in stability, ease of development and assembly, versatility, simplicity, airflow management, and adaptability for future studies. PMTR-3 demonstrated some potential but needs more enhancement in electronic integration and structural development. However, PMTR-2 faces significant potential challenges in providing stability, versatility, electronic integration, and adaptability for effective and safe operations.

Design of a test rig for the characterization of friction and wear in hot-metal gas-forming of AA 5083 aluminium sheets

Advanced aluminium sheet-forming processes such as the hot-metal gas-forming represent a challenging solution for producing small lots in the high-end car bodies industry, and the adoption of single cavity moulds made from low-cost, easily machinable materials such as cast iron reduces the overall sheet-forming costs. The tribological properties of the mould-sheet tribopair are of great interest for optimizing the sheet forming obtaining an acceptable esthetic surface finishing. This study presents the design and construction of a lab-scale experimental test rig for the tribological characterization at high temperatures of the mould-sheet tribopair. The proposed test method reproduces the sliding at the mould-sheet interface with contemporary sheet straining up to ε = 0.8 at strain rates in the 1.2*10-3 to 2*10-2 s-1 range. A series of experiments were carried out in dry and lubricated conditions for a ductile iron EN-GJS grade sliding against a AA 5083 aluminium alloy while straining. After comparing the experimental results with the literature data from other test rigs, comparable results were obtained as COF regards, ranging between 1.2 to 2.5 in dry sliding and between 0.05 to 0.2 in lubricated sliding. The morphological characterization of the sliding surfaces and cross-sections highlights the strong tendency to galling in dry sliding conditions expecially for low strain rates.

The Underwater Berlin Research Turbine: A Wind Turbine Model for Wake Investigations in a Water Towing Tank

The design of a three-bladed horizontal axis research wind turbine for wake investigations is described. The turbine has a rotor diameter of 1.3 m and will be operated in a large water towing tank at a submergence depth of 2.5 m, yielding 3.3 % blockage. The test rig is configured to allow for underwater-stereo-particle-image-velocimetry measurements of the near and the far wake at chordwise Reynolds numbers approaching 700 000. The low-Reynolds number airfoil SG6040 is selected to constitute the rotor blades. Cavitation-free operation is assured by assigning a rated angle of attack of 1°. The blades are designed to maintain a constant circulation along the blade span and to minimize tip deflections. The blade pitch angles are adjustable. Various blade designs, with and without passive flow control devices, can be tested by replacing individual blade sections. This eliminates the need for multiple sets of blades. Sensors for acquiring the turbine’s thrust, torque, rotational speed, the azimuthal positions of the blades, and the imposed blade root bending moments are incorporated into the design. The wind turbine simulation suite QBlade is utilized to simulate the turbine characteristics. A model of the entire test rig is derived, representing its structural properties. Results from the analytical verification of the structural model are provided. QBlade is utilized to analyze the test rig design by imposing design loads and calculating the modal properties.

A test rig for the validation of CFD simulations of a passenger vehicle under hood environment

As part of global efforts to reduce greenhouse gas emissions, the automotive industry is moving towards the electrification of its fleet – including full electric and hybrid vehicles. Considering hybrid vehicles, the energy efficiency and thermal management of powertrains including IC engines remains an important contribution. In this regard, engineers need accurate tools to understand heat-transfer in engine bays. This work presents a flexible test rig design to be used for the validation of CFD simulations of an underhood environment. The test rig and measurement equipment are introduced in detail with experimental data (and CAD) being available.A possible test scenario presented in this research is when an engine is subjected to heavy loads (i.e., constant uphill driving) and the vehicle is subsequently stopped. The experimental results are analysed and, furthermore, the data in terms of flow and temperature fields is compared against the results of the numerical simulations. This sort of comparison is the main usage scenario for the constructed rig, and it demonstrates the value of this facility for research. The rig's geometry and the experimental data being available can additionally be used to facilitate development and validation of various CAE methodology as well as simulation techniques.

Design of a test rig for grease endurance tests

BackgroundThe performance and endurance of lubricating greases is often assessed through model tests (like four-ball tests or SRV tests). This approach has some limitations, especially when greases with special fillers are investigated, because simplified laboratory test conditions can never replicate real operating conditions. ObjectiveFor a more reliable assessment on the performance of a lubricating grease, lubricants must be tested in close-to-actual operational conditions, e.g. through component tests. This paper presents both the design and implementation of a dedicated test rig to test lubricating greases through middle-sized thrust ball bearings. MethodsThe test rig design is optimized to monitor the effectiveness of lubrication and determine the useful life of grease by recording representative parameters, namely bearing temperature at different location in the bearing, vibration level, and electric contact resistance (ECR) through the bearing. ResultsThe results of a couple of assessment tests are presented and confirm that the test rig is working as expected. ConclusionsThe chart of the parameters being monitored shows that the instant performance of grease lubrication can be tracked during the endurance tests, and grease failure identified. The special mechanical layout of the rig also allows the user to obtain additional information that is usually not available in other commercial greased bearing testers. This work is meant to be the first step of the development a new approach to evaluate the grease lubrication performance and a few experimental results are included as they are intended as a functional validation of the prototyped test rig.

Experimental investigation of the corrosion behavior of Eurofer97 steel in contact with Lithium ceramic breeder pebbles under specific Helium Cooled Pebble Bed breeding zone atmosphere

For sub-sized fatigue specimens made of EUROFER97 in unconstrained contact to ceramic breeder pebbles, exposed to purge gas conditions for different durations in an oven, a chemical surface attack was observed which led to a significant reduction of fatigue lifetime [Aktaa et al., 2020]. To better reproduce the flow of the purge gas in the breeding zone of a Helium-Cooled Pebble Bed Breeding Blanket, the experiment was now repeated by placing the same kind of samples in the helium loop HELOKA HEMAT, where the gas is permanently circulated in a closed circuit, and its water content is controllable. The composition of the gas was monitored with a mass spectrometer and humidity sensors. The samples were exposed to a mixture of helium and 0.1vol% hydrogen at DEMO relevant operating conditions (550 °C, 1.2 bars abs.) for a duration of 8, 16, 32, and 64 days, respectively. New sample holders were designed which allow direct contact of the samples with the gas mixture. A special procedure for the handling of the test section was implemented to avoid contact of the hygroscopic pebbles with air humidity during the preparation phase and during the extraction of the samples from the test rig.The present contribution discusses the various considerations on which the test rig design was based, followed by a description of the experimental setup and preliminary results of the testing campaign. These are similar to the results achieved in the oven experiment. In the future, the loop will be used for tests with up to 200 Pa partial pressure of steam in helium; a mixture that is considered relevant for the DEMO purge gas composition.

Computational modeling and analysis of a fluid test rig

Nanofluids, which are suspensions of metallic or ceramic nanoparticle fillers in a variety of liquids, are a new category of heat-transfer fluids. Owing to the changes in thermal conductivity caused by nanofillers, they have thermal properties that are superior to those of conventional fluids; this leads to a more efficient heat transfer, making them attractive for various industrial applications. Using numerical models to support in situ experiments is necessary to analyze nanofluids’ thermal properties and flow; creating a test ring has been suggested to describe the characteristics and behavior of fluids under controlled conditions. Modeling and computational analysis support such advances, which are essential for understanding and optimizing phenomena occurring during experimental tests; the modeling and computational analysis of a test rig designed to characterize a diphenyl oxide/biphenyl blend base fluid are presented in this research work. The test rig design included an integrated stainless-steel piping system with a flow-controlled pump and heat exchanger; the computational model considers the conjugate effects of fluid dynamics to facilitate the construction of test rigs.

Design of a Compressor Test Rig for Immobilization of the Stall Cell

Capturing internal flow experimentally presents significant challenges due to the asymmetric propagation and strong unsteadiness of a stall cell in the circumferential direction. In this study, a low-speed counter-rotating axial compressor test rig was designed based on a counter-rotating compressor to immobilize a stall cell and measure its internal flow characteristics. Determining an appropriate speed ratio that is capable of stabilizing the circumferential position of the stall cell in the counter-rotating compressor enabled visualization measurements to be conducted successfully. The preliminary results demonstrated the successful immobilization of the stall cell using an appropriate rotating speed ratio. Furthermore, the oil flow visualization measurements confirmed the presence of a distinct stall cell structure on the casing wall. This work represents an innovative approach towards immobilizing stall cells in axial compression systems.

Experimental investigation of the impact of non-condensing gas on the condensation of n-propanol on a low-finned tube

This paper investigates the impact of a non-condensing gas on the condensation heat transfer of n-propanol on a low-finned and plain tube. Despite the potential of low-finned tubes to enhance outer heat transfer during condensation, the literature lacks measurement data on the condensation of solvents and bulk chemicals on these tubes. No experimental investigations on the impact of non-condensing gas on the heat transfer during the condensation of solvents on low-finned tubes are available in the literature. This paper addresses these gaps by presenting measurements of the heat transfer during the condensation of n-propanol in the presence of nitrogen on a horizontal GEWA-K28 low-finned tube and a plain tube using a novel test rig design. The results show that even a small amount of nitrogen significantly reduces the outer heat transfer coefficient. This effect is more pronounced on the low-finned tube than on the plain tube. The experimental data provided in this article can serve as a basis for developing calculation models for the condensation heat transfer of substances from the chemical industry on low-finned tubes.

Conceptual Design of Experimental Test Rig for Research on Thermo-Flow Processes During Direct Contact Condensation in the Two-Phase Spray-Ejector Condenser

Abstract The paper presents the conceptual design of a prototype experimental facility for mixing jet-type flow condensers investigations when the steam in exhaust gases is condensed on the water jet in the presence of CO2. The proposed experimental test rig was designed to give abilities to investigate the effectiveness of jet condensers experimentally as part of the CO2 capture phase and especially to investigate Spray-Ejector Condensers (SEC) developed as the combination of ejector and condenser devices. The paper presents the design and key features of the prototype installation components. The basic design was developed based on the simulation results, and for this purpose, model of installation, including characteristics of individual components, was built. The developed model helps to evaluate the main performances of the conceptual test rig and supports the test-rig design process. The main components and the features of the steam generation unit, CO2 supply and mixing with steam, process water preparation, and H2O and CO2 separation subsystem are discussed. The measuring system was designed to test the efficiency of compression and condensation processes of the SEC fed by the CO2/H2O gas mixture. The performances of the two-phase jet condensers can be analyzed by experimental investigation and calculation of heat transferred to the cooling water during direct contact condensation with the presence of CO2. The paper presents the results of heat flowrates and their uncertainties for the selected period of the experimental test, confirming the application of the novel developed test rig.

Structure optimization design of gasket test rig based on response surface model

In order to enhance the temperature regulation response speed of the gasket test rig and reduce the hysteresis of the temperature control system, structural optimization is implemented in the hardware part of the test rig. Firstly, a multi-physical field coupling method is employed for comprehensive performance testing of high-temperature and high-pressure gaskets, establishing a heat-fluid-solid coupling simulation and analysis model based on ANSYS. Then, internal temperature distribution of the gasket test device is calculated considering initial and boundary conditions. Next, data is collected using Latin hypercube sampling method, and optimal structural parameter combinations are determined through a multi-objective optimization approach utilizing response surface method and improved genetic algorithm. Finally, collected data is further utilized with response surface method and improved genetic algorithm multi-objective optimization technique to obtain optimal structural parameter combinations for the gasket test device which are verified by heat-fluid-solid coupling simulation. The temperatures tested before and after optimization are analyzed for comparison purposes. The results demonstrate that optimized gasket test rig significantly enhances its temperature control performance.

Approach to evaluate handling processes of polyethylene oxide (PEO)-based composite cathodes

The development of battery technology has made great advances in recent years. However, the increasing demand for electric mobility also highlights the limitations of conventional lithium-ion battery (LIB) technology, such as limited range and fast charging capability, as well as challenges related to battery safety. Among all the technology alternatives, the solid-state battery technology shows great potential to enable higher safety due to the use of non-flammable solid electrolytes instead of liquid electrolytes as well as higher energy densities by replacing the graphite anode with a lithium metal anode. In addition to the trend towards improved battery cell performance, there is also a growing need for the production of application-specific cell geometries. At the Institute of Production Science (wbk), the approach of agile cell production for conventional lithium-ion batteries is currently being investigated. In order to extend the scope of this material and format flexible approach, manufacturing processes for solid-state batteries (SSB) are being considered and further investigated. As a first objective, this work presents a concept for the evaluation of the handling processes of polyethylene oxide (PEO)-based composite cathodes with a special focus on the pick-and-place process. PEO-based composite cathodes are mechanically sensitive, with adhesive and limp characteristics. Therefore, the design of a semi-automated test rig is presented, which allows reproducible gripping, moving and placing of PEO-based composite cathode single sheets and thus stacking on pre-defined platforms. A camera system is integrated to monitor and quantify the process quality. An image processing tool is developed to determine the positioning accuracy and to detect possible damages on the electrode surface from handling. Furthermore, a concept for performing the handling tests is presented.

Friction Saturated Limit Cycle Oscillations—Test Rig Design and Validation of Numerical Prediction Methods

Abstract In this paper, an experimental test rig for friction saturated limit cycle oscillations is proposed to provide a validation basis for corresponding numerical methods. Having in mind the application of turbine blades, an instrumented beam-like structure equipped with an adjustable velocity feedback loop and dry frictional contacts is designed and investigated. After dimensioning the test rig by means of a simplified one-dimensional beam model and time domain simulations, the specific requirements of limit cycle oscillations for the design of the frictional contact, the velocity feedback loop and the excitation system are discussed and possible solutions are presented. Also appropriate measuring principles and evaluation techniques are assessed. After commissioning of the test rig, the influence of the negative damping and the normal contact force on the limit cycle oscillations is measured and the practical stability is investigated. The test rig shows linear dynamics for sticking contact and highly repeatable limit cycles. The measured results are discussed regarding the consistency with theory and compared to the predictions of a three dimensional reduced order model solved in frequency domain by the harmonic balance solver OrAgL. It is demonstrated that the numerical modeling strategy is able to accurately reproduce the measured limit cycle oscillations, which stabilized for different contact normal forces and self-excitation levels.

Vehicle Underhood Environment Investigations Using a Simplified Test Rig

Energy efficiency and thermal management continue to be critical areas in the vehicle development process. Independent of whether it is a vehicle with an internal combustion engine, hybrid, or fully electrical, engineers require proper and accurate tools to comprehend heat transfer in engine bays. However, developing such tools using a fully detailed production geometry can be challenging. This work presents a simplified and flexible test rig design of the vehicle underhood environment in two different variants: a passenger car and a commercial truck. The rig design in CAD and experimental data for the two rig configurations are made available upon request. These data will allow for the validation of different simulation approaches against the experimental dataset. An example of such a validation is presented in this paper. The load case scenario represented includes constant speed driving under heavy loads continued by a complete halt, which is followed by soaking for 100 min. The differences in experimental results for different rig variants are shown and analyzed. A good correlation between the experiments and CFD is obtained.

MULTI-CHANNEL MEASURING INSTRUMENT AND DESIGN OF A ROLLING BEARINGS TEST RIG

This paper presents the vibrodiagnostic test rig for analyzing the condition of rolling bearings. The rollingbearings are the most widespread mechanical elements, which are also considered critical elements within the mechanical assembly. Typically functionality, reliability and exploitative properties of the entire machine system depend on the functional capabilities of rollingbearings. The paper presents a design of a rolling bearings vibrodiagnostic test rig, which allows for simulating loads that are close to real loads during the operation of bearings, as well as a measuring instrument VibroLog, which is used for the acquisition and display of measured data. The newly developed measuring instrument VibroLog modular device for measuring and analysis of several diagnostic bearing parameters: vibration, speed, temperature and sound pressure. With this modularity, it enables easier diagnostics and speeds up the process of finding problems and faults in bearings.

A Dual-pronged approach for evaluation of contact stresses in nylon hybrid composite gears under misalignment

Polymer based composite gears have been a subject of intense studies by virtue of their wide gamut of applications. The authors have therefore embarked on developing a polymer-based composite with Graphene oxide (GO) and Tungsten Di-sulphide (TD) as reinforcements specifically for gear-based applications. The work outlined in this paper mainly deals with the fabrication of spur gears with the developed composite and investigating the contact stresses induced in these gears under misalignment of shafts. A dual-pronged approach is adopted in this procedure. The first being simulation studies using ANSYS WORKBENCH, while, the second and the most vital approach is through experimentation. The experimental approach required the design and development of a universal gear test rig (GTR) equipped with Data Acquisition System [DAS], which was successfully accomplished. The GTR was particularly premeditated to accommodate and adjust the alignment of the shaft axes. The experimentation was conducted under radial, axial and angular misalignments and combinations thereof. The composite material developed for this specific application was observed to function effectively in-comparison to the existing gear materials particularly under misalignment. The strains and stresses obtained from analytical and experimental methods were compared and found to be nearly identical under corresponding misalignments. Furthermore, it can be deduced from the studies that the combined effect of radial and yaw misalignments produces the highest strain, which is in fact, almost ten times that of strain in other forms of misalignment. The results of this research work will contribute in enhancing the understanding of nylon composite gear’s performance under misalignment conditions, enabling the best maintenance practices in industries.

Design and Fabrication of Test Rig for Static Pushing and Pulling Experiments

Muscular strength data associated with pushing and pulling forces are crucial for ergonomists to design tasks and equipment in manual materials handling. Usually, ergonomists measure pushing and pulling forces using a force gauge. Subjects participating in the pushing and pulling experiments need to grip and hold the force gauge. Additional weight from the force gauge can affect the muscular strength of the subjects, which impacts the validity and reliability of the pushing and pulling data. However, research on the design and fabrication of test rigs for facilitating pushing and pulling experiments seems to be scarce. This study aimed to design and fabricate a test rig to facilitate ergonomists and subjects in performing symmetric two-handed static pushing and pulling experiments. To develop the test rig, the researchers performed a maximum force measurement, a computer-aided design model, materials selection, a finite element analysis, a functionality test, and a reliability test. Seven subjects with a body mass of more than 120 kg participated in the validation of the developed test rig. Key findings of this study showed that the test rig could sustain the pushing and pulling forces up to 900 N, representing almost double the muscular strength of the subjects. This study concluded that the developed test rig was sturdy and helpful for facilitating ergonomists in quantifying the magnitude of pushing and pulling forces.

Design of the LIMELIGHT Test Rig for Component Testing for High-Temperature Thermal Energy Storage with Liquid Metals

Thermal energy storage systems for high temperatures >600 °C are currently mainly based on solid storage materials that are thermally charged and discharged by a gaseous heat transfer fluid. Usually, these systems benefit from low storage material costs but suffer from moderate heat transfer rates from the gas to the storage medium. Therefore, at the Karlsruhe Liquid Metal Laboratory, liquid metals are investigated as alternative heat transfer fluids for such heat storage systems, making use of the broad temperature range, in which the metals are in a liquid state, and their efficient heat transport capabilities. In this work, the design and construction of a high-temperature test rig using liquid lead is presented. The goal of the experiments is to demonstrate the operability of a pump, valves and measurement equipment at 700 °C in a challenging corrosive environment. Based on material pre-tests in stagnant lead at 700 °C, which are also shown in this study, aluminizing and pre-oxidation of the pipes and components are applied for enhanced corrosion protection.

The UNSW tip clearance flow noise test rig

A new test rig to measure the far-field sound, surface pressure fluctuations and flow-field in tip clearance flows has been designed at UNSW. The test rig is a part of the UNSW anechoic wind tunnel (UAT) and has been designed to allow studies of the tip clearance flow and sound radiation across a vast parameter space—tip clearance height, Reynolds number, angle of attack, and the tip geometry. This paper will present and discuss the design, characterization, and capabilities of this new test rig, along with some far-field sound results for a tip clearance flow formed by placing a stationary cambered airfoil adjacent to a wall. The measurements were performed for 51 different clearance heights at free-stream velocity of 30 m/s. The geometric angle of attack in the measurements was 5.6 and the clearance height Reynolds number ranged between 2000 and 102,000. The far-field sound was measured using a 64-microphone spiral phased array and the array output was beamformed to reveal the tip clearance noise sources. It is expected that the test rig will aid in a better understanding of the sound radiated by tip clearance flows which may be used to devise noise control strategies in the future.