Design Of Test Bench Research Articles

Low-GWP refrigerants in heat pumps: An experimental investigation of the influence of an internal heat exchanger

In heat pumps, the use of refrigerants with a low global warming potential (GWP) gains importance due to increasingly strict regulations regarding their ecological impact. In this regard, hydrocarbons (HCs), hydrofluoroolefins (HFOs), and their mixtures are the most promising options due to their thermodynamic properties. Besides the impact of the refrigerant, the cycle configuration (e.g., basic cycle and internal heat exchanger cycle) strongly influences the efficiency of the heat pump. While the potential of low-GWP refrigerants in internal heat exchanger (IHX) cycle configurations is widely investigated in numerical studies, there is a lack of experimental validation. Therefore, this work experimentally evaluates four HCs (R290, R600a, R436A, R1270) and the HFO R1234yf in comparison to R134a in a brine-water heat pump test bench. The test bench design allows to switch between the basic and IHX cycle, thus, enabling the simultaneous impact evaluation of the cycle configuration and the refrigerant on the performance. In the experiments, R1270 shows the highest efficiency for all operating points followed by R290 in the basic cycle. The IHX cycle improves the efficiency for all refrigerants in comparison to the basic cycle. The zeotropic mixture R436A achieves the highest efficiency improvements of up to 27.5% compared to the basic cycle, whereas the efficiency of the single-component refrigerants increases by 10% on average. Despite the significantly higher improvements of R436A due to the IHX, R1270 still leads to the highest coefficient of performance (COP) of up to 6.6 (B12/W35) in the IHX cycle configuration.

Modification of 2fn-Recuv Test Bench

The objective of this study is to modify the 2fn-recuv test bench. The test bench is used to carry out drone flight simulations. It can provide a controlled environment to ensure the drone’s safety. The test bench allows precise data collection and analysis for an unmanned aerial vehicle (UAV). First, a literature review is conducted to understand and analyse the design of the previous test bench. The limitations of CNC machines are also being studied to ensure the modified design can be fabricated. Based on the findings and results, a 3D drawing is created, taking into account the need for machining. The first prototype is made using a 3D printer. It allows for initial testing and checking for possible failures of the design. The completed part of the prototype is then fabricated using a CNC machine. The new test bench is made of aluminium to give it more rigidity and strength. Stress analysis is done using Solidworks 2020 to ensure the test bench can withstand the weight of the drone. The test bench is tested using Labview to record the angle of each movement of the drone, such as pitch, roll, and yaw. The maximum and minimum values indicate the angle of the test bench for the drone’s flight simulation.

The study of a novel magnetic crankshaft

This paper introduces a revolutionary mechanism, the Four-Translator Magnetic Crankshaft (FTMC), designed to address inherent limitations of the Magnetic Lead Screw (MLS) in energy storage and driving efficiency. The FTMC combines features of the MLS and a traditional cross crankshaft, enabling efficient energy conversion between continuous rotatory motions and reciprocating linear motions. The study presents the FTMC's working principle, theoretical calculations, 3D finite element analysis (FEA) validation, and comprehensive performance analyses. The FTMC's rotor, featuring a unique magnet array, allows for continuous rotation while the four translators reciprocate with a 90-degree phase difference. This breakthrough resolves the energy storage challenge faced by MLS, leading to enhanced efficiency and frequency. The paper explores the FTMC's static and dynamic performance, demonstrating its superiority in achieving 4.6 times higher reciprocating speeds or 93.3 % lower driving torque compared to the same-sized MLS in the limiting case. Furthermore, the study proposes an innovative assembly design with a 2-air gap topology, addressing potential radial attraction issues and reducing translator mass. The anticipated performance under ideal conditions, based on 3D FEA results, showcases the FTMC's ability to transmit about 1.4 kW power with efficiencies exceeding 75 % at rated load angles and 30 Hz driving frequencies. Theoretical insights into the FTMC's capabilities open promising avenues for future research and prototyping. Experimental validation is recommended to confirm the mechanism's maximum driving ability, offering significant advancements in Magnetic Lead Screw and high-speed magnetic drive systems. Future studies should focus on prototype manufacturing and controllable load test bench design to validate the presented theoretical analysis.

Design and construction of a versatile test bench for non-stationary fluid systems

Con el propósito de establecer una plataforma versátil para la investigación y enseñanza en ingeniería y ciencia de fluidos, se diseñó y construyó un banco de pruebas especializado para la Universidad Metropolitana. Este banco se enfoca en evaluar sistemas de fluidos no estacionarios, priorizando la medición precisa de caudal, presión y nivel en tanques. El desarrollo se centró en la selección de sensores y materiales de bajo costo, destacando la importancia de mediciones confiables y precisas. Se formuló un algoritmo en Matlab® para el cálculo sistemático de parámetros. La automatización se logró mediante un Arduino Mega, con la interfaz Humano-Máquina en Matlab® para facilitar la operación. Rigurosas pruebas demostraron la capacidad del banco para simular condiciones reales de manera efectiva. Los resultados, obtenidos experimentalmente y mediante Matlab®, respaldaron la eficacia y fiabilidad del sistema desarrollado, contribuyendo a la investigación y enseñanza en ingeniería y ciencia de fluidos.

Development of PLC-Based Hardware Test-Bench Prototype for Solar-Wind-Battery-Based Microgrid System’s Control Algorithm Validation

Programmable Logic Controllers (PLCs) are gaining traction in microgrid operation due to their real-time deployment, reliable and robust operation, and fast response, even in harsh environments. Recognizing the critical need for robust and reconfigurable microgrid control and operation, this research proposes a hardware test-bench prototype using the Reconfigurable Allen-Bradley—Micro820/2080-LC20-20QBB PLC to demonstrate control algorithms aiming for efficient control, energy management, and resilient microgrid automation. The design and construction of a prototype controller test bench, along with the PLC configuration, wiring diagrams, and control logic, constitute the significant contributions of this research. The proposed controller test bench’s performance is evaluated through similar condition simulations in the presence of disturbances induced by the reduced contributions of renewable energy sources, such as solar and wind. The results illustrate the effectiveness of the developed control algorithm implemented in the proposed controller, ensuring the stable operation of the microgrid. Consequently, this work advances the simulation-based validation of microgrid control algorithms and provides insights into the practical application of a PLC-based hardware test bench under various environmental conditions.

Numerical Investigation of an Experimental Setup for Thermoplastic Fuselage Panel Testing in Combined Loading

The main purpose of this study comprises the design and the development of a novel experimental configuration for carrying out tests on a full-scale stiffened panel manufactured of fiber-reinforced thermoplastic material. Two different test-bench design concepts were evaluated through a numerical modeling strategy, which will be validated at the next stage using a targeted series of mechanical tests. A baseline experimental setup was developed after a number of candidate configurations were numerically investigated. The supporting elements along with the load introduction systems were defined in such a way as to represent the stiffness of a fuselage barrel section and its representative loading scenarios. The test rig and the investigated thermoplastic panel were numerically simulated to acquire valuable data pertaining to deformations and stresses when subjected to different loading combinations. Two distinct load cases were numerically examined: the first case was the in-plane compression of the thermoplastic panel, while the second case consisted of an internally applied pressure load introduced via an inflatable airbag, installed under the panel. Both loading scenarios were recreated inside the numerical virtual environment in order to examine two distinct stiffening configurations as well as to determine the maximum/limit loads to be used in the planned future experimental campaign. It was concluded that the designed test rig could successfully be used for the structural evaluation of fuselage panels under representative loading conditions.

Design, Numerical and Experimental Testing of a Flexible Test Bench for High-Speed Impact Shear-Cutting with Linear Motors

Given the use of high-strength steels to achieve lightweight construction goals, conventional shear-cutting processes are reaching their limits. Therefore, so-called high-speed impact cutting (HSIC) is used to achieve the required cut surface qualities. A new machine concept consisting of linear motors and an impact mass is presented to investigate HSIC. It allows all relevant parameters to be flexibly adjusted and measured. The design and construction of the test bench, as well as the mechanism for coupling the impact mass, are described. To validate the theoretically determined process speeds, the cutting process was recorded with high-speed cameras, and HSIC with a mild deep-drawing steel sheet was performed. It was discovered that very good cutting edges could be produced, which showed a significantly lower hardening depth than slowly cut reference samples. In addition, HSIC was numerically modelled in LS-DYNA, and the calculated cutting edges were compared with the real ones. With the help of adaptive meshing, a very good agreement for the cutting edges could be achieved. The results show the great potential of using a linear motor in HSIC.

Design and Optimization of Hydropneumatic Suspension Simulation Test Bench with Electro-Hydraulic Proportional Control

Available hydropneumatic suspension simulation test benches have insufficient loading accuracy and limited functionality rendering them unsuitable for performance testing of heavy vehicles with this type of suspension. Therefore, a multi-functional compound simulation test bench was designed that used an electro-hydraulic proportional control technique. A mathematical model was established to describe the hydraulic loading system, and the transfer function of the system was derived. The gain and phase margins confirmed the stability of the system. A simulation model was established in the Simulink environment and step and sine signals of different frequencies were applied separately to analyze the dynamic characteristics of the system. The results showed that the system responded slowly and exhibited phase lag and signal distortion. The dynamic characteristics of the system were improved by incorporating an adaptive fuzzy PID controller. Simulation results showed that the response of the system to the step signal stabilized at the preset value within 0.3 s with no oscillation or overshoot. The improved system performed well in replicating the random vibrations of heavy vehicles operating on Class B and C roads. This confirmed that the system can satisfy the loading requirements of heavy vehicle hydropneumatic suspensions and can be used as a simulation test bench for such suspensions.

Performance Analysis of a Dynamic Test Bench Based on a Linear Direct Drive

This paper describes the design and performance of a dynamic test bench used for dynamic testing of special sensor systems intended for use in vehicle chassis. In order to economically meet all requirements of a dynamic driving simulation, the dynamic test bench is being developed on the basis of a linear direct drive. The test bench has a modular design and can be used flexibly, i.e. vertically or horizontally. No ferromagnetic material is used in the measuring range of the sensor to minimize measurement inaccuracies. The performance requirements to be met are to the achievable acceleration and frequency, the stroke distance and the positioning accuracy. The test bench must be capable of accelerating at a minimum of 30 g while realizing an oscillation of at least 12 Hz. Regardless of the dynamic requirements, a minimum stroke distance of 500 mm is required. The required positioning accuracy is 1 mm. To ensure that all requirements are met, the performance limits of the test bench are determined experimentally and validated mathematically. In addition to the maximum acceleration and the maximum realizable frequency, the maximum stroke speed of the test rig is determined. Furthermore, the critical resonance frequencies of the test bench, which can lead to disturbances, are determined. As a result, all required performance values are exceeded by the dynamic test bench.

Analysis of the Test Bench Design Influence on the Cooling Performance of a Rail Vehicle Brake Disc

The presented article aims at assessment of the influence of test bench design on the cooling performance of a rail vehicle brake disc. The test bench is designed for experimental analyses of rail vehicles' brake components. The work includes an introduction to the solved problem, as well as a description of importance of airflow simulations in virtual environment. Creation of a geometrical model and its most important features are described. The research is performed by means of the computational fluid dynamics. For this method, it is important to set-up the boundary conditions, which are presented in the next part of the article. The results of the computational fluid dynamics simulations are presented for the solid disc and for the ventilated disc. The simulations of the solid disc showed the better convergence of calculations for various time-steps in comparison to the ventilated disc.

Development of a High-Performance Low-Weight Hydraulic Damper for Active Vibration Control of the Main Rotor on Helicopters—Part 1: Design and Mathematical Model

The helicopter vibrations generated by the main rotor/gearbox assembly are the principal cause of damage to cockpit instruments and discomfort of the crew in terms of cabin noise. The principal path of vibration transmission to the fuselage is through the gearbox rigid support struts. With the aim of reducing these vibrations, this paper presents the design of a low-weight high-performance active damper for vibration control developed by Elettronica Aster S.p.A. The system is intended to replace the conventional struts and is composed of an electro-hydraulic actuator hosted within a compliant structure. This parallel nested structure allows the system to reach a high-power density. A physics-based mathematical model was used as a design digital twin to optimize the performance to meet the strict requirements. The active damper was designed for a reference application of a 15-seat medium-sized twin-engine helicopter. The model was used to perform the tests specified in the acceptance and testing procedure document, showing the compliance with the requirements of the current design. The damper physical realization, test bench design, experimental campaign, and model validation will be presented in Part 2.

Simulation and developments for large pellet formation and acceleration for shattered pellet injection of the ITER DMS

Amongst the technological developments needed for ITER, the disruption mitigation system (DMS) is one of the most challenging since it has to mitigate the consequences of high-energy plasma disruptions to ensure the lifetime of ITER's structure and in-vessel components. ITER DMS is using Shattered Pellet Injection, whose technology needs to be developed for ITER specific requirements.In the framework of the “Technology Fundamental Studies for DMS” contract with ITER Organization, as part of the ITER DMS Task Force activities, and CEA, the DSBT (Low Temperature Systems Department) designed and operates a pellet injection test bench to produce and accelerate large cryogenic pellets with diameters from 10 to 28.5 mm and length/diameter ratios up to two. The objective of this activity is to study and to optimise the pellet formation and acceleration process using pure Protium, Deuterium, Neon and mixtures of these gases.Analytic and numerical studies were used to define the geometrical and cryogenic parameters for the pellet desublimation in the in-situ condensation cell of the cryostat. An analytical model has also been developed for the pellet acceleration in the single stage gas gun to validate the propellant valve design aiming at achieving velocities of up to 500 m/s for 28.5 mm protium pellets and 200 m/s for neon pellets.The complete test bench is composed of the gas propulsion system, the cryostat with its key component the pellet formation cell, the flight tube and the target chamber with viewing ports. The mechanical assembly is completed with specific instrumentation and fast data acquisition systems for the observation of the pellet formation and acceleration. The pellet integrity and trajectory are characterised by shadowgraphy with high resolution, high-speed cameras located at 1 m and 3 m after the barrel exit and with an accelerometer and a target foil in the target chamber.This document details the simulation studies, the selected test bench design and first obtained results.

Design and Analysis of UAV Test Bench for Engine/Motor Characterization

A thrust test bench is an instrument which can measure the Thrust, Rpm, Power, Torque, Temperature Explicitly etc. This is composed of the test bench architecture attached to the motor or the engine through the rotating shaft. An absorber being attached to the engine means nothing but an extra component which drives the energy of the motor, that is a propeller if assumed. The main objective here is to design a Test Bench which can maximum hold the weight of UAV Engines or motors within 15kgs and to conduct Structural Finite Element Analysis on different parts of the test bench to determine the stress behaviour. The parameters which the test bench can measure are Thrust, Velocity, Rotational Speed, Torque, Cylinder Head Temperature, Exhaust Temperature etc. This is achieved by using certain sensors introduced with a DAQ system for precise and accurate measurements of the parameters.

Experimental method research and miniature durability test-bench design of electric sliding door

With recent enhancements in vehicle electrification, electric sliding doors have received significant research attention; however, the testing methods for the sliding doors components need to be improved. Herein, according to the durability evaluation index of sliding doors, a miniaturized durability test bench is designed for the electronic lock system and sliding door power output mechanism assembly. The motion trajectory of the electronic lock system can be fitted as a circular arc curve through dynamic characteristics analysis; therefore, a four-bar linkage with a flexible link is used to simulate the trajectory. Through the finite element simulation method, the test-bench stress is calculated at room temperature and a high temperature (75°C); this facilitates the selection of an appropriate material (GCr15). This experimental method is an economical, reliable, and accurate scheme to standardize the durability test of the electronic lock system and power output mechanism assembly.

Design and development of mechanical test bench for testing and calibration of multiple blood pressure measuring devices.

Blood pressure (BP) measurement is an important physiological parameter for human health monitoring, which plays a significant role in the diagnosis of many incurable diseases. However, due to inaccuracies in the different types of BP measuring devices, the calibration of these BP measuring instruments is a major concern for a medical practitioner. Currently, these devices' calibration, testing, and validation are performed using rigorous methods with complex clinical trials and following the available documentary standards. This article describes the design and development of an indigenous mechanical test bench (MTB) system for the testing and calibration of multiple BP devices, as per International Organization of Legal Metrology (OIML) recommended documents e.g., OIML R 16-1 and OIML R 16-2. The developed system can test and calibrate 20 BP devices, simultaneously. The traceability of the developed MTB is established by performing its calibration against the Air Piston Gauge, a national primary vacuum standard. The estimated expanded measurement uncertainty evaluated is found to be ±0.11mmHg, which is almost one order better than the measurement uncertainty required for the test and calibration of BP measuring instruments as per standard. The MTB has successfully been used to test and calibrate several BP measuring instruments. The data of one such device is reported herein as an indicator of the performance process. The calibration of these BP measuring instruments was performed in the static mode, and the estimated expanded measurement uncertainty was found to be ±1.25mmHg. The developed MTB system would prove to be an excellent instrument for calibration laboratories, hospitals, regulatory agencies, and other users to test and calibrate 20 BP measuring devices simultaneously and cost-effectively.

Design and Research of Test Bench for Loading and Performance Testing of Aerospace Precision Ball Screw

Aiming at the problem of insufficient research on the motion failure caused by the degradation of the grease of the precision ball screw pair under the typical working conditions of high frequency and high load in aerospace, a set of high frequency inertial loading test bench is designed. Loading and performance testing functions are integrated. The mechanical structure of the test bench, the inertia adjustment device and the connecting member of the pendulum rod are designed, which can simulate the loading under aerospace conditions. Installing multiple sensors can test the force response characteristics, vibration characteristics, temperature rise characteristics and transmission efficiency of the precision ball screw pair when it operates under different frequencies and different axial forces. The axial force of the nut with different rotational speeds under inertial load is tested by experiments.

Design and Validation of New Torsion Test Bench for Intermediate Strain Rate Testing

Design and Validation of New Torsion Test Bench for Intermediate Strain Rate Testing

Dual-Circuit-Based Test Bench Design for HVDC Circuit Breaker Verification

High-voltage direct current (HVDC) circuit breaker development and deployment strongly depend on the testing process, which ensures that the HVDC circuit breakers will satisfy design requirements. This article presents an HVDC circuit breaker test bench circuit configuration that can provide controllable large output currents to simulate different fault conditions for the current breaking test and high output voltage for the dielectric withstand test. The current breaking test circuit is based on multiple cascaded power converters connected in parallel to provide the necessary output current capability. Each cascaded power converter is composed of multiple cells that are operated by a phase-shifted pulsewidth-modulated signal for greater controllability and higher quality of the output waveform. The dielectric withstand test circuit is a simple high-voltage source with a low power rating that can also be used to charge the test bench and the internal circuitry of the circuit breaker that is to be tested. The proposed test bench ensures that fault conditions can be replicated accurately and offers greater flexibility by being able to test mechanical, semiconductor-based, or hybrid HVDC circuit breakers with different current and voltage ratings on the same hardware without any changes. The idea and the operating principle of the proposed test bench are verified experimentally on a downscaled system that consists of three cascaded power converters connected in parallel with three cells per cascaded power converter and with a total equivalent switching frequency of 92.5 kHz.

Design and Development of a Cold-Flow Test-Bench for Study of Advanced Nozzles in Subsonic Counter-Flows

As advanced nozzles may offer alternative solutions to conventional nozzles for the future class of reusable launch vehicles, a critical aspect is to tailor these novel technologies to current recovery strategies, more specifically to vertical landing sustained by retro-propulsion. Researchers at Technische Universität Dresden have developed a dedicated test-bench for the vacuum wind tunnel facility, where Advanced Nozzle Concepts (ANCs), such as aerospike and dual-bell nozzles, are tested in cold-gas configuration while invested by subsonic counter-flows. The main objective of the test campaign is to evaluate the performance and altitude–compensation characteristics of such ANCs by simulating a vertical landing manoeuvre through the variation of ambient pressure experienced during the landing burn. A detailed description of design and development of the test-bench, together with preliminary results from the commissioning activities, are here offered to the reader. The force measurements, together with pressure and temperature data, contribute to evaluate thrust levels and coefficients, as well as the monitoring of the interaction between the nozzle cold-flow and the opposing free-stream. A background-oriented schlieren system allows to visualise the external flow-field. In conclusion, an outline of the upcoming test campaign and a description of the expected results is offered.

Experimental verification of predicted capability of a wind turbine drivetrain test bench to replicate dynamic loads onto multi-megawatt nacelles

A total of 27 test profiles from the IEC 61400-1 design load cases were tested using a 7.5-MW wind turbine drivetrain test bench and two multi-megawatt wind turbine drivetrains. Each test profile consisted of simultaneous vertical, lateral, and longitudinal forces, yawing and nodding bending moment, and rotational speed. These test-bench inputs were compared with the forces, bending moments, and speed that were applied to the wind turbine drivetrains to quantify the test-bench tracking error. This tracking error was quantified for a range of ramp-rate limits of the yawing and nodding bending moments. The experimental results were compared with predictions from an evaluation method for the capability of wind turbine drivetrain test benches to replicate dynamic loads. The method’s predictive capability was found to be sufficient for the goal of early screening and its formulation is applicable to any wind turbine drivetrain test bench and drivetrain design.