Gear Prognostics Simulator Valenian Full Life Test Bench Product

Drivetrain Gear Prognostics Simulator(VALENIAN-PT500DPS)
Gear life test - Full life cycle test of planetary gearbox gears (optional); - Full life cycle test of parallel gearbox gears; - Full life cycle test of helical gearbox gears (optional); The load gearbox and radial loading system provide the load; - Rolling bearing fault diagnosis test; Study the relationship between gear failure mechanism and factors such as load, speed, and lubrication; Study the prediction model of the remaining life of gears based on damage development, rotational speed, amplitude and loading load; Research on signal processing and sensing techniques for condition monitoring of bearing and gear failure prediction; - Study the relationship between vibration, motor current, load, friction and noise; - Validate model-based fault diagnosis and prediction algorithms;

These simulators are designed for industrial research or fundamental research applications.

Different test bench are following:

Gear Prognosis for the study of gear trains

Drivetrain forecast for the study of industrial transmissions

Gear Full Life Test Bench Product Valenian Teaching Equipment
VALENIAN has developed the gear full life test bench (PT500-DPS) specifically for the research on fault diagnosis and life prediction of industrial gearboxes. The PT500-DPS gear full life test bench includes two sets of single-stage parallel shaft test gearboxes with rolling bearings, which can simulate gear transmission ratios from 1 to 0.7. The gearboxes can be loaded with a large enough torque to cause wear and damage failure of the gears. All the mechanical structures of the test bench are modular for easy study of the dynamics and noise characteristics, health monitoring and vibration characteristics of the gearbox based on diagnostic and predictive techniques. The test bench is stable in performance, capable of withstanding large load shocks, and has ample space for gear replacement, installation, and the installation of various sensors. The test bench can simulate faults such as tooth surface wear, tooth cracks, tooth surface pitting and tooth loss of straight and helical teeth. It can also simulate faults in the inner ring, outer ring, and rolling elements of rolling bearings, as well as coupling faults. A single fault can be introduced, or multiple faults can be introduced simultaneously, to study the coupling effect among different fault types. Simulate the fluctuation effect of actual on-site loads by loading loads and studying the damage and expansion characteristics of gears and bearings.

Gear transmission is a device that transmits motion and power through gear pairs. It is one of the most widely used mechanical transmission methods in modern mechanical equipment. It is accurate, efficient, compact in structure, reliable in operation and long in service life. Gears are key components in mechanical systems, and they may deteriorate or fail during system operation due to factors such as poor lubrication and shock loads. The operating conditions of gears in mechanical equipment are rather complex. They can operate normally under high speed and high load conditions, and at the same time, they need to withstand variable loads. To address these issues, it is necessary to conduct condition monitoring of gear operation, assess the health status of gears in real time, and predict their remaining service life to prevent severe gear damage from causing major faults in mechanical equipment. To achieve research and validation of various fault diagnosis and life prediction methods for gears under complex conditions, VALENIAN has developed an experimental environment that can simulate various load conditions and fault patterns of gears. To better assist researchers in timely understanding the performance degradation process of gears and identifying factors affecting gear life, and to continuously enrich the test database in experiments to provide data support for intelligent prediction and fault diagnosis algorithms, test the feasibility of the algorithms, and thus provide a technical validation environment for the full life cycle management of gears.


Bearing failure simulation - Parallel shaft gearbox bearing fault simulation (bearing inner ring, Bearing Outer ring, rolling elements, cage, comprehensive fault simulation); Gear fault simulation - Sun gear, planetary gear, ring gear fault simulation (optional); - Parallel shaft gearbox gear fault simulation; - Helical gear kits and faulty parts replaceable (optional);

The gear full life test bench consists of drive motor, drive control box, support bearing box, torque and speed sensor, accompanying gear box, test gear box, base and loading system, etc.
Both the test and test gearboxes are standard with a parallel gear structure, with a gear module of 3.0. Normal gears are assembled in the gearboxes, which are pre-lubricated with gear oil.

Straight gear specifications: Single-stage parallel shaft gearbox Straight gear input Angle: 20° module 3.0 Reduction ratio: 1:0.7 (1 st class :28/40)


Gearbox box maintenance: 1. Normal gears and defective gears are integrated in the gearbox, and the gearbox is always covered, so there is almost no need to replace the gears. If the gears in the gearbox get rusty due to moisture during long storage, place the gearbox in a dry and well-ventilated area, add a certain amount of lubricating oil, and manually turn it several times every month. 2 If the oil becomes cloudy or emulsified, change the gear oil and clean the inside carefully, as dirt can damage the gears and bearings. To allow the large gears to come into contact with the lubricating oil. Depending on the gear configuration, about 5 liters of oil will be needed to reach this state. SAE 80W-90 gear lubricating oil is recommended unless different viscosities are required for the experiment, and the lubricating oil can be discharged through a manual ball valve on the side of the box.
The double support bearing is supported by four deep groove ball bearings with inner diameter f30 (HRB6006), and the support bearing housing is designed as a sealed, lubricated system structure. The bearings inside the housing are normally assembled with normal bearings, and faulty bearings with specific defects can also be selected.

When the stress caused by mechanical failure (imbalance, misalignment) is concentrated on the bearing, bearing failure can lead to catastrophic mechanical failure, resulting in significant losses in production and efficiency. Therefore, it is very important for fault diagnosis engineers to understand the vibration phenomenon caused by bearing failure. It is important to study the vibration caused by bearing failure by placing faulty bearings one by one in the machine.

For this purpose, a detailed study of different types of faulty bearings can be conducted as follows.



Dynamic torque tachometer sensors are detections of torsional moment perception on various rotating or non-rotating mechanical parts. Torque sensors convert physical changes in torque into precise electrical signals. It converts rotational speed signals into square wave signals and enables real-time display and real-time output functions.


Display the current measured torque value and rotational speed value in real time. The current power value can be calculated directly. Supports RS485 communication, supports active upload protocol. Communication rate up to 500 or 1000 times per second. The sensor supports simultaneous output of current and voltage for transmission. The sensor comes with an OLED display with a resolution of 128*64

Display and adjust various test conditions such as speed, torque, output frequency, output voltage, IGBT temperature, bus voltage, output power, output current, output torque Settings through touchscreen operation mode. It also has an emergency stop button to stop the machine immediately in case of an emergency. The motor module and power supply have a dedicated mobile electrical control box.