Powertrain & Gear Testing

Robotic drive test rig

Overview

The robotic drive test rig is a custom-built test bench for coaxial gear drives – planetary gearboxes and precision reducers used in robotics applications. It is designed for lifetime and performance testing of the complete drive unit: input (drive) and output (brake) power are provided by electrically controlled drive and brake motors, applying controlled speed and torque on both sides of the tested drive while the parameters that matter for robotic joints are measured – durability, backlash, transmission error and NVH behaviour. The platform is available in two configurations: an R&D-oriented version for flexible laboratory testing and an automated end-of-line version for production testing.

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Robotic drive test rig - end-of-line testing version

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Robotic drive test rig - R&D testing version

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Two configurations

R&D and end-of-line versions

Version 1

R&D testing

A self-standing rig for research and development. The tested drive is mounted manually and run through flexible load regimes for lifetime evaluation, prototype validation and design optimisation.

Manual mounting and operation
Constant load, load spectra and time-varying regimes
Full instrumentation for R&D data acquisition
Interchangeable mounts for various drive geometries

Version 2

End-of-line testing

An automated configuration for production – e.g. end-of-line assembly testing. The rig is upgraded for automatic handling and a defined array of pass/fail testing functionalities, tailored to the specific assembly and line requirements.

Automated (end-of-line) assembly testing
Defined pass/fail test functionalities
Configured around your assembly and cycle time
Major upgrade – scoped to your application

Preorder inquiry

Interested in the robotic drive test rig? Tell us about your drive and testing requirements and we'll get back to you within 24 hours with configuration options and a quote.

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Features and specifications

The drive side positions axially to accommodate different gearbox widths, and adaptable input/output connectors together with an interchangeable test-drive mount let the rig accept a range of coaxial drive geometries. All critical sensing equipment ships with calibration certificates, and the electronics, data acquisition and safety systems are included. The rig is operated from a regular Windows PC or laptop over an Ethernet connection to the test rig.

Testing capabilities

Lifetime testing of planetary gearboxes and precision reducers for robotics
Constant load and load-spectra testing
Predefined time-varying load operation regimes
Coaxial (fully aligned) input and output axes

Drive and load system

Input (drive) and output (brake) power via electric motor control on drive and brake sides
Input and output rotational speed measurement
Axial positioning of the drive side for mounting and various drive geometries
Adaptable input and output side connectors to the tested drive
Interchangeable test-drive mount for various drive geometries

Control and software

Dedicated software for data acquisition, visualization and storage (Windows OS compatible)
Operated from a regular Windows PC or laptop
Ethernet communication with the test rig
Optional industry-grade PC integrated into the rig for independent control and analysis¹

Safety and compliance

Self-standing rig with integrated safety equipment
Safety features in line with relevant EU machinery directives
Calibration certificates for all critical sensing equipment
Power supply: 220 VAC or 400 VAC depending on the final configuration

Included

Electronics, data acquisition and safety equipment
Measurement, visualization and storage software
Calibration certificates for critical sensors
Interchangeable mounts and drive-side connectors

Specifications

Representative base configuration – the rig is custom-built and specifications are tailored to each application.

Parameter	Specification
Input torque	0.5 – 20 Nm
Input speed	3000 – 25 000 rpm
Output torque	30 – 2000 Nm
Output speed	80 – 6000 rpm (dependent on output torque)
Center distance	0 mm (coaxial – fully aligned input/output axes)
Axial positioning range	Per requirement
Load application	Constant load, load spectra, time-varying regimes
Drive / brake	Electric motor control
Data acquisition & software	Included (Windows OS compatible)
Communication	Ethernet to Windows PC / laptop
Power supply	220 VAC or 400 VAC (configuration dependent)

¹ On request, an industry-grade PC can be integrated into the test rig for independent device control and data analysis. Additional costs apply.

Add-ons

Additional modules

The rig can be extended with optional modules that add thermal, NVH, backlash and transmission-error testing, as well as full production-line automation. Modules can be ordered with the rig or retrofitted later.

A. Temperature control modules

A.1 Elevated temperatures – surrounding air controlled between ambient and 100 °C; tested drive unit between 40 °C and 120 °C
A.2 Cryogenic to elevated temperatures – surrounding air controlled between −40 °C and 100 °C; tested drive unit between −40 °C and 120 °C
Requires an additional thermal chamber and tempering system

B. NVH diagnostics

B.1 Vibration measurements – detects increases in vibration at a selected location; multiple accelerometers can be installed (incl. Dewesoft DAQ and 2 calibrated piezo accelerometers)
B.2 Noise measurements – detects increases in noise at a selected location; multiple microphones can be installed (incl. DAQ and a calibrated laboratory condenser microphone)
B.2.2 Anechoic chamber upgrade – minimizes echoes and insulates the drive for absolute noise-emission measurements
NVH data acquisition and basic analysis software included

C. Backlash evaluation module

One side is fully fixed while the other is rotated, measuring rotational angle and applied torque
Produces backlash “hysteresis” curves (torque vs. angle)
High-resolution rotary encoder, DAQ module and retention adapters included

D. Transmission error evaluation module

Transmission error measured by comparing rotary-angle signals on input and output shafts (accounting for the exact gear ratio)
High-resolution rotary encoders on drive and brake sides
DAQ module and analysis software included

Modules B, C and D share the same DAQ module and related electronics – ordering several together reduces the overall price.

E. Testing automation module (end-of-line)

Upgrades the rig for automated (e.g. end-of-line) assembly testing
A major upgrade, highly dependent on the assembly and the selected array of testing functionalities
Scoped and quoted per application

Delivery lead time is typically 6–8 months after order confirmation, depending on the ordered modules and current component lead times. Lifetime service support (maintenance, recalibration and upgrades) is provided. Contact us for current pricing, module bundles and lead times.