Testing of transmissions has been conducted at BOSMAL since 1974, starting with the development of the transmission for the Polish Fiat 126p. Currently, we have two modern test benches for performing durability and dynamic tests for European and global transmission manufacturers and petrochemical companies producing lubricants. We perform durability and dynamic tests; we also conduct tests on transmission fluids, and perform spectral analyses of vibrations in the transmission system. We also conduct tests on complete e-axles and hybridised transmissions.
Testing of manual and automatic transmissions, gearboxes and e-drives
Gearbox development studies
- upgrades of currently used gearboxes for passenger cars and vans
- integration of gearboxes with new engines
- functional and durability analyses
- durability tests of gearboxes, mechanisms and bearings on individual gears and during driving cycles (including maximum engine torque and power)
- durability tests and dynamic tests (under load) of various types of manual and automatic (including DCT and CVT) gearboxes, used in transverse 4×2 drivetrains
- simulation of gearbox operation in a vehicle (passenger car or light commercial vehicle)
- simulation of petrol and Diesel engines
- simulation of work under road load conditions (including aerodynamic and rolling resistance, vehicle inertia, etc.)
- simulation of driver behaviour (from aggressive/sport to ecological driving styles)
Transmission and gearbox durability tests
Transmission durability tests allow the durability and wear of gearboxes to be tested over significant mileages in a much shorter time than if conducted via on-road tests. Due to their repeatability, these types of tests allow comparison of various design solutions.
We are able to conduct tests on two test benches, on manual and automatic transmissions for vehicles with front-wheel drive and transverse engine mounting.
During durability tests we conduct analysis of gear vibration, monitoring its state.
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Apator Control workstation -
AVL 412/402 workstation -
AVL 412/402 workstation – operator’s office -
AVL 412/402 workstation – cabinet room
Durability and dynamic testing of gearboxes/transmissions and e-axles – AVL 412/402 testbed
The AVL 412/402 testbed facilitates the execution of durability and dynamic tests on manual, automatic, dual-clutch and continuously variable transmissions. Thanks to the addition of a battery emulator to the testbed setup, it is also possible to perform comprehensive testing of hybridised transmissions, as well as complete e-axles with their e-machines and inverters when simulating the vehicle battery.
DynoPrime driving motor and DynoTrain loading unit
The DynoPrime driving motor, simulating a vehicle engine, is a permanent magnet water-cooled AC machine.
The DynoTrain loading units, simulating road load, are AC air-cooled machines.
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AVL 412/402 workstation – operator’s office -
AVL 412 workstation -
AVL 412/402 workstation – cabinet room
Battery Emulator (250 kW)
The battery emulator integrated into the transmission test stand enables testing to be carried out on complete electric drive axles (engine, gearbox, inverter, semi-axles) and hybrid transmissions with transverse engine mounting, including under simulated operating conditions (simulation of the vehicle and its battery, as well as the road and the driver).
Durability tests on manual transmissions – Apator Control testbed
The testbed allows durability tests to be performed on manual transmissions for front-wheel-drive vehicles.
The driving motor, simulating a vehicle engine, is an air-cooled AC machine.
Type: Schorch LN8250M-A
The loading motors, simulating road load, are air-cooled DC machines.
Type: Leroy Somer LSK 2804 CSM 03
Dynamic testing
Puma automation software for running automatic steady state and dynamic tests with or without driver and vehicle simulation.
Testing can be conducted on manual transmissions (MT), automatic transmissions (AT), dual-clutch transmissions (DCT) and continuously variable transmissions (CVT).
Dynamic tests can be conducted to check and fine-tune shifting procedures, test how the transmission will behave in a simulated vehicle on a simulated road or track with a simulated driver.
Dynamic transmission tests can be conducted with high repeatability in comparison to road testing, without external factors like different drivers and variable road conditions.
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Dynamic testing – plot -
Dynamic testing – plot
Vibroacoustic analysis for transmission tests
To evaluate vibrations during the tests we use Reilhofer’s deltaAnalyser system.
The system compares the gearbox vibration profile at the beginning of the test with vibrations recorded during the test.
The system ensures early detection of gearbox wear/damage and helps the operator to pinpoint its location (e.g. damage to the teeth of the 3rd gear on the driven wheel and indicate the wear/damage progress history). The process of gearbox wear/damage detection works automatically, runs continuously and is integrated into the test bench control system to stop the test in case of damage occurring or set emergency thresholds being exceeded.
The system performs FFT analysis of the signal from the vibration sensor
(a knocking sensor used on combustion engines).
Just like any vibration analysis system, deltaAnalyser compares the spectrum of the gearbox at the beginning of the test to the spectrum recorded recently and generates a graph showing overall wear of the gearbox, which can be easily understood by a typical test bench operator.
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Vibroacoustic analysis for transmission tests -
Vibroacoustic analysis for transmission tests
Spectrum analysis and tolerances at the beginning and at the end of the test.
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Vibration spectra at the beginning and end of the test -
Vibration spectra at the beginning and end of the test
Trend index and deviation spectrum throughout the entire test.
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