Load-free wheelset gearbox test stand for S-Bahn Berlin GmbH

S-Bahn Berlin GmbH carries out the refurbishment of wheelset gearboxes for S-Bahn's own vehicles in the main workshop Schöneweide. These include BR 480, BR 481/482, and BR 483/484. After refurbishment, flushing and a load-free functional test of the wheelset gearboxes are required to remove contaminants from the refurbishment process and ensure the perfect functionality of the wheelset gearboxes in operation. The test stand foundation must be planned and manufactured according to the bidder's requirements by the client. The present publication refers to the manufacturing, delivery, assembly, commissioning, training, trial operation, and final acceptance of a load-free wheelset gearbox test stand including all necessary peripherals for the main workshop Schöneweide of S-Bahn Berlin GmbH. Only wheelset gearboxes of the vehicles in use by S-Bahn Berlin (BR 480, BR 481/482 & BR 483/484) are to be tested on the machine. The test stand must be suitable for the following tasks/functions: --- Rotatable mounting and storage of the wheelset shaft mounted on the wheelset gearbox - Storage is carried out on the bearing seats of the wheelset shaft using fixed and floating bearings --- Anti-rotation device of the wheelset gearbox in a defined zero position on the test stand via the torque support --- Mounting of the test stand components on a solid T-slot base plate (installed flush with the ground) - Incl. max. vibration damping through a suitable machine mounting system to the foundation --- Modular design of the test stand for easy setup and expansion possibilities --- Adaptability of the test stand to all three BR of the S-Bahn - BR480 - BR481/482 - BR483/484 --- Precisely controllable drive of the wheelset gearboxes using a drive motor - The test object is driven via a universal shaft and flange connection to the face-side bores of the wheelset shaft (no direct drive via the gearbox coupling) - Speeds up to 707 rpm (related to the wheelset shaft) --- Protective enclosure of the test stand to protect the operator and the environment, as well as noise reduction --- Process monitoring using camera and monitor technology with optimal lighting --- Filling of the wheelset gearboxes using oil systems - Manual filling and emptying - Automatic flushing of the oil in the wheelset gearbox in a closed bypass circuit - Coarse and fine filtration of the oil --- Program-guided support for the operator --- Program-controlled automatic execution of the test process - Automatic flushing of the wheelset gearbox - Automatic test runs including parameterizable speed ramps --- Metrological recording of temperatures and vibrations by calibrated measuring chains including - 01 piece triaxial vibration sensor (screwed) - 06 pieces temperature sensors (magnetic on bearing seats) - Min. 01 piece temperature sensor (insertion probe on oil sump) - Min. 01 piece temperature sensor (ambient temperature as reference) --- Graphical evaluation and display of temperature, vibration, speed, and total power recording curves --- Internal storage of test results --- Logging of test results in ".pdf/A" format and export to a DB Group Drive --- Remote maintenance access via "DB sichere Fernwartung 2.0" The test stand, along with all peripherals, must be designed in accordance with CE conformity and the latest state of the art. Only wheelset gearboxes with mounted wheelset shafts are to be tested (without mounted wheels, brake discs, wheelset bearings, couplings, or other attachments). The mass of the heaviest test object is approx. 750kg.