Research

High-Performance Plain Bearings Test Rig

The power density of fast moving machines such as turbines, compressors, transmissions or electric engines increases continuously and leads to heightened requirements on the construction and materials of bearings. Reliably forecasting the decisive parameters of sliding bearings such as maximum temperature, maximum pressure, minimum lubricating gap height, power loss, oil throughput as well as rigidity and dampening is crucial in order to construct high performance plain bearings. To be able to validate development tools, it is essential to perform tests on a test stand. In a large joint project, the Research Association for Drive Technology (FVA) and Research Association for Combustion Engines (FVV) together with 19 industrial companies planned and constructed such a high performance plain bearings test stand. The test stand made it possible to conduct tribological and flow mechanics tests as well as to investigate the rotor dynamic properties of highly loaded plain bearings at high circumferential speeds of up to 200 m/s and is one of the most modern in the world.

» The industrial joint research has made possible a high performance plain bearings test stand that is unique worldwide. With its help, important properties of high speed plain bearings can be investigated. «
Prof. Dr.-Ing. Hubert Schwarze | Institute of Tribology and Energy Conversion Machinery (TU Clausthal)

Motivation

Plain bearings are indispensable for high speed machines such as turbines, compressors, transmissions or electric engines. In order to properly construct high performance plain bearings it is essential to be able to reliably forecast decisive parameters such as maximal temperature, maximal pressure, minimum lubricating gap height, performance loss, oil throughput as well as rigidity and dampening. That is why the design and simulation processes that are used must be continuously improved. In order to be able to verify development work tools, investigations on a test stand are mostly indispensible.

Methodology

The test stand components necessary for the tests, including the static and dynamic load devices, measurements, controlling as well as technology for logging and processing data, were designed and constructed at the Institute. The construction of the test stand – at least in the sensitive area in and around the rotor – also took place at the Institute. The test stand costs around 1.8 million Euros. The construction of the test stand occurred in three stages: Stage 1 for radial bearings at multiaxial load, meaning for testing up to the highest circumferential speeds; Stage 2 for the testing of single and double acting axial bearings; and Stage 3 for combine radial axial bearings, meaning hydrostatic jacking.

Result

The test stand made it possible to conduct tests on the tribological and flow mechanical properties as well as rotor dynamic properties of highly loaded plain bearings at extremely high circumferential speeds of up to 200 m/s and is one of the world's most modern test stands. A special highlight is the measurement technology, costing 120,000 Euros, which despite extreme speeds is capable of keeping up with the turning rotating shaft and detecting the distance of the rotors to the bearing through the use of inductive sensors. With these characteristics, the high performance plain bearings test stand is one of the most powerful in the world. The test stand makes a contribution to German manufacturers and service providers in the turbo, transmissions and electrical engineering being able to retain their international competitiveness.

Documentation

High-performancePlain Bearings Test Rig | Develop a high performance plain bearings test for determining tribological parameters at high loads and maximum circumferential speeds | Project No. 924

Themis

Status
Finalised

Programme
FVV Funding

Budget
330.440,50 EUR

Time Period
2006-09-06 to 2011-12-31

Research Association for Combustion Engines (FVV) eV

Lyoner Strasse 18
60528 Frankfurt am Main
Germany

Research Association for Drive Technology (FVA) eV

Lyoner Strasse 18
60528 Frankfurt am Main
Germany

Industry

Dr.-Ing. Morched Medhioub
Kingsbury GmbH

Dipl.-Ing. Albert Schmitz
Renk AG

RTD Performers

Institute of Tribology and Energy Conversion Machinery (ITR) | TU Clausthal

Head of Research:
Prof. Dr.-Ing. Hubert Schwarze
 
Research Associate:
Dr.-Ing. Hardwig Blumenthal

Clausthal University of Technology

Institute of Tribology and Energy Conversion Machinery (ITR)

Leibnizstrasse 32
38678 Clausthal-Zellerfeld
Germany

Project Management

Stefanie Jost-Köstering

FVV
+49 (0) 69 6603 1531
+49 (0) 69 6603 2531


Research Association for Combustion Engines eV

Lyoner Strasse 18
60528 Frankfurt am Main
Germany
T +49 69 6603 1345