How do you test a group of devices as large as an elephant? One bite at a time.
Client Challenge
Our customer needed a sophisticated test system to evaluate the performance of a massive rotating gear set within an elephant-sized gearbox. The system required precise data acquisition from over 300 sensors, including:
- 100+ Accelerometers
- 18 Proximity Probes
- 12 Microphones
- 200+ mixed analog signals monitoring temperatures, pressures, and flows
The client sought a solution that could accommodate different designs of gearboxes while being simple enough for entry-level operators to use effectively.
Our Solution
Our team developed a robust and flexible test system designed to meet the unique demands of the application:
High-Performance Data Acquisition
- Optimized the system to capture simultaneous data from accelerometers and proximity probes at an unprecedented 200,000 samples per second.
- Leveraged advanced hardware and software integration to ensure seamless processing of diverse signal types without compromising accuracy.
Scalability for Multiple Gearbox Designs
- Built the system to support testing of various Device Under Test (DUT) configurations.
- Included modular components to adapt to design changes with minimal reconfiguration.
User-Friendly Interface
- Developed an intuitive software interface, allowing operators with minimal training to run complex tests.
- Automated processes for sensor calibration, test execution, and data logging, reducing the potential for errors.
Results
Efficiency
Accelerated test cycles while maintaining precision across hundreds of data channels.
Flexibility
Successful testing of multiple DUT variations without additional system modifications.
Accessibility
Enabled entry-level operators to perform tests, reducing the need for specialized personnel.