There is a need for optimizing the energy efficiency and tribological performance of critical machine elements in electromechanical drivetrains. These elements are well-understood under nominal steady-state operating conditions, yet, their behavior and (tribological) performance under realistic dynamic operating and off-nominal design conditions largely remains a blind spot in both industry and science. For example, in industrial drivetrains rolling element bearings are typically selected and used for operating conditions that are not well documented in the catalogue (e.g., oscillatory movements, amount of pre-tensioning); in automotive applications, electrification is changing the boundary conditions of these bearings (e.g., increased speeds, varying axial loads).
In this infrastructure project, EMD_TRIB, a modular test bed is developed for examining and testing the tribological performance of individual critical elements under realistic dynamic operating conditions (dynamic rotational speeds up to 25k rpm; controlled oscillating motions; acceleration/deceleration and start/stop; dynamic multi-axial loading) and off-nominal design conditions. The scope of the infrastructure includes 4 types of machine elements, i.e., rolling/sliding bearings, dynamic seals, gear-pairs and cam-follower mechanisms. A well-conditioned and monitored lubrication unit will be included, allowing for different well-controlled lubrication conditions at the tested element. For precise measurements, EMD_TRIB will be equipped with advanced data capturing, combining classic sensors, inline lubrication and lubricant monitoring and inline vision-based inspection such as high-speed cameras.