Driveline Durability, Wear and Life Testing

At a glance

Millbrook performs a range of driveline durability, wear and life tests, including gear set fatigue testing.

Driveline durability, wear and life test rigs also used for ISO 16750 electric drive unit testing at Millbrook
Millbrook Revolutionary Engineering axle test system

A passenger car manufacturer approached Millbrook to conduct gear set testing on an electric drive unit (EDU).

Driveline durability, wear and life test rigs also used for ISO 16750 electric drive unit testing at Millbrook

The testing was completed without the electric motor fitted into the drivetrain, so Millbrook used a high-speed input machine instead. The flexibility of Millbrook’s driveline test systems enabled the test team to swap machines to suit the test application; in this case, a high-torque, lower-speed input machine was used. High-power output machines were used to absorb the input energy through the test piece.

As fatigue load cases tend to be further up the S-N curve, input and output loads on EDUs for fatigue testing are usually very high compared to the average load seen by the component in service.

The test piece was subjected to continuous high torque, at levels defined by the S-N curve, for a duration determined by Miner’s rule so that the accumulated damage was representative of the component’s life cycle. Due to the very high loads the tests tended to be very short in duration (<24 hours).

The testing enabled the manufacturer to make early design changes to strengthen the internal components and gear geometry for the next phase of development.