Germany – Test benches – Lastfreier Radsatzgetriebeprüfstand für die S-Bahn Berlin GmbH

S-Bahn Berlin GmbH carries out the overhaul of gear units of its own vehicles at the main workshop in Schöneweide. This includes the BR 480, BR 481/482 and BR 483/484. After the overhaul, flushing and a load-free functional test of the gear units is required to remove contaminants from the overhaul process and to ensure the proper functioning of the gear units during operation. The test stand foundation must be designed and manufactured by the AG according to the requirements of the bidder. The present publication refers to the manufacture, delivery, assembly, commissioning, training, trial operation and final acceptance of a load-free gear unit test stand including all necessary peripherals for the main workshop Schöneweide of S-Bahn Berlin GmbH. Only gear units of the vehicles used 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 bearing of the gear unit-mounted wheel set shaft - bearing is carried out at the bearing seats of the wheel set shaft by means of fixed and floating bearings

- Anti-rotation locking of the gear unit 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 at ground level) - incl. max. vibration damping by means of a suitable machine mounting system to the foundation

- Modular design of the test stand for easy set-up and possibilities for expansion

- Adaptability of the test stand to all three BR of the S-Bahn - BR480 - BR481/482 - BR483/484

- Precise controllable drive of the gear units by means of a drive motor - The drive of the test object is effected via a universal joint and flange connection to the end face bores of the wheel set shaft (no direct drive via the coupling of the gear unit) - Speeds up to 707 rpm (based on the wheel set shaft)

- Protective enclosure of the test stand for the protection of the operator and the environment as well as noise reduction

- Process observation by means of camera and monitor technology with optimal lighting

- Filling of the gear units by means of oil systems - Manual filling and emptying - Automatic flushing of the oil in the gear unit in a closed bypass circuit - Coarse and fine filtration of the oil

- Program-controlled support of the operator

- Program-controlled automatic sequence of the test process - Automatic flushing of the gear unit - Automatic test runs incl. parameterisable speed ramps

- Measuring of temperatures and vibrations by calibrated measuring chains incl.

- 01 piece triaxial vibration sensor (screwed on)

- 06 pieces temperature sensors (magnetically attached to bearing points)

- Min. 01 piece temperature sensor (insertion probe in the oil sump)

- Min. 01 piece temperature sensor (ambient temperature as reference)

- Graphical evaluation and display of the temperature, vibration, speed and total power consumption curves

- Machine-internal storage of the test results

- Logging of the test results in the format „.pdf/A“ and export to a DB Group Drive

- Remote maintenance access via „DB secure remote maintenance 2.0“

The test stand is to be designed with all peripherals in accordance with CE conformity to the latest state of the art. Only gear units with mounted wheel set shaft are tested (without mounted wheel discs, brake discs, wheel set bearings, couplings or other attachments). The mass of the heaviest test object is approximately 750kg.