Advanced Test System Technology

ZF Luftfahrttechnik GmbH
Ralf Kümmel
Program Manager Test Stands
Aerospace Testing 2005, Hall 1 Upper D17

ZF Luftfahrttechnik – ATX 2005 Page 180

 Facts & Figures
ZF Luftfahrttechnik GmbH

Capital Structure
100%

ZF Friedrichshafen AG

z Located at Airport Kassel-Calden, Germany

z Industrial site with 60,000 m²
z 6 Buildings with 16,900 m²
z 320 Employees

ZF Luftfahrttechnik – ATX 2005 Page 181

 Organisational Structure
ZF Friedrichshafen AG

ZF Friedrichshafen AG
Shareholder: 93,8 % Zeppelin-Stiftung, Friedrichshafen / 6,2 % Dr.-Jürgen-Ulderup-Stiftung, Lemförde

Klare Zeichen, mehr Profil.

Corporate Headquarters Friedrichshafen

Unternehmensbereiche
Divisions Regions

„ Car Driveline Technology „ North America

„ South America
„ Car Chassis Technology „ Asia Pacific

„ Commercial Vehicle and Special Driveline Technology

Business Units
„ Off-Road Driveline Technology and Axle Systems
„ Rubber-Metal Technology
„ Powertrain and Suspension Components „ Marine Propulsion Systems
„ Aviation Technology
„ Aftermarket Trading

„ Steering Technology – ZF Lenksysteme GmbH

A Joint Venture with Robert Bosch GmbH Sales and Service Organisation

ZF Luftfahrttechnik – ATX 2005 Page 182

 Market Structure
ZF Friedrichshafen AG

Cars & Commercial Vehicles < 6 t 62 %

Commercial Vehicles > 6 t 21 %

Construction Machinery 4%

Agricultural Machinery 3%

Marine 3%

Rail Vehicles, Special Vehicles, 2%

Industrial Engineering, Aircraft

Others 5%

ZF Luftfahrttechnik – ATX 2005 Page 183

 ZF Worldwide

119 6 27 28 > 500

Production Main Development Sales & Service Aftermarket After Sales
Locations Locations Centers and Trading Service Points
Representative Companies
Offices

ZF Luftfahrttechnik – ATX 2005 Page 184

 ZF Luftfahrttechnik GmbH
Range of Products and Services

Service, Maintenance
Multipurpose Test Stands and Production

Design & Development

ZF Luftfahrttechnik – ATX 2005 Page 185

 Advantages of Multipurpose Test Stands

Aim:
Testing of dynamic components
after repair and overhaul on
full power test stands

Quantity of High investment

test specimen per test specimen
per type

Solution:
Multipurpose Test Stands

ZF Luftfahrttechnik – ATX 2005 Page 186

 ZF Luftfahrttechnik GmbH
Multipurpose Gearbox Test Stands

ZF Luftfahrttechnik – ATX 2005 Page 187

 Gearbox Test Stand Technology
Full load via brake

ZF Luftfahrttechnik – ATX 2005 Page 188

 Gearbox Test Stand Technology
Full load mechanical closed loop

ZF Luftfahrttechnik – ATX 2005 Page 189

 Gearbox Test Stand Technology
Full load via motor generator loading

ZF Luftfahrttechnik – ATX 2005 Page 190

 Gearbox Test Stand Technology
Full load via hydraulic loading

ZF Luftfahrttechnik – ATX 2005 Page 191

 Full Load via Moment Change Device
Multipurpose Gearbox Test Stand Technology

ZF Luftfahrttechnik – ATX 2005 Page 192

 The New Standard
Multipurpose Test Stand Technology

ZF Luftfahrttechnik – ATX 2005 Page 193

 Automatic Control System
General Layout

Operating PC
Test program- & limit value-
Fieldbus (CAN, Modbus Plus) administration
Digital / analog input / output Monitoring & protocol generation

Digital
PLC programmable logic control
Drive Control

Inverter
Teststand Accessorie-
Test specimen systems
AC Drives gearboxes

ZF Luftfahrttechnik – ATX 2005 Page 194

 Multipurpose Test Stand Technology
Test Run Measurements

) speeds
) torque
) rotor thrust
) rotor mast bending
) wear / debris
) heat balance
) oil pressure
) oil flow
) bearing temperatures
) vibrations

) dynamic patterns (visual inspection)

ZF Luftfahrttechnik – ATX 2005 Page 195

 Auxiliary Systems
Design Examples

ZF Luftfahrttechnik – ATX 2005 Page 196

 Multipurpose Test Stand
Eight Helicopter Main Gearbox Types

Main
Main Gearbox
Gearbox Types
Types A109
A109
A119
A119
Bell
Bell 204
204
Bell
Bell 205
205
Bell
Bell 206A
206A
Bell
Bell 206A-1
206A-1
Bell
Bell 212
212
Bell
Bell 412
412
Dimensions
Dimensions Length
Length 4.880
4.880 mm
mm
Width
Width 3.375
3.375 mm
mm
Height
Height 5.520
5.520 mm
mm
Weight
Weight approx.
approx. 35
35 to
to
Maximum
Maximum Test
Test Speed
Speed 6.000 min-1-1
6.000 min
Maximum
Maximum Test
Test Power
Power 2.100
2.100 kW
kW
First
First Operation
Operation 1998
1998

ZF Luftfahrttechnik – ATX 2005 Page 197

 Multipurpose Test Stand
IDS, Gearbox under Development

Main
Main Gearbox
Gearbox Type
Type IDS
IDS

Dimensions
Dimensions Length
Length 4.880
4.880 mm
mm
Width
Width 3.375
3.375 mm
mm
Height
Height 5.520
5.520 mm
mm

Weight
Weight approx.
approx. 35
35 to
to

Max.
Max. Test
Test Speed
Speed 6.000 min-1-1
6.000 min

Max.
Max. Test
Test Power
Power 2.100
2.100 kW
kW

First
First Operation
Operation 1998
1998

ZF Luftfahrttechnik – ATX 2005 Page 198

 Tilt Axis Gearbox Test Stand

Gearbox
Gearbox Type
Type BA609
BA609 TAGB
TAGB

Max.
Max. Test
Test Speed
Speed 9.150 min-1-1
9.150 min

Max.
Max. Test
Test Power
Power 1.520
1.520 kW
kW

Length
Length 5.300
5.300 mm
mm
Width
Width 2.160
2.160 mm
mm
Height
Height 3.560
3.560 mm
mm

Weight
Weight approx.
approx. 13
13 to
to

First
First Operation
Operation 2000
2000

ZF Luftfahrttechnik – ATX 2005 Page 199

 Multipurpose Test Stand
Five Helicopter Main Gearbox Types

Main
Main Gearbox
Gearbox Types
Types CMH
CMH
AB139
AB139
NH90
NH90

Possible
Possible Adaptation
Adaptation A129
A129 (Int.
(Int. && Mult.)
Mult.)
BA609
BA609 Prop.
Prop. (LH+RH)
(LH+RH)

Dimensions
Dimensions Length
Length 6.560
6.560 mm
mm
Width
Width 4.250
4.250 mm
mm
Height
Height 6.680
6.680 mm
mm

Weight
Weight approx.
approx. 75
75 to
to

Max.
Max. Test
Test Speed
Speed 34.500 min-1-1
34.500 min

Max.
Max. Test
Test Power
Power 6.000
6.000 kW
kW

First
First Operation
Operation 2002
2002

ZF Luftfahrttechnik – ATX 2005 Page 200

 Multipurpose Test Stand
Four Helicopter Gearbox Types (MGB, IGB & TGB)

Main
Main Gearbox,
Gearbox, S-70A
S-70A &
& S-70B
S-70B
Intermediate
Intermediate Gearbox
Gearbox &
& AS532
AS532
Tail
Tail Gearbox
Gearbox Types
Types

Possible
Possible Adaptations
Adaptations AH-1Z
AH-1Z
Ka-50
Ka-50

Dimensions
Dimensions Length
Length 12.500
12.500 mm
mm
Width
Width 4.400
4.400 mm
mm
Height
Height 7.200
7.200 mm
mm

Weight
Weight ca.
ca. 90
90 tt

Max.
Max. Test
Test Speed
Speed 23.500 min-1-1
23.500 min

Max.
Max. Test
Test Power
Power 4.400
4.400 kW
kW

First
First Operation
Operation 2003
2003

ZF Luftfahrttechnik – ATX 2005 Page 201

 Multipurpose Test Stand
Four Helicopter Gearbox Types (MGB, IGB & TGB)

Main
Main Gearbox,
Gearbox, ALH
ALH
Intermediate
Intermediate Gearbox
Gearbox &
& Sea
Sea King
King
Tail
Tail Gearbox
Gearbox Types
Types

Possible
Possible Adaptations
Adaptations LOH
LOH
Ka-28/32
Ka-28/32

Dimensions
Dimensions Length
Length 12.500
12.500 mm
mm
Width
Width 4.400
4.400 mm
mm
Height
Height 6.800
6.800 mm
mm

Weight
Weight ca.
ca. 105
105 tt

Max.
Max. Test
Test Speed
Speed 21.700 min-1-1
21.700 min

Max.
Max. Test
Test Power
Power 4.000
4.000 kW
kW

First
First Operation
Operation 2004
2004

ZF Luftfahrttechnik – ATX 2005 Page 202

 ZF Luftfahrttechnik GmbH
Multipurpose Whirl Tower for Main Rotor Blades

ZF Luftfahrttechnik – ATX 2005 Page 203

 Advanced Whirl Tower Technology
System Configuration

ZF Luftfahrttechnik – ATX 2005 Page 204

 Advanced Whirl Tower Technology
Test-Run Measurements

For series production

‹ upward thrust of each rotor blade (indirect via track)

‹ air resistance (indirect via lag angle / direct via one 1/rev)
‹ force of control rods (direct via measuring pins)
‹ vibration (if necessary)

Additional measurements for development

‹ total rotor upward thrust (direct via strain gauge)

‹ rotor mast torque (direct via measuring shaft)
‹ rotor mast bending moment (direct via strain gauge)
‹ blade forces (direct via strain gauge)
‹ vibration characteristics (vibration sensor)

ZF Luftfahrttechnik – ATX 2005 Page 205

 Multipurpose Whirl Tower
Five Main Rotor Blade Types

Rotor
Rotor Blade
Blade Types
Types BO105
BO105
BO105
BO105 KWS
KWS
BK117
BK117
EC135
EC135
EC145
EC145

Max.
Max. Test
Test Power
Power 900
900 kW
kW

Voltage
Voltage 800
800 V
V DC
DC

Height
Height 5.800
5.800 mm
mm

First
First Operation
Operation 1981
1981

Upgrades
Upgrades 1983,
1983, 1998,
1998, 2000
2000

ZF Luftfahrttechnik – ATX 2005 Page 206

 Multipurpose Whirl Tower
Eight Main Rotor Blade Types

Rotor
Rotor Blade
Blade Types
Types Tiger
Tiger
ALH
ALH
BO105
BO105
BO105
BO105 KWS
KWS
BK117
BK117
EC135
EC135
EC145
EC145

Possible
Possible Adaptation
Adaptation CH53
CH53

Max.
Max. Test
Test Power
Power 1.230
1.230 kW
kW

Voltage
Voltage 800
800 V
V DC
DC

Height
Height 6.700
6.700 mm
mm

First
First Operation
Operation 1986
1986

Upgrades
Upgrades 2000,
2000, 2001,
2001, 2002
2002

ZF Luftfahrttechnik – ATX 2005 Page 207

 Main Rotor Blade Whirl Tower

Rotor
Rotor Blade
Blade Type
Type ALH
ALH

Possible
Possible Adaptation
Adaptation Sea
Sea King
King

Max.
Max. Test
Test Power
Power 1.230
1.230 kW
kW

Voltage
Voltage 800
800 V
V DC
DC

Height
Height 6.700
6.700 mm
mm

First
First Operation
Operation 1993
1993

ZF Luftfahrttechnik – ATX 2005 Page 208

 Thanks for your kind attention !

ZF Luftfahrttechnik – ATX 2005 Page 209