Mechanical Gear Test Rig

Develop a novel test rig to systematically characterise the torque capacity, mechanical efficiency, and failure behaviour of different gear geometries under controlled, repeatable loading conditions.

All components — frame, gear mounts, bearing housings, loading mechanism — designed in Fusion 360. Dynamic motion analysis validated gear meshing behaviour and identified stress concentrations before fabrication.

• →Full assembly modelled parametrically in Fusion 360
• →Dynamic motion analysis — verified gear meshing forces
• →Modular gear mount — accommodates different modules and ratios
• →Adjustable torque loading mechanism

Torque sensors on input and output shafts for efficiency calculation, load cells for radial/axial force measurement, and rotary encoders for speed and slip — feeding automated DAQ with real-time plotting.

• →Input and output torque sensors for efficiency curve
• →Load cell for radial and axial force measurement
• →Rotary encoder for speed and slip quantification
• →Automated DAQ with real-time data plotting

Mechanical design and simulation complete. Fabrication in progress under university workshop oversight. Electronics integration and sensor calibration are the next milestones.