| The helicopter main transmission is one the three key components of helicopter, it is the essential part needed for turbo shaft engine power output and the most complex, heaviest and biggest component of the transmission system. Therefore, the fatigue life and reliability analysis of gears and bearings of the main transmission and the heat generation and lubrication system analysis is of great importance. In this paper, a lubrication and fatigue test rig for pressurized-oil-lubricated gear has been developed, the test rig can be used as a miniature test machine in designing helicopter main transmission.This paper first analyzed and compared the loading and lubricating method of gear test rigs from domestic and abroad, and then the design requirement of test rig was proposed to meet the specific needs of helicopter main transmission designing. In order to meet the requirement of main transmission gear fatigue life parameters, the test gear box and loading method was improved, and proposed a design scheme of the lubrication system. Then, the reliability of the test gear box of gear lubrication and fatigue test rig was checked. The strength of test gear shaft and life of bearing is checked using simulation software called Romax Designer. The lubrication oil flow rate and nozzle diameter is designed based on power loss of gears and bearings. Completed the hardware and software design of test and control system, realized the monitoring and control of the test gear long term running.Finally, some test runs are carried out on the gear lubrication and fatigue test rig. Results showed that the test rig can run smoothly under the control of the controlling system. Gear fatigue life under various speed and torque and gear lubrication under various oil pressure and flow rate can be carried out. During these tests, the test gear running and nozzle injection condition can be observed from outside; also, the gear temperature can be measured using infrared thermal imager. |
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