Powertrain & Gear Testing

UTT worm gear test rig

Overview

The UTT (Universal Torque Tester) is a general-purpose worm gear test rig designed for quasi-static heavy torque loads. It enables precise testing of worm gear pairs under controlled conditions with multi-axis positioning for accurate alignment of the worm shaft and worm wheel. The system accommodates a wide range of worm wheel sizes (OD 40–200 mm) and delivers output torques up to 1000 Nm, making it suitable for both R&D and quality assurance of worm gear transmissions.

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Availability

Features and specifications

The UTT test rig features a motorized drive side with an electric motor and 60:1 gear reduction delivering 55 Nm input torque at 23.3 rpm output speed. A precision torque sensor measures the input torque (min. 0.5 Nm), while elastomer couplings isolate vibrations in the drivetrain. The worm shaft is supported by interchangeable bearing housing heads that accommodate bearing diameters from 15 to 62 mm and clamping diameters from 8 to 22 mm.

Multi-axis positioning enables precise alignment of the test specimen: X-axis (lateral) translation of ±55 mm, Z-axis (center distance) translation of 20–85 mm, Y-axis (vertical) translation of 0–60 mm, and Z-axis rotation of 0–90° for the worm wheel. Horizontal positioning accuracy is 0.02 mm and vertical accuracy is 0.05 mm, with angular accuracy of ±0.01°.

Drive system

Electric motor with 60:1 gear reduction
Output torque: 55 Nm (input), up to 1000 Nm (output)
Input speed: 1400 rpm / Output speed: 23.3 rpm
Rated power: 0.16 kW
Inline torque sensor (min. 0.5 Nm)
Elastomer couplings for vibration isolation

Worm shaft mounting

Interchangeable bearing housing heads for variable bearing sizes
Shaft bearing diameters: 15–62 mm
Shaft clamping diameters: 8–22 mm
Bearing-to-bearing length range: 45–140 mm
Independent X-direction movement of each bearing housing

Multi-axis positioning

X-axis (lateral) translation: ±55 mm
Z-axis (center distance) translation: 20–85 mm
Y-axis (vertical) translation: 0–60 mm
Z-axis (worm wheel) rotation: 0–90°
Horizontal positioning accuracy: 0.02 mm
Vertical positioning accuracy: 0.05 mm
Angular positioning accuracy: ±0.01°
Linear rail guides with positioning wheels and brake systems

Worm wheel fixation

Worm wheel OD range: 40–200 mm
Worm wheel hub diameter: 15–40 mm
Pin-based mounting for high torque transfers
Ratcheted washer mounting (interchangeable option)
Worm wheel console carrier with rotational stage

Control and DAQ software

Intuitive user interface for test control and data acquisition
Direct test parameter input for ramp-load tests
Tabular import for complex time-dependent load signals
Live graphical overview of test parameters
Automatic test data export
Connection via ethernet cable (Windows OS required)

Safety and structure

Robust welded frame rated for 450 Nm reaction torque
Removable polycarbonate protection glass with hinge mechanism
Rubber vibration dampers integrated into the base
Separate electronics cabinet with PLC, power supplies, and amplifiers

Available upgrades

Sample temperature control in loading area: ambient to 150 °C
Low-temperature control down to −40 °C (upon feasibility review)

Specifications

Parameter	Specification
Min. input torque (directly measured)	0.5 Nm
Max. input torque (directly measured)	85 Nm
Output torque	1000 Nm
Worm shaft input speed	20 rpm
Worm shaft bearing diameters	15–62 mm
Worm shaft clamping diameter	8–22 mm
Worm wheel OD	40–200 mm
Worm wheel hub diameter	15–40 mm
Relative center axis angle between gears	0–90°
Horizontal positioning accuracy	0.02 mm
Vertical positioning accuracy	0.05 mm
Angular positioning accuracy	±0.01°
Approximate dimensions (W × D × H)	950 × 740 × 760 mm
Connectivity	Ethernet (Windows OS)