Achieving equipment operating condition monitoring and predictive maintenance represents a significant research focus within intelligent equipment operation and maintenance. This research designed and developed a mechanical power-circulating ultra-high-speed gear transmission test rig. The test rig aims to overcome the limitations of traditional test rigs concerning dynamic loading capability and testing range, thereby enabling research into the lifecycle health monitoring of critical transmission components and the study of fault evolution mechanisms. This test rig innovatively employs a mechanical power-circulating structural design, forming a closed-loop system comprising by main drive motor, gearbox, loading system, torque/speed sensors, lubrication system, and intelligent control unit. Within this system, the main drive motor provides system power output and compensates for power losses. The loading system utilizes a loader and a control motor to freely apply and regulate dynamic loads. Complemented by a multi-channel sensor network that acquires key parameters such as torque, speed, vibration, and temperature in real-time, an integrated test rig encompassing mechanical transmission, electrical control, and data acquisition has been established.

  The technological innovations of this test rig are manifested in three key aspects. Firstly, the adoption of a mechanical power-circulating flow design significantly reduces external energy consumption through energy recycling. Secondly, the development of a dynamic loading module featuring a large angular displacement range and rapid response characteristics. Thirdly, the implementation of a modular and combinable architecture, allowing flexible configuration of the transmission structure based on the type of test specimen (such as gearboxes, couplings and bearings,) to accommodate diverse installation requirements. The test rig achieves a maximum test speed of 50,000 rpm and a maximum power capacity of 1000 kW.

  This test rig primarily serves the reliability verification and lifecycle health monitoring of core components within transmission systems. Specific applications include: 1) Implanting capabilities for both typical abrupt failures and progressive wear failures, providing data support for validating fault diagnosis algorithms and optimizing maintenance strategies. 2) Quantitative evaluation of gear contact strength, bending strength, and fatigue life. 3) Comparative studies on the influence of different material pairings and heat treatment processes on gear performance. 4) Performance assessment of lubricants and analysis/verification of oil film load-bearing characteristics. This test rig holds significant engineering application value for transmission system testing in fields such as aerospace, new energy vehicles, and wind power equipment.