SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench

SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench

1. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Overall Description

The SSCH110-6000-12000 110kW hydraulic transmission system test bench is designed specifically for performance verification and reliability testing of small and medium-sized industrial hydraulic equipment. It integrates a 110kW high-speed electric dynamometer, a 45MPa-class industrial high-pressure hydraulic pump, a multi-condition load simulation module, and an intelligent measurement and control system. This enables comprehensive parameter testing of hydraulic pumps and motors under medium-to-high pressure (≤45MPa), medium-to-high load (110kW continuous loading), and a wide speed range (0-12,000 rpm). The system supports ≥85% power recirculation to the grid and is suitable for hydraulic transmission components used in small and medium-sized metallurgical machinery, ship deck machinery, and light engineering machinery. It can perform performance calibration, 500-1,000-hour endurance testing, and fault simulation, meeting the testing needs of small and medium-sized industries for precision testing, energy efficiency, and flexible adaptability.

2. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Core Components

(1) Industrial high-pressure hydraulic pump

• Rated pressure: 45MPa (suitable for mainstream pressure requirements of small and medium-sized equipment), flow rate: 65L/min
• Applicable medium: industrial anti-wear hydraulic oil (L-HM46/68), with 1000 hours of continuous operation stability
• Function: Provide continuous medium and high pressure oil source for load modules, accurately simulate the actual oil supply conditions of ship winches and small metallurgical rolling mills

(2) Fuel tank module

• Available volume: 200L (meeting the oil circulation needs of small and medium-sized systems), boost adjustment range: 0-0.3MPa
• Filtration system: three-stage precision filtration (precision 10μm), equipped with online oil cleanliness monitoring (adapted to ISO 4406 16/13 level)
• Advantages: Avoid wear of hydraulic components caused by oil contamination, and ensure stable oil temperature under wide speed test (oil temperature control ±2°C)

(3) 110kW electric dynamometer (core test unit)

• Speed range: 0-12000r/min stepless speed regulation (suitable for low-speed and heavy-load conditions of ship deck machinery and high-speed conditions of small equipment)
• Overload capacity: 120% rated power (short-term duration of 10 minutes, to cope with the impact load of hydraulic pump start and stop)
• Control mode: electromagnetic force loading, steady-state torque control accuracy ±0.2% FS, support torque/speed/power three-loop control
• Energy-saving features: The efficiency of testing power back to the grid is ≥85%, reducing the energy consumption cost of long-term testing

(4) Torque and speed sensor

• Measuring range: torque 0-400Nm, speed 0-12000r/min
• Accuracy level: ≤0.1% FS (static), ≤0.2% FS (dynamic), sampling frequency 1kHz
• Adaptability: Anti-electromagnetic interference design meets the signal stability requirements of parallel testing of multiple devices in industrial workshops

(5) Variable frequency inverter system

• Control technology: Direct Torque Control (DTC), output frequency accuracy ±0.01Hz
• Environmental adaptability: operating temperature 0℃~45℃, protection level IP54 (dustproof and splashproof, suitable for dusty environments in metallurgical workshops)
• Communication and compliance: Supports Modbus-RTU industrial protocol (interconnection with workshop MES system), noise ≤ 82dB (compliant with JB/T 7039-2016 noise limits)
• Power requirement: 380V ± 10% three-phase 50Hz (no separate transformer required, reducing deployment costs for small and medium-sized enterprises)

(6) Multi-condition load module

To meet the testing needs of small and medium-sized equipment, three types of load modes are integrated:

• High-pressure relief load: 45MPa-class relief valve group, used to test the high-pressure steady-state pressure-flow characteristics of hydraulic pumps (such as small metallurgical presses);
• Proportional throttling load: 0-65L/min proportional valve adjustment, simulating the flow changes of ship windlass "start and stop-low speed and heavy load";
• Heavy-duty loading cylinder: 30kN-class hydraulic actuator, suitable for simulating lifting loads on small and medium-sized construction machinery (such as small loaders).

(7) Intelligent measurement and control module

• Data acquisition: Multi-channel synchronous acquisition (sampling frequency 300Hz), supporting 120+ parameters including pressure (0-60MPa), flow (0-80L/min), torque, speed, oil temperature, etc.
• Analysis function: Automatically generate volumetric efficiency and total efficiency curves, and output dedicated test reports for marine/metallurgical equipment (compliant with ISO 10770-1 and GB/T 17487 standard formats);
• Convenient operation: 10-inch touch screen, supports parameter preset and test process automation (reducing manual intervention).

(8) Remote control module

• Hardware architecture: DSP+FPGA dual-core processor, paired with an X86 industrial-grade CPU (1.0GHz main frequency, 1GB memory, 8GB DOM disk);
• System and interconnection: Pre-installed Win10 IoT Industrial Edition, supports local/remote control within 500m (suitable for unmanned small and medium-sized workshops);
• Data docking: It can be connected to the ship's shore-based monitoring system and the metallurgical workshop production management system to realize the linkage between test data and equipment operation and maintenance.

3. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Technical Parameters

4. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Reference Standards

Domestic standards

• GB/T 3766-2021 "General rules and safety requirements for hydraulic transmission systems and their components" (basic safety compliance)
• GB/T 17487-2021 "Hydraulic Pump Test Methods" (Core Test Process Basis)
• GB/T 23537-2017 Hydraulic Piston Pump (Special Standard for Testing Small and Medium-Sized High-Pressure Piston Pumps)
• JB/T 7039-2016 "Limits of Noise Values for Hydraulic Pumps" (Industrial Workshop Noise Compliance)
• CB/T 3826-2013 "Test Methods for Ship Hydraulic Pumps" (Special Test Basis for Ship Deck Machinery Pumps)

International Standards

• ISO 4413:2010 Hydraulic fluid power-General rules and safety requirements for systems and their components (Global hydraulic system general safety standard)
• ISO 10770-1:2019 "Hydraulic fluid power-Pumps and motors-Part 1: Nominal pressures, nominal displacements and nominal speeds" (calibration standard for nominal parameters of small and medium-sized pumps)
• DIN 24313:2019 Hydraulic fluid power-Test methods for pumps
• ISO 9906:2012 "Reciprocating internal combustion engines-Performance" (performance test of hydraulic pump drive motors)
• DNV GL-RP-0038:2020 Guidelines for hydraulic systems in marine applications

5. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Core Advantages

(1) Precise adaptation of small and medium-sized equipment

The high speed of 12,000 r/min covers both low-speed, heavy-load and high-speed, light-load operating conditions of ship deck machinery (such as winches and steering gear). The 45 MPa pressure adapts to the hydraulic pump requirements of small and medium-sized metallurgical and engineering machinery, avoiding the waste of testing resources caused by "a large horse pulling a small cart."

(2) Cost-effective energy-saving design

With an energy retransmission efficiency of over 85%, it recovers approximately 93.5kWh of electricity per hour at a full 110kW load, saving over 60% in annual energy costs compared to traditional resistive load test benches. It is particularly suitable for batch quality inspection (such as hydraulic pump factory testing) and short-to medium-cycle endurance testing in small and medium-sized enterprises.

(3) Flexible switching between multiple scenes

The load module supports rapid switching between three modes: high-pressure overflow (small metallurgy), proportional throttling (ship anchoring), and heavy-load loading (construction machinery). It can complete hydraulic transmission tests on three types of small and medium-sized equipment without replacing core components, thereby improving test bench utilization.

(4) High adaptability to industrial environment

The variable frequency inverter system has IP54 protection and forced water cooling, making it suitable for the dusty environments of metallurgical workshops and the humid environments of ship repair yards. It supports Modbus protocol and docking with the workshop MES system, allowing it to be integrated into existing production chains without additional modifications.

(5) High reliability and low maintenance cost

The dynamometer's core bearings are from the SKF Small and Medium-sized Industrial Heavy-Duty Series. The oil tank's three-stage filtration system reduces wear on hydraulic components, ensuring annual maintenance time of ≤30 hours. Key components come with a one-year warranty, reducing operational and maintenance pressure on small and medium-sized enterprises.

(6) Compliance and certification assurance

The test bench design complies with CE (EU Machinery Directive 2006/42/EC) and GB/T 3766 safety standards, and can provide test reports issued by CNAS-accredited laboratories to meet the compliance requirements of the shipbuilding and metallurgical industries.

6. SSCH110-6000-12000 110kW Industrial Hydraulic Transmission System Test Bench Core Application Areas

(1) Testing of hydraulic pumps for small and medium-sized metallurgical machinery

• Applicable equipment: 35-45MPa hydraulic pumps for small steel rolling mills and metallurgical auxiliary presses;
• Test content: High-pressure steady-state pressure-flow characteristics, 1000-hour endurance reliability, and the impact of oil temperature fluctuations on efficiency;
• Value: Ensure the continuous operation stability of metallurgical auxiliary equipment and reduce the risk of production line downtime.

(2) Hydraulic transmission test of ship deck machinery

• Applicable equipment: 30-40MPa hydraulic pump/motor for ship windlass, winch, and steering gear;
• Test content: low-speed and heavy-load (5-50r/min) torque output accuracy, start-stop impact load tolerance, and adaptability to high and low temperature (-10~50℃) working conditions;
• Compliance: Meets the requirements of DNV GL and CCS classification societies for hydraulic system reliability.

(3) Testing of hydraulic components of light engineering machinery

• Applicable equipment: auxiliary hydraulic pumps (25-40MPa) and travel motors of small loaders and excavators;
• Test content: load-sensing control performance, anti-pollution ability (ISO 4406 19/16 level simulation), volumetric efficiency degradation trend;
• Value: Provides accurate component selection data to construction machinery manufacturers to improve equipment operation endurance.

(4) Quality inspection of hydraulic pumps for small and medium-sized injection molding machines

• Suitable equipment: 30-45MPa high-pressure plunger pump for injection molding machine with clamping force of 500-1000T;
• Test content: Flow response speed in mold clamping/injection conditions, volumetric efficiency (≥90%), and noise level (≤75dB);
• Advantages: Supports rapid testing of batch pump bodies (single unit test cycle ≤ 2 hours), meeting the production capacity needs of injection molding machine manufacturers.

(5) R&D and verification of hydraulic transmission components

• Applicable scenarios: R&D of 50-150kW medium-power pumps for hydraulic pump manufacturers;
• Test content: high-pressure seal structure optimization, valve plate design verification, and adaptability to different hydraulic oil media;
• Tools: Provides custom test process editing functions and supports multi-variable comparative testing in the R&D stage.

7. Industrial Hydraulic Transmission System Test Bench Model List