Dynamometer and translational movement improvement for the REPA test rig in the Solar Platflorm of Almeria

Kurzfassung

In this technical report, I will describe two tasks I carried out during my internship at the Solar Platform of Almeria (PSA) on the REPA Test Rig project, supervised by the German Aerospace Centre (DLR). Firstly, I assessed the needs of the Test Rig and its current status, as this was crucial in selecting the appropriate dynamometer. My first task was to select and adapt a new six-axis dynamometer for the test rig, which I divided into four stages. I researched and understood how dynamometers work and how temperature affects them. Through testing two dynamometers, I discovered that zero drift is the primary cause of error due to temperature. I also compared several suppliers. I chose Kistler, a distributor for SRI, as the best option for the requirements. Kistler adjusted the dynamometer to alter its full scale. Due to the significant dimensional differences between the old and new dynamometers, new mounting plates had to be designed to maintain the same height, as the swivel used by the dynamometer had to remain in the same position. Most of the plate designs were based on the dimensions of the previous plates and input from the Maintenance Head. Producing the necessary drawings with the precision required for their optimum operation was part of my contribution to this fourth stage. The second objective was to enhance the translational movement features of the REPA Test Rig. To accomplish this, I adopted the same approach as the previous task and broke it down into subtasks. Initially, I collected data by reviewing the bearing selection guidelines and researching the reasons for their malfunction. Upon my arrival, the model being used had malfunctioned due to the dynamic forces of the system. As part of my subtask, I summarised all the technical requirements necessary for the improvement of the system. With this information at hand, the subsequent step was choosing the suitable product. Due to limited information on driving forces, I arranged meetings with different manufacturers who presented their varied views and priorities. Schaeffler's cylindrical roller bearings were the final choice. To accommodate the augmented bearing diameter, I constructed an adapter for the current axle. Almost at the close of the task, I presented my work at the PSA. At the meeting, a fellow suggested that we substitute bearings with bushings. Following an assessment of their suitability and discussion with colleagues, it was decided that bushes were the better option. I was responsible for drawing up the design and ensuring the correct tolerances to ensure that it worked. On receipt of the bushings, I verified that the measurements were correct for their installation.