VIVAERO

NDE Clarke Pitchline expands compact gearboxes range

Coventry-based NDE Clarke Pitchline has announced an expansion of its range of compact, high-performance gearboxes to support the burgeoning need for high-speed ground-based testing of critical aerospace components.

The expansion of the CA modular gearbox range is a direct response to the continued technical evolution within the sector, which is seeing the growing electrification of aircraft sub-systems, driven by a desire for ever greater speed and efficiency. 

Suitable for both research & development and product acceptance testing, the CA range draws on NDE Clarke Pitchline’s extensive capabilities in designing and manufacturing high-speed precision gearboxes which fit within a compact envelope.

hanks to proprietary sealing technology, the CA range is not subject to the leakage of oil lubricant which can potentially invalidate test results in other systems and create health & safety and operational issues. Gear geometry is optimised thanks to advanced finite element analysis (FEA) and in-house testing, while noise-vibration-harshness (NVH) is class-leading due to a proprietary hardening and gear grinding process, with gears able to be ground to DIN class 3 - or even above if demanded by the application. This also helps to deliver high energy density and reliability improvements. 

The range is ATEX-certified, enabling it to be used in fuel-rich environment to test components such as engines and fuel pumps. Each CA gearbox also comes with an integrated condition monitoring system to allow for optimised service intervals, and as an option, this can be monitored 24/7 by NDE via a cloud-based platform

Boasting very low NVH attributes, the CA range is ideal for testing components such as fuel pumps, turbines, spindles, generators, permanent magnetic alternators (PMAs) and high-speed motors, for all types of aircraft from large civil, business and military aircraft, to helicopters, freight aircraft, and even UAVs whose high-speed engines can be tested using the new range. 

The line-up can test at speeds of up to 50,000rpm, future-proofing test facilities against subsequent increases in required test speeds. All CA gearboxes can be incorporated into custom designed driveline systems including full electrical drive systems, drive stands and fixtures, conditioned oil lubrication and associated couplings, providing a complete turnkey solution. Each gearbox can also be tailored to test a variety of component types. 

The range consists of four models. Available as both a flange-mounted or foot-mounted variant, the CA-400 can test at output speeds of up to 15,000rpm and a maximum torque capacity of 1,290Nm. Optional built-in condition monitoring features and high-precision torque measuring options are also available.

The CA-600 gearbox can operate at up to 50,000rpm with maximum torque capacity of up to 260Nm and is again available in both flange mounted and foot mounted configurations. Built-in condition monitoring functionality is included as standard and optional EX G Zone 2 certification is also available.

Available in foot-mounted configuration, the CA-800 is a specialist lightweight high-speed gearbox drive head manufactured in lightweight cast aluminium with enhanced structural rigidity, allowing use on vibration shaker tables or where there are weight/space limitations. It can operate at up to 15,000rpm with a high-power density and peak torque capacity is 1,200Nm.

The CA-1000 Series gearbox has been designed for higher torque applications requiring relatively higher speeds, with peak torque of up to 2500Nm and operating speeds of up to 10,000rpm. Innovative over-torque disconnect functionality provides safe isolation in the event of a test unit failure creating a seizure of the driveline. 

Chris Edgington, Director at NDE Clarke Pitchline, explained: “To meet ever more stringent operating requirements especially around overall efficiency, Units Under Test (UUTs) must be tested to a variety of parameters including the amount of torque demanded to turn at a given condition; high speed reliability; wear rate; and operating parameters in extreme cold. Meanwhile, a variety of different media, such as bespoke oil circuits, hydrogen and liquid nitrogen, are being employed to cool UUTs, which each have unique characteristics to understand.

“This has generated a demand for reliable, higher-speed component testing capabilities which are more versatile than current ground-based testing equipment, which typically consists of older gearboxes designed for lower speeds and more prone to leakage, or significantly more expensive and performance-compromised motor-based testing systems, which are not suited to delivering high  torque at high speeds in a customisable package.

“The CA range has been specifically designed to operate at and beyond the higher speeds being employed in the sector today, allowing users to future-proof their operations as speeds rise even further in the years to come.”

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