Case study · Transmission rebuild company

Rebuilt transmissions are now delivered with measurements

Test software that runs a rebuilt transmission on the test bench, measures torque, speed, temperature, gear pressures, retarder temperature and retarder speed, and stores the result in a report tied to the serial number. Before this system the company had no test setup that could take measurements.

Before

The company had no test system. Whether a rebuilt transmission worked correctly could not be measured; it only became clear once it was fitted to the vehicle.

Critical values such as gear pressures and retarder behaviour could not be seen as numbers, so checks relied on the technician's experience and listening.

There was no measurement record or report to say a delivered transmission had passed a test; when a unit came back, it was impossible to tell whether the problem came from the rebuild or from use.

What we built

Measurement setupThe bench sensors were connected to the software through a PLC; torque, input/output speed, oil temperature, gear pressures, retarder temperature and retarder speed are shown live.
Test recipesTest steps, durations and acceptance limits are defined as a recipe for each transmission type; a new type can be added without changing the software.
Step-by-step testThe operator enters the serial number and picks the recipe; the test runs through warm-up gear shifts running under load retarder engagement, and each step is assessed against its acceptance limits.
Serial-number reportMeasurement curves and results are produced as a PDF report and archived by serial number; the transmission is delivered to the customer with its report.

After

For the first time the company delivers rebuilt transmissions with measurements; gear pressures and retarder behaviour are judged by numbers, not by estimate.

Each transmission's test record is kept by serial number; a returned unit can be compared with its delivery measurements. The test report has become an assurance document handed to the customer.

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