Building a Dynamic Rig for Trusted Bearing Validation Data

The challenge

Evaluating bearing behaviour under static or simplified loading does not translate reliably to real world engine applications. In service, bearings see rapidly varying loads, high peak forces and transient events such as stop-start. Validating materials, lubrication behaviour, and friction under representative conditions requires a test environment that can reproduce these accurately and repeatedly. The mechanical layout, hydraulic response, control strategy, and measurement system all influence whether the applied loads are representative, and the validity of the data obtained. 

PTL’s role

PTL led the overall facility design, including the mechanical system, hydraulic architecture and dynamic response analysis. Working with a tier-one hydraulic supplier, the final rig was capable of controlled load changes of approximately 400 kN, returning to zero in around 6 ms. The response of the fast-acting electrohydraulic valve was analysed in Simulink and GTSUITE prior to build, and a full mechanical model was created to understand stiffness, conformability and system dynamics before committing to hardware, ensuring the rig could meet the required load profiles.

Why it mattered

The demanding loading was the primary requirement that shaped the hydraulic sizing, control strategy and mechanical design. Meeting that target allowed the rig to generate bearing loads that closely match those seen in service. As a result, the data produced is suitable for bearing material validation, lubrication model development and friction characterisation. The test facility has produced published technical work, enabled by the data quality and repeatability achieved.