Before launching a new product on the market, a certain amount of factors are simulated and
tested. This is done to predict the product’s behaviour due to several external influences. The
product will undergo a series of versions before finally reaching the market. This is called the
The company Punch Powertrain is in such a prototype-phase for a transmission called VT5. This
type of transmission makes use of a primary and secondary shaft, each having their own pulley.
This type of shaft, including its directly related parts, is known as a variator.
The variator is made up of a certain amount of parts which can translate or rotate with respect
to each-other. During operation of the transmission, a certain amount of forces will act on it,
which will result in deformation of certain of its parts, including the variator. The rate of
deformation will influence transmission performance, efficiency and lifespan. It is crucial to
predict the rate of deformation to guarantee a high level of quality and longevity.
A first prediction is done in the form of a Finite Element Analysis (FEA). This principle makes use
of a software package to accurately simulate virtual parts. The simulation provides information
on deformation and stress, including their location. The accuracy of the FEA will decrease as the
assembly becomes more complex. This is due to the fact that the part constraints are subject to
To validate the FEA, Punch Powertrain wants to perform actual deformation tests and compare
the results to those of the FEA. Doing this will give the possibility to fine-tune future simulations,
thereby improving their accuracy. Punch Powertrain requires a test which will accurately
measure the deformation of the pulley at several locations. During a six-month period I have
worked full-time on a project at Punch Powertrain to generate such a test.
The objective of this thesis is to develop a test rig that will accurately measure the deformation
of the pulley sheaves (±10μm). This test needs to provide data which can be used to validate the
This report starts with a general introduction. Here, the choice for the test rig concept will be
explained, along with the reason why it was chosen. Thereafter, details about the necessary
tools and parts will be explained. Their shape and size were chosen based on a number of
calculations, simulations and tolerance studies, which are also included in the report. The results
of an FEA will be explained. Finally, guidelines will be described for the test-engineers.
|Joeri Van Mierlo (Promotor), Steve Vanlanduit (Promotor), Stijn Leterme (Promotor), Peter Wouters (Promotor) & Mohamed El Baghdadi (Promotor)