Development of an experimental test bench for the validation of prognostic algorithms for electromechanical actuators

This experimental thesis aims to develop and set up a total of two test benches concerning the validation of Simulink prognostic models. De facto, in the context of this thesis, I have worked on two main topics: 1. an upgrade of a pre-existent experimental test bench with the aim of studying mechanical plays consequences on an additive manufacturing based planetary gearbox assembly; 2. the design and production phases of a different test platform, concerning fatigue implications on planetary gearboxes performance models. The modelling, testing and research has been carried out with eng Luca Boggio and dr. eng. Matteo Bertone with the indispensable help of eng Pier Carlo Berri. The practical testing took place in a facility inside DIMEAS department, where the first experimental test bench is located. The first test platform had been realised by eng Pier Carlo Berri, eng. Pietro Sciandra and eng. Valentina Boschetti in the context of their thesis, whereas further safety measures were put into place afterwards. The first part of this document covers the work we have carried out together to set the test bench up for the tests. The final achievements, along with graphs, model validations and data processing results can be seen in eng Luca Boggio and dr. eng. Matteo Bertone theses whereas I will cover the test bench reshaping from a more practical perspective. In the second part of the thesis the design and development process for the second test bench is reported. In fact the thesis is divided into four main chapters: after a short introduction where the importance of modelling and the current state-of-the-art brushless technologies are examined, the paper goes on with the description of the first test bench and the modifications we implemented. After that, a profuse number of pages focuses on the design process concerning the second test bench. A chapter with final considerations and future developments is then reported. Finally, two appendixes are present at the end of the project. The first one briefly shows some design iterations concerning the second test platform, while the last appendix displays a parallel work carried out in the first weeks of work at DIMEAS facility. Nevertheless, the results showed in this work are of great value as they are suitable for an industrial use of Electromechanical Actuators too; for instance when installed over a vast kind of machinery (e.g. CNC machines). Moreover, given the low number of experimental databases for EMA, these platforms could provide extensive data sets enhancing industrial prognostic capabilities.