JIMMA UNIVERSITY

Jimma Institute of Technology

Post Graduate Study

Faculty of Mechanical Engineering
MSc. In Mechanical System Design Engineering

Product Testing Equipment

Assignment-1

By:
1) Tesfaye Olana RM0978/09

Submitted to: Chalachew Setegne

Jan, 2018
 Assignment-1

What are the differences between test plan preparation, and data collection plan
preparation?

1. A test plan describes what is to be tested and how. It is a road map for all personnel and it
defines and controls the content and relationship of all testing. It ensures timely, efficient
and economical implementation of the tests. Data collection may be grouped into two
stages: data collection plan and data collection. Data collection plan includes defining
goals and objective of data collection. The plan also involves ensuring data collection or
measurement repeatability, reproducibility, accuracy and stability.
2. A test plan is a document that describes the scope, approach, resources, and schedule of
intended testing activities, while a data collection is a document that describes both typical
and atypical situations that may occur in the use of an application.
3. Test plans define the scope, approach, resources, and schedule of the intended testing
activities, while data collection define test conditions, data to be used for testing, and
expected results, including database updates, file outputs, and report results.
4. A test plan is a description of the scope, approach, resources, and schedule of intended
testing activities, while a data collection is a description of test cases that ensure that a
business process flow, applicable to the customer, is tested from end to end.

By: Tesfaye O., JiT, 2018 1

 Assignment-1

Test plan for Gear box

Prepared By: Tesfaye Olana

Version: 1
Date: 24/01/2018
Status: Draft

1. Introduction
Gearing is one of the most critical components in a mechanical power transmission system, and in most
industrial rotating machinery. It is possible that gears will predominate as the most effective means of
transmitting power in future machines due to their high degree of reliability and compactness. In addition,
the rapid shift in the industry from heavy industries such as shipbuilding to industries such as automobile
manufacture and office automation tools will necessitate a refined application of gear technology. A
common gear design is the spur gear.

A given company is developing a gear box that has single input and single output, speed reduction
ratio of 10 and two spur gears. The gearbox weighs 20 kg and it is to be connected to a motor with
2000rpm maximum speed and 4 HP output. It has 40cmx40cm*50cm overall dimension. This test
plan is prepared to test in the light of the given specification in two days test duration.

2. Purpose of test plan

The purpose of this document is to summarize the test strategy as it relates to the implementation
of gear box. This test plan provides managers and test personnel with the necessary approach to
validate that each process performs correctly and that the requirements of the system have been
satisfied. This test plan will provide the following:
 Detail the approach and strategy for testing of the solution
 Describe the planning, test case preparation and scheduling, including resource
requirements
 Explain the execution, results documentation and review of the testing
 Provide the test cases which will be executed for this testing effort

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3. Scope of Testing
The scope of this test plan is to check gear box based the specific criteria given from the company
in the introduction. The horse power, single input output, revolution in rpm conformance, speed
reduction ration, overall volume of the geometry are the specified requirements for the test plan.

4. Test item specification

No. Description Detail
1 Input/output Single
2 Horse power 4hp
3 Input speed in rpm 2000rpm
4 Volume 40cmx40cmx50cm
5 Speed reduction 1:10
6 Weight 20kg

6. Features to be tested
The following features of the gearbox should be tested accordingly to conformance of the
specification

No. Item Description

1 Housing Casing that surrounds the mechanical components of a gearbox. It provides
mechanical support for the moving components, a mechanical protection
from the outside world for those internal components, and a fluid-tight
container to hold the lubricant that bathes those components.
2 Bearing Transfer axial motion from the input to gear
3 Shaft Helps to mount gear on it
4 Gear transfer motion and speed reduction ratio
5 Key Torque transmitting between shaft and gearing

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 Assignment-1

7. Testing strategy and approach

gear box testing

strategy

component Operating load sound/vibration drive train

Design check test
analysis test test installation

material strength disassembly of sound lubricant

low load test
test gearbox measurement cleanliness

lubrication
component overload test
performance

friction coeficient load pattern check overspeed test

bearing test run bearings speed rpm

lubrication test sealings

load distribution

8. Test plan schedule

This test plan is expected to be done in two days according to the following schedule based on the
testing strategy

Test-1: Design check test

Item Specification Test Acceptance Test Quantity Start End

No. description criteria responsibility date date
1 Material
strength
2 Lubrication
performance
3 Friction
coefficient
4 Bearing test
run

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 Assignment-1

5 Lubrication
test
6 Load
distribution

Test-2: Component Analysis

No. Component Test Acceptance Test Quantity Start End

analysis description criteria responsibility date date
1 Disassembly
of gear box
2 Components
3 Load pattern
check
4 Bearings
5 Sealing
6 Shaft
7 Key

Test-3: Operating load Test

No. Operating Test Acceptance Test Quantity Start End

loads description criteria responsibility date date
1 Low load
2 Over load
3 Operating
load
4 Operating
loads

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Test -4: Sound/ Vibration Test

No. Sound/vibration Test Acceptance Test Quantity Start End

test description criteria responsibility date date
1 Sound
measurement

Test -5: Overall test summary evaluation

responsibility
Specification

Acceptance
description

Validation
Item No.

criteria
Test

Test
1 Gear Test to verify that Gears are Engr. 1
alignment in alignment

2 Bearing Test to verify that bearing

Alignment are aligned successfully
3 Motor Load Test to verify that the motor
can handle the loads of the
various configurations

4 Assembly Test to determine how long

time it take to assemble Each
mechanism
5 Weight Test to determine overall <20kg
weight of mechanism
6 Size Test to determine the 40cmx40cmx50cm
overall size of the
mechanism

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 Assignment-1

7 Production Test to determine the

cost overall cost of a system
8 Configurable Test the number of
Component different configurations the
design can do
9 Horse power The output force that can be >4hp
gained from the gear box

9. Test plan schedule

Test Number Day: 1 Day: 2
Morning Afternoon Morning Afternoon
Test-1
Test-2
Test-3
Test-4
Test-5

After the test in problem 2 is over, what kind of evaluation is to be carried out:
content analysis or data mining? Why?
Content analysis evaluation type should be carried out, because the data are not hidden and also
they are useful information which helps during testing of the gear box.

By: Tesfaye O., JiT, 2018 7