What is the Gearbox Demonstrator?
The Gearbox Demonstrator is a purpose-built demonstration and test system developed at Tegema to showcase a novel gearbox concept based on a new mechanical operating principle.
The gearbox is an innovative transmission technology that achieves continuously variable speed ratios through a unique meshing mechanism, offering potential advantages in efficiency, compactness, and controllability over traditional gearbox designs. The demonstrator was built to physically prove out the concept and present its capabilities to potential industrial customers and development partners.
Purpose of the demonstrator
Engineering a new mechanical principle is one thing; convincing the market is another. The demonstrator served multiple roles:
- Validating that the gearbox operates as theoretically predicted under real load conditions
- Providing an interactive, hands-on demonstration for potential customers, allowing them to see and feel the technology in action
- Enabling engineering measurements of torque, speed, efficiency, and thermal behaviour across the operating envelope
Technology
The demonstrator system comprised:
- C/C++ firmware on a real-time embedded controller managing motor drive, speed and torque setpoints, and safety interlocks
- Drive electronics for the servo motor and load motor, enabling controllable input/output conditions across the gearbox’s operating range
- An operator panel and display allowing visitors to interactively change operating parameters and observe the response in real time
- Sensor integration for speed, torque, temperature, and vibration, with real-time display and logging for engineering analysis
- Bespoke PCB design for power distribution, sensor conditioning, and communication between subsystems
My role
I contributed to this project as an electronic engineer at Tegema, responsible for the design and development of the embedded control software and electronics. This included the real-time firmware, PCB design and test, HMI integration, and commissioning of the complete demonstrator system.
