Development of a User-Friendly Real-Time Load Calculation Tool for Gearbox Testing

Real-time data analysis has gained increasing attention as industries aim to streamline testing processes and reduce feedback delays. Traditionally, load calculations have been conducted through post-processing methods, which, while reliable, introduce significant latency in test evaluation and decision-making. Recent developments propose shifting to real-time processing to enhance efficiency, yet challenges remain regarding system limitations and user interaction. This thesis investigates the development of a real-time load calculation tool designed to support engineers during mechanical testing, with a particular focus on usability. The study applies a combination of Design Science Research (DSR) and Goal-Directed Design (GDD) to iteratively design, implement, and evaluate a lightweight and user-friendly solution. A key component of the work was the creation of a digital instruction manual tailored to support diverse user groups. The resulting tool enables real-time monitoring of load parameters with low system impact, and the accompanying manual proved effective in guiding users through the setup and operation of the tool. User feedback from testing sessions indicated that clarity, structure, and visual support were essential for adoption. Technical evaluations showed that signal synchronization, optimized code, and persistent data handling are critical for reliable real-time operation. In conclusion, the findings suggest that combining technical robustness with a user-centered design approach can significantly improve the effectiveness and accessibility of real-time tools. The study highlights the potential for advancing real-time practices within mechanical testing environments by aligning computational performance with practical usability. Keywords: Real-time load calculation, gearbox testing, user-centered design, duty cycle, AVL PUMA 2, instruction manual, usability, user experience (UX), post-processing.