Influence factors on gearbox power loss

Abstract

Purpose Besides other approaches, fuel savings in automotive applications and energy savings, in general, also require high‐efficiency gearboxes. Different approaches are shown regarding how to further improve gearbox efficiency. This paper aims to address these issues. Design/methodology/approach The paper takes the following approach: theoretical and experimental investigations of bearing arrangements and gear design as well as lubricant type and lubricant supply to the components lead to efficiency optimisation. Findings No‐load losses can be reduced, especially at low temperatures and part‐load conditions when using low‐viscosity oils with a high viscosity index and low oil immersion depth or low spray oil supply of the components. Bearing systems can be optimised when using more efficient systems than cross‐loading arrangements with high preload. Low‐loss gears can contribute substantially to load‐dependent power loss reduction in the gear mesh. Low‐friction oils are available for further reduction of gear and bearing mesh losses. All in all, a reduction of the gearbox losses in an average of 50 per cent is technically feasible. Originality/value Results from different projects of the authors and from the literature are combined to quantitatively evaluate the potential of power loss reduction in gearboxes.