Improved calculation method for load-dependent gear losses

The topic of this study is to investigate the load-dependent losses of practical spur gears, for which the existing calculation method is analyzed in detail and improved.

In drive technology, spur gears are frequently used for the transformation of torque and speed. Power transmission always involves power losses. Thereby, particular interest has to be given to the load-dependent gear loss as it often accounts for a large share of the total loss.

According to the state of the art, the calculation of load-dependent gear loss is mainly based on (i) gear loss factors derived from simplified load distributions and (ii) a mean coefficient of friction derived from empirical equations based on spur gears without flank modifications. In practice, however, helical gears for improved NVH (Noise-Vibration-Harshness) behavior and flank modifications for uniform contact patterns are used. The modified mesh and contact conditions of modified helical gears affect the load-dependent gear losses significantly. Hence, significant deviations compared to the state of the art can occur.

Comprehensive experimental investigations at the FZG efficiency test rig and FZG Bearing power loss test rig have been carried out to investigate the load-dependent gear losses of modified helical gears. The results are used to improve an existing calculation method that distinguishes between geometrical and tribological influence factors. Thereby, the local mesh and contact conditions along the plane of action are considered by the gear loss factor H_VL according to Wimmer, whereas the calculation of the mean coefficient of friction µ_mz has been enhanced by regression analyses. A comparison of the improved calculation method to the state of the art shows improved accuracy for determining the load-dependent gear losses and hence the efficiency of gear boxes.