Research Topic

Short Title	Gears under electrical load
Start of Project	Q2/2025
Funding	FVA-Nr. 1064/I Research Association for Drive Technology e.V., FVA
Project Partner	Lehrstuhl für Maschinenelemente, Getriebe und Tribologie (MEGT), Rheinland-Pfälzische Technische Universität Kaiserslautern-Landau
Contact	Dr.-Ing. T. Tobie

Project Description

Electric drive systems operated with fast-switching frequency converters are subject to parasitic common-mode voltages, which can induce electrical currents in mechanical components. While the effects of these electrical stresses on rolling bearings have been extensively studied, there is a lack of systematic research on their impact on gears. Electrically induced damages, such as surface alterations, discharge craters, or changes in lubricant properties, pose potential risks, particularly in the context of the advancing electrification of transportation and industry.

The objective of this project is to develop a testing methodology for systematically investigating the load carrying capacity of gears under electrical stress. To achieve this, the proven FZG backto-back gear test rig will be modified to precisely introduce electrical signals into the gear contact and create reproducible load conditions. The research focuses on the interaction between mechanical and electrical stresses along the contact line. Critical operating conditions leading to electrical discharges in the lubricant film will be identified.

The methodological foundation of the project includes adaptations to the FZG test rig, the definition of relevant operating conditions, and the development of appropriate measurement and evaluation methods. The findings will not only provide new insights into the damage mechanisms of gears but also establish a basis for future research.

In the long term, the project contributes to optimizing the reliability and service life of electrically stressed gear systems. Small and medium-sized enterprises, in particular, will benefit from the ability to assess electrical stresses at an early stage and develop targeted countermeasures.