Efficiency
In addition to sufficient load capacity and favorable noise behavior, the efficiency behavior of gear units is increasingly becoming the focus of research.
The power loss of a gearbox is made up of gear, bearing, seal, and other losses.
The FZG efficiency test rigs are used to perform efficiency tests on oil- or grease-lubricated spur gears under a wide range of operating conditions, enabling an assessment of the influences of the macro- and microgeometry of the gearing, tooth flank roughness and, if applicable, its coating, lubricant, and stresses on the frictional behavior.
The FZG idling loss dynamometer is used to carry out drag torque tests on various practical gear units, enabling an assessment of the influences of housing, oil level, lubricant, temperature, and speed on idling losses. In parallel, oil distribution and idling losses are determined using CFD simulation and validated with test results.
The following figure shows the result of a CFD simulation for the wheelset of a test transmission. Results from CFD simulations can be validated by tests with the FZG high-speed camera and transparent housing on the efficiency test rig.
