Gear Unit Oil Level Adjustment for Churning Loss Reduction
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Solution Overview
Problem
Gear units with oil lubrication experience significant churning losses due to oil accumulation at the bottom, leading to inefficient power transmission and lubrication during operation.
Innovation Solution
A gear unit design incorporating a temporary storage system that temporarily lowers the oil level during operation by transferring oil from the oil pan to a receptacle, which is emptied automatically during standstill, reducing churning losses and maintaining effective lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gear unit is filled with oil for good lubrication during standstill, then lubrication is improved, but churning losses increase during operation
Solution Approach 1:
The patent applies the dynamics principle by implementing an oil level adjustment device that dynamically changes the oil level in the oil pan based on operational state. During standstill, the oil level is maintained high for lubrication, while during operation, the device actively lowers the oil level to reduce churning losses. This dynamic adaptation resolves the contradiction between maintaining lubrication and reducing energy loss.
Solution Approach 2:
The patent employs parameter changes by modifying the oil level parameter according to operational conditions. The oil level adjustment device changes the physical parameter of oil level height - keeping it high during standstill for lubrication and lowering it during operation to minimize churning losses. This parameter adaptation directly addresses the contradiction between lubrication needs and energy efficiency.
2Productivity
If the oil level is lowered during operation to reduce churning losses, then power transmission efficiency is improved, but lubrication during startup may be insufficient
Solution Approach 1:
The patent applies preliminary action by ensuring that during standstill periods before operation, the oil level is maintained at a high level in the oil pan. This preliminary preparation ensures that when the gear unit starts up, sufficient oil is already available for immediate lubrication of bearings and gearing parts, preventing wear during the critical startup phase while still allowing for reduced oil levels during operation.
3Loss of energy
If a temporary storage system is added to adjust oil levels, then churning losses are reduced, but device complexity increases
Solution Approach 1:
The patent applies the self-service principle by designing an oil level adjustment device that operates automatically based on the operational state of the gear unit. The device self-regulates the oil level without requiring external control systems or complex mechanisms - it automatically lowers the oil level during operation and maintains it during standstill, reducing complexity while achieving energy loss reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances power transmission efficiency by reducing churning losses and ensuring consistent lubrication, while also allowing for automatic oil level adjustment and improved heat dissipation through strategic oil flow management.
Implementation Method 1
the temporary storage is in the form of a receptacle that has openings such that, and the delivery device is conceived and implemented such that the maximum oil flow delivered by the delivery device, especially during operation of the gear unit with the nominal speed of the gear unit, is greater than the oil flow returned from the temporary storage to the oil pan, effected through the openings
Implementation Method 2
oil from the oil pan of the gear unit is able to be delivered to the temporary storage, especially with the aid of a delivery device
Implementation Method 3
During operation of the gear unit, especially at nominal speed of the input shaft and/or output shaft, the gearing parts of the gear unit spray and hurl oil around. In particular, oil is also sprayed out from the gearings engaging with each other
Data Source
AI summary
A gear unit at least partially filled with oil,whereina device is provided in the gear unit for lowering the oil level, especially of the oil pan of the gear unit, during operation, the device including at least one temporary storage.