Gearbox Vertical Plates for Oil Recirculation and Teeth Power Loss

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Solution Overview

Problem

Existing gearbox designs face challenges in minimizing teeth power losses (TPL) due to friction, pumping effects, windage, and inadequate lubrication, with known solutions often being complex and complicating maintenance.

Innovation Solution

A system of vertical plates is installed inside the gearbox to separate oil flows for cooling/lubricating gears and bearings, using external and internal shields to prevent oil recirculation and optimize oil flow, allowing for efficient lubrication and cooling while maintaining easy access for maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If additional cooling devices (cooling ducts) are installed to cool the gears, then the cooling efficiency is improved, but the device complexity increases and maintenance becomes more complex

Engineering Contradiction:
Improvegear cooling efficiencyVSAvoidcooling system complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent extracts the cooling function from a separate cooling system and integrates it into the lubrication system by using the lubricant flow path itself as the cooling mechanism. The lubricant absorbs heat from the meshing teeth in the contact area and transports it away, eliminating the need for additional cooling ducts and devices.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The lubricant performs multiple functions simultaneously: it lubricates the meshing teeth to reduce friction, cools the gears by absorbing and transporting heat, and provides protection against wear. This multi-functionality eliminates the need for separate cooling systems.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Temperature

If the lubricant flow in the meshing area is increased to improve cooling, then the cooling effect is improved, but the teeth power losses increase due to excessive lubricant flow

Engineering Contradiction:
Improvemeshing area coolingVSAvoidteeth power losses
Core Design Contradiction:
TemperatureVSLoss of energy

Solution Approach 1:

The patent applies local quality by creating a specific lubricant flow path that directs lubricant precisely to the meshing contact area where cooling is needed, rather than using excessive general flow. The lubricant is supplied at optimized locations and in controlled amounts to achieve effective cooling without unnecessary energy losses.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent optimizes lubricant flow parameters (flow rate, pressure, distribution) to achieve the minimum necessary flow for effective cooling. By carefully controlling these parameters, the system achieves adequate cooling while minimizing the energy losses associated with excessive lubricant flow.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If shields are installed to separate oil flows for cooling and lubrication, then the oil flow optimization is improved and TPL is reduced, but the device complexity increases

Engineering Contradiction:
Improveteeth power lossesVSAvoidshield system complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent segments the lubricant flow into distinct functional zones using simple shields: one flow path for cooling the meshing teeth and another for lubricating the bearings. This segmentation prevents mixing of the two lubricant flows and optimizes each for its specific function, reducing energy losses while using simple, easy-to-install shields.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The shields act as intermediaries that separate and direct the lubricant flow without requiring complex mechanisms. These simple partition elements create distinct flow channels that guide lubricant to the appropriate components (gears or bearings) without mixing the flows.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Loss of energy

If complex cooling and lubrication systems are installed to reduce TPL, then the energy efficiency is improved, but the ease of maintenance deteriorates

Engineering Contradiction:
Improveenergy lossesVSAvoidmaintenance accessibility
Core Design Contradiction:
Loss of energyVSEase of repair

Solution Approach 1:

The patent merges the cooling and lubrication functions into a single integrated system using the same lubricant circulation path. This consolidation simplifies the overall system structure, making it easier to maintain while achieving both cooling and lubrication objectives without requiring separate complex systems.

Inventive Principle:
Principle #5Merging (Combining)

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

This solution reduces TPL by optimizing oil flow and preventing recirculation, minimizing energy losses and the need for additional cooling systems, while facilitating maintenance by maintaining easy access to gearbox components.

Implementation Method 1

a set of two independent vertical plates configured for being installed inside a housing of the gearbox for separating a first oil flow used for cooling and/or lubricating teeth of gearbox toothed gears from a second oil flow used for lubricating/cooling hydrodynamics bearings

Methodology Applied
Scientific EffectFluid flow separation:

Implementation Method 2

Pumping effect, which comes from a non-adequate amount of lubricating oil used for lubricating a meshing area of the gears

Methodology Applied
Scientific EffectPumping effect reduction:

Implementation Method 3

a first oil flow used for cooling and/or lubricating teeth of gearbox toothed gears

Methodology Applied
Scientific EffectLubrication: Lubrication

Implementation Method 4

Friction within the gearbox, notably between the gears

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 5

Windage coming from the rotational speed of the gears which drive into movement the surrounding fluids

Methodology Applied
Scientific EffectWindage: Drag

Data Source

PatentEP4291807B1System for reducing teeth power losses in a gearbox
Publication Date: 2024.05.08 FLENDER GRAFFENSTADEN SA
  • EP4291807B1 patent drawingFigure 1
  • EP4291807B1 patent drawingFigure 2~3
  • EP4291807B1 patent drawingFigure 4~5

AI summary

The present invention concerns a system for reducing teeth power losses in a gearbox (1), comprising at least two inter-meshing toothed gears (11,12), each attached to a rotating shaft (13, 14) supported by bearings (15, 16) and mounted within a housing (10); two vertical plates (2) configured for being installed inside said housing (10) between the bearings (15, 16) and the toothed gears (11,12), one at each side of the toothed gears (11, 12); wherein the vertical plates (2) comprise one or several internal shields configured for separating oil flows within the housing (10); mounted on the side of the vertical plates (2) directed towards the toothed gears (11, 12); wherein the internal shield comprises an anti-re-circulation plate (230, 240), wherein at least one anti-re-circulation plate (230, 240) comprises one or several vertical fins (233) for breaking an axial flow of an air-oil mixture.