Kein Folientitel

1
Industrial Improvements based on COST 532
Tribology Research
Low-loss gears Coating Diamor
Developments of the project
COST 532 WG meeting Uppsala, Sweden
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 1
TU München B.-R. Höhn
2
WP1 (TUM, AVL) Analysis of Minimum Friction in
Gears and Engines
WP2 (IWT)
WP4 (TUD)
Multilayer
Solid Powder
Powertrain
Coatings
Lubricants
WP7 (AVL)
WP3 (TUD)
Piston-Liner
WP0 (VDMA, TUM, AVL) Technical Management and
Co-ordination
Ceramic
WP9 (all IAG, RTD, SME) Dissemination and
Exploitation
and Valve Train
Coatings
System Testing
WP6 (TUM)
Components
WP5 (TUM)
Minimised
Phase Transition
Liquid Lubricant
Lubrication
Quantity
WP8 (TUM, AVL) Synthesis - Design Optimisation
for Friction
WP9 (all IAG, RTD, SME) Dissemination and
Exploitation
Minimisation and Lube Elimination in Gears and
Engines
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 2
TU München B.-R. Höhn
Overview Oil-free Powertrain
3
Planned Industrial Improvement Low-loss gears
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 3
TU München B.-R. Höhn
Low-loss gears
4
C-type gears (reference)
Low-loss gears (TUM)
4,5 1,75
22,4 41,6
1,44 0,49
0 15
1,44 1,43
14 20
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 4
TU München B.-R. Höhn
Development of Low-loss gears
5
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 5
TU München B.-R. Höhn
C-gears vs. Low-loss gears
6
8
load dependent gear losses
load dependent bearing losses
no-load gear and bearing losses
6
4
torque loss Nm
2
0
LS5 T
94 Nm
LS7 T
184 Nm
LS9 T
302 Nm
1
1
1
2
0.5
2
2
20
8.3
20
8.3
0.5
20
8.3
0.5
rotational speed m/s
Efficiency tests (Oil lubrication)
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 6
TU München B.-R. Höhn
7
250
J
FVA26A99
1 C-type gears, dip lubrication (centre line,
90C)
Oil
T
188Nm
J
2 Low-loss gears, dip lubrication (centre line,
90C)
Pinion
Oil
J
3 Low-loss gears, oil/air lubrication (28ml/h,
60C)
Oil
200
150
Noise level dB
100
50
0
1
3
2
Total noise level
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 7
TU München B.-R. Höhn
Structure-borne noise measurements
8
Wear tests (with plastic gears)
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 8
TU München B.-R. Höhn
9
Industry partners for further testing of Low-loss
gears
ZF Friedrichshafen AG, Germany
Handtmann Elteka, Germany
Commercial use in near future possible
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 9
TU München B.-R. Höhn
Industry cooperation
10
Industrial Improvement in Commercial Use Coating
Diamor
in cooperation with
Fraunhofer Institut für Werkstoff- und
Strahltechnik, Germany
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 10
TU München B.-R. Höhn
Coating Diamor
11
PVD coating
Coating characteristics
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 11
TU München B.-R. Höhn
Coating Diamor
12
Twin-disc-tribometer at dry lubrication
ta-C
a-CH
TS-WC-Co
LPS-SiC
SSN
1.80E-07
1.00E-03
1.60E-07
1.40E-07
1.20E-07
1.00E-04
1.00E-07
Wear rate mm³/Nm
Wear rate mm3/Nm
8.00E-08
6.00E-08
1.00E-05
4.00E-08
2.00E-08
0.00E00
1.00E-06
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Mean friction coefficient
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 12
TU München B.-R. Höhn
Twin disc tribometer tests
13
Test with gears (Dry lubrication)
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 13
TU München B.-R. Höhn
14
500.000
450.000
400.000
350.000
300.000
Lifetime
250.000
Lifetime
200.000
150.000
100.000
50.000
0
Balinit DLC
Diamor (only pinion coated)
TS WC-Co
Diamor (3µm)
Diamor (6µm)
Diamor (only pinion coated, retry without run-in)
Ikos Dynamant
TS WC-CoCr
Diamor (3µm) (vibratory finished)
Comparison tests (Dry lubrication)
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 14
TU München B.-R. Höhn
15
Combination Low-loss gears Coating Diamor
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 15
TU München B.-R. Höhn
16
Thank you for your attention!
OFP Oil-Free Powertrain Contract No
IPS-2001-CT-98006 A. Grossl / 02.11.06 / 16
TU München B.-R. Höhn