Advanced Gearbox Lubrication Analysis: A Virtual Lab for Design Optimization

For over two decades, our Montreal-based engineering simulation consultancy has provided advanced solutions to a diverse range of industries. Our expertise has facilitated the resolution of complex engineering challenges, leveraging the latest technologies in computational fluid dynamics (CFD) and heat transfer analysis. Among our recent projects, one particularly notable case involved a company specializing in converting combustion engine vehicles to electric vehicles. That company developed a compact electric motor paired with a 2-speed gearbox, illustrated in Figure 1, designed to optimize performance and efficiency.

During the development process, the manufacturer identified a critical region that could lead to an overheating bearing problem. Figure 2 shows a cut view centered on the narrow gap between the second gear and the input gear. Anticipating this problem, the manufacturer added a deflector to their design. The goal was to guide more lubricant toward the narrow gap to induce better cooling of the bearing. They built a test bench and faced the anticipated problem. Despite the deflector, they observed some damage on the input gear bearing. Paint labels were placed on the neighboring gears and indicated high temperatures confirming the overheating problem. To expedite the iteration process and identify a viable solution, the client sought our assistance to develop a comprehensive analysis workflow that could replicate the problem and test potential solutions efficiently. Our first objective was to reproduce the problem, by simulating the exact same configuration as the one on their test bench. Once correlated, we could investigate the results, understand the lubricant behavior and test several concepts to solve the overheating problem. This case presented an excellent opportunity to demonstrate the capabilities of advanced simulation techniques in addressing real-world engineering problems, ultimately contributing to the company’s success in developing reliable and efficient products.