In transmission development, one of the core tasks is the design of the lubrication system. With increasing requirements in terms of rotational speed and size, new challenges emerge for this area. Because of these challenges, current verification methods reach their limitations.
Difficult optical accessibility for visual analyses
Limited speed and temperature of transparent structures
Not reproducible time-behavior for luminescent dye tests
No sensors for lubrication system analyses available
Therefore, more accurate and sophisticated lubrication analyses are needed to supplement current methods. With the innovative FMwMD-sensor, the quality of the development and as a consequence, the functional reliability of series applications can be improved.
The Flow Meter with Medium Detection-sensor, in short FMwMD, was designed for the quantification of multiphase flows and is a new approach for analyzing the lubrication in transmissions. By integrating several measurement principles into one miniaturized sensor, the flow velocity and the temperature of the lubricant can be measured. Furthermore, the sensor is capable of detecting solid oil and gaseous phases as well as oil splashes and air bubbles.
The benefits of using the FMwMD-Sensor are versatile and improve many aspects throughout the development process as well as throughout the lifetime of series applications.
Increased speed of analysis process compared to conventional methods
Measurement at test positions with difficult accessibility
Qualitative measurement data as supplement to visual analyses
Cost savings due to more accurate verification of simulation models
Based on the generated measurement data, a map of the lubrication condition depending on rotational speed, tilt angle and temperature can be created for each tested component. By combining the data of several sensors, which are placed at critical components, a lubrication condition map of the whole transmission system can be derived.
The FMwMD-sensor was developed for applications in transmissions. For that reason, it is capable of withstanding harsh environmental conditions. Because of its minimized size, it adapts perfectly to individual test points and is, therefore, minimally invasive. Therefore, the sensor poses the ideal supplement for current analysis methods.
At the TU Graz - AVL Transmission Center, the FMwMD-sensor is already successfully in use in several projects with industry partners.