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I've been trying to wrap my head around calculating gear efficiency accurately. It seems straightforward in theory: (output power / Input Power) * 100%, but the practical submission gets tricky. Especially when you're dealing with complex gearboxes or variable loads.
What are some common pitfalls people encounter when measuring input and output power? I'm thinking about things like accurately measuring torque and RPM, properly accounting for parasitic losses (bearing friction, lubrication), and ensuring consistent measurement conditions.For example, how much does temperature affect the viscosity of the lubricant, and in turn, the gearbox efficiency?
Are there any specific tools or techniques you've found particularly helpful for getting reliable efficiency numbers? I've seen some suggest using a dynamometer, but those can be expensive. Are there option methods that offer reasonable accuracy for smaller-scale experiments? I'm especially interested in hearing about methods for estimating or measuring losses that are arduous to directly quantify.