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I always found the "ELI5: How Do Gearboxes Transmit Power Efficiently?" explanations a little unsatisfying, focusing on how gear ratios change torque and speed, but not really diving into the efficiency part. It truly seems like there's an assumption gears are somehow perfectly efficient, which isn't true. Friction is a huge factor, right? I'm curious how much of the engineering goes into minimizing that friction in different gearbox types.Like, how does the design of a constant-mesh gearbox in a car differ in its approach to efficiency versus a simple spur gear system you might find in a power tool? Are specialized lubricants the biggest game-changer, or is it all about the precision machining and minimizing contact surfaces?
Thinking about it more, is there a point where the complexity of trying to maximize efficiency actually decreases overall power transmission efficiency due to added internal resistance from more parts? It feels like there has to be a cost/benefit analysis involved at some point during design. And does anyone know how much energy is typically lost in different types of gearboxes as heat, on average? I'd be interested in seeing some real-world measurements.