EVALUATION AND THERMAL MODELING OF A HIGH-POWER GEARBOX

Abstract

This paper presents an evaluation of a high-power gearbox intended for driving belt conveyors in open-pit mining, with a particular focus on thermal modeling and stability under continuous heavy-duty operation. To improve thermal performance and ensure long-term reliability, thermal Finite Element Analysis (FEA) was conducted to optimize the geometry and cooling characteristics of the gearbox housing. Based on the simulation results, a prototype was manufactured and subjected to experimental validation on a test bench, simulating real operating conditions. Key performance parameters, including temperature distribution, structural integrity, and operational efficiency, were monitored and analyzed. The test results demonstrated that the optimized gearbox design successfully meets the thermal and mechanical requirements for demanding industrial applications. The study confirms the effectiveness of using thermal FEA in the early design phase and highlights the importance of integrated simulation and testing in the development of reliable power transmission systems.