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The DuraPlate Cooling System

Increase drive performance and thermal capacity without additional power or water supply.

Duraplate Cooling System

Falk V-Class right angle and parallel gear drives are used in rugged applications in the toughest environments. To maximize performance, safety, and life of the drive, V-Class cooling features include cast cooling fins on the ductile iron housing surface and oil feed passages in the housing to better circulate oil.
 

Even with all these advanced cooling features there are still some applications that require more drive cooling such as pumps, and any gear drive located in an enclosed space with low air flow. For those applications we offer the DuraPlate cooling system to provide additional thermal capacity to your V-Class gear reducer.

See the DuraPlate Cooling System on a Falk V-Class Gearbox

How Does the DuraPlate Cooling System Work?

Roll over the hotspots to learn how DuraPlate works:
A shaft-driven pump requires no additional motors, electrical equipment, or plumbing
A thermostat controls when oil is sent to the heat transfer plates for additional cooling
Steel heat transfer plates prevent corrosion, provide superior durability, and maximize heat dissipation
A radial shaft fan does not require external power
Cool oil is returned directly to the high-speed end of the gear drive to maximize drive cooling
The DuraPlate cooling system is integral to the gear unit itself
A shaft-driven pump requires no additional motors, electrical equipment, or plumbing
A thermostat controls when oil is sent to the heat transfer plates for additional cooling
Steel heat transfer plates prevent corrosion, provide superior durability, and maximize heat dissipation
A radial shaft fan does not require external power
Cool oil is returned directly to the high-speed end of the gear drive to maximize drive cooling
The DuraPlate cooling system is integral to the gear unit itself
 

Falk offers the DuraPlate cooling system for environments with extreme thermal challenges. The DuraPlate is a self-contained heat exchanger integral to the gear unit itself, simplifying installation and minimizing the risk of damage. DuraPlate will typically double the thermal capacity of the gear reducer, which often allows the unit’s thermal ratings to equal or exceed the mechanical ratings. 
 

DuraPlate requires no external power or a water supply because it’s powered by a shaft-driven pump mounted in an intermediate gear shaft. This configuration requires no additional motors, electrical equipment installation, or plumbing for water.
 

Stainless steel hoses provide durable and protected oil circulation for a long drive lifespan. The DuraPlate heat exchanger is manufactured with heavy-gauge stainless steel to prevent corrosion despite extreme operating conditions, and the steel resists damage from the inevitable bumps it will receive in industrial service.
 

When the gearbox is operating, the shaft-driven pump draws oil from the gearbox sump continuously and the gear lubricant is delivered to a thermally actuated valve. However, the DuraPlate system is designed to respond dynamically to its working environment. For example, when the V-Class is operating without need for additional thermal capacity, the oil is returned directly to the gearbox. Then, when the V-Class oil temperature exceeds approximately 140°F, the valve begins to redirect the oil to travel through the DuraPlate heat exchanger.
 

The internal geometry of the heat exchanger causes the oil to travel back and forth across the heat exchanger until it reaches the far side. The shaft fan mounted on the high-speed shaft of the gearbox ensures that heat is rapidly drawn from the heat exchanger. Once the oil has traveled through the DuraPlate heat exchanger, it has been sufficiently cooled for return to the gearbox sump. 

Duraplate Cooling System Gearbox

Benefits of Duraplate over a Conventional Forced Air Cooling Unit

The DuraPlate system minimizes the number of parts needed and maximizing reliability while optimizing performance through advanced technology and understanding of gear systems. The system’s benefits surpass those of traditional forced air cooling units, resulting in a safer, simpler, cooling solutions for your most demanding applications.

 

 Conventional Forced Air Cooling UnitDuraPlate Cooling System
Unit DesignA separate cooler must either attach to the gear unit or have its own mounting base, adding cost to both transport and installation. This also increases the likelihood of damaging the cooling unit during handling.DuraPlate is integral to the gear unit, barely extending the required space envelope.
MaterialMade with more delicate materials, such as copper, which makes the heat exchanger much more susceptible to damage and clogging.Both DuraPlate’s heat exchanger and hoses are protected by braided stainless steel, which will promote a long operating life even in corrosive environments.
Power and Water SupplyA separate cooling unit requires its own electric motor to power the oil pump and fan, increasing cost and the footprint of the unit. These additional components require additional electrical wiring and equipment, which increases cost and reduces the reliability of the system.DuraPlate requires no external power or a water supply because it’s powered by a shaft-driven pump mounted in an intermediate gear shaft. This configuration eliminates the need for additional motors, electrical equipment installation, or plumbing for water.
ReliabilityA conventional radiator has its own electric motors to power the oil pump and fan, which are frequently the points of failure in these applications. When the fractional horsepower motor driving the pump fails, the entire gear drive and its application must be shut down immediately. This can result in high downtime costs due to the failure of a small pump or fan motor.DuraPlate is designed with a long-lasting shaft mounted pump that will provide years of reliable service combined with a shaft mounted cooling fan that minimizes the amount of failure points and maximizes drive reliability.

Learn more about Falk V-Class:

V-Class Right Angle

V-Class Parallel