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.
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.