Dana’s new e-Powershift transmission
By Mike Brezonick13 September 2021
Dana Inc. today debuted its new Spicer Electrified e-Powershift transmission, a modular two-speed unit designed to offer power take-off (PTO) functionality for electrified heavy-duty mining vehicles. The new transmission was unveiled at MinExpo in Las Vegas.
Dana said the transmission delivers high efficiency and superior performance in a compact package that simplifies the mining industry’s transition to electrification. A dual-motor version supports continuous power outputs up to 322 hp (240 kW), while the single-motor configuration is engineered for 161 hp (120 kW) of continuous output. The motors are Dana’s TM4 high-voltage units from 350 to 800 V.
“For more than half a century, Dana has been a trusted top-tier supplier of drive systems that deliver superior performance for mining vehicles,” said Jeroen Decleer, senior vice president, Off-Highway Drive and Motion Systems for Dana Inc. “The new e-Powershift transmission showcases how we are leveraging our comprehensive portfolio of electrification technologies to provide mining OEMs with complete solutions that can help accelerate their journeys to e-mobility.”
The flexible, power-dense design of the e-Powershift transmission makes it ideal for a wide range of applications, including small- to medium-sized loaders and trucks used in underground mining, as well as construction wheel loaders, large lift trucks, and terminal tractors, the company said. The dual-motor configuration shown at MinExpo is designed to deliver the optimal tractive effort in every duty cycle without torque interruption.
Dana said the e-Powershift transmission offers efficient shifting through a patented wet clutch and synchronizer, and it can be configured with four-wheel drive disconnect and a PTO that eliminates the need for an additional motor and inverter.
The system can be a turnkey solution, with drivetrain integration simplified through the use of a single APC transmission control unit. It uses proprietary software engineered to optimize machine operation through numerous drive and PTO modes, including hill-hold and functional safety readiness, Dana said.
The e-Powershift transmission was also shown as part of a complete system that includes heavy-duty Spicer axles and Spicer driveshafts.
The Spicer Electrified e-Powershift transmission will be available for prototype testing by original-equipment manufacturers (OEMs) by the end of this year.
Brevini gearbox upgrades
Dana also announced upgrades to its line of Brevini helical and bevel helical gearboxes used in mining and bulk material handling applications. The new gearboxes will be available starting in early 2022.
The enhancements include three new monoblock models to more precisely address torque demands, as well as series-wide design enhancements aimed toward improving power density.
“Mining and bulk material-handling customers rely on heavy-duty gearboxes to keep the flow of ore and aggregate moving and support sustained profitability,” Decleer said. “Long known for their unmatched reliability and durability, Brevini helical and bevel helical gearboxes have been refined to offer performance improvements that enhance productivity and further benefit the bottom line.”
Offering nominal output torques up to 1000 kNm (737,562 lb. ft.), Brevini helical and bevel helical gearboxes are typically used in conveyors, stacker reclaimers, wagon tipplers and ship loading and unloading equipment used in mining and bulk material handling.
They have been redesigned for higher torque density to deliver more power from a smaller package, which improves efficiency, reduces weight and minimizes lubrication requirements, Dana said.
Brevini helical and bevel helical gearboxes are engineered with low-temperature housings and special seals that support operations in extreme environments. They can be customized with a wide range of gear configurations, ratios and input and output shafts, the company said.