Design of 9 Speed Gear Box

Design of Gear Box
Using PSG Design Data Book
Sample Problem
Design a gearbox to give 9 speed output from a
single input speed. The required speed range is
180 rpm to 1800 rpm.
Given:
n
=9
Nmin = 180 rpm
Nmax = 1800 rpm
Step - 1 Calculation of Step ratio

Nmax
Nmin
n-1
1800
9-1
=
180
= 1.333
Refer PSG Data Book P. No : 7.20 to check

whether, the calculated step ratio is a std. value
Since its not a std. value, Lets find a multiples

of std. value come close to calculated step ratio
1.6
1.25
1.12
1.06
Cannot be used
Cannot be used
1.12 x 1.12 = 1.254
1.06 x 1.06 x 1.06 x 1.06 x 1.06 = 1.338
Multiples of 1.06 gives nearest value of 1.333

As 1.06 is multiplied 4 times we skip 4 speed
Hence std. = 1.06 & R 40 series is selected
Step - 2 Selection of Speeds

100
106
112
118
125
132
140
236
250
265
280
300
315
335
560
600
630
670
710
750
800
1338
1418
1503
1593
1689
1790
1898
150
355
850
160
170
180
190
200
212
224
375
400
425
450
475
500
530
900
950
1000
1060
1123
1191
1262
The speeds are;

180,236,315,425,560,750,1000,1320,1790
Check for deviation
lets calculate the allowable deviation and actual

deviation for the given range of speed.
Allowable deviation = 10 ( - 1) %
= 10 (1.333 - 1) %
= 3.33 %
Actual deviation
= (Nmax actual - Nmax) x
Nmin
Nmax
= (1790 - 1800) x 180

1800
= - 1.0 %
Since the deviation is within the allowable

range we can design for standard speeds.
The selected standard speeds are;

180,236,315,425,560,750,1000,1320,1790
Step - 3 Structural formula & Ray

Diagram
The structural formula for 9 speed gear box is
3 (1) 3 (3)
Stage 1 - Single input is splitted into 3 speeds
Stage 2 - 3 input is splitted into 9 speeds
ie., each input is splitted into 3 speed
1790
Selected speeds are;
1338
180,236,315,425,560,
750,1000,1320,1790
1000
750
560
425
315
236
180
Stage 1
Stage 2
Lets group the final

output speeds into 3,
since the structural
formula is
3 (1) 3 (3)
Lets select the input speed of stage 2. For that the

input speed should satisfy two following conditions.
At Least one output speed should be greater than
input speed. (1 for 3 o/p and 2 for 4 o/p)
The input and output must satisfy the following
ratios
Nmin
Ni/p
0.25
Nmax
Ni/p
1790
1338
1000
750
Stage 2
Lest find input speed for the

lowest output speed set.
For the
first condition,
possible input speeds are 750
& 560.
For the second condition,
560
Nmin
425
Ni/p
315
Nmax
236
Ni/p
180
Stage 1
Stage - 2
180
= 0.32
0.25
= 1.78
660
= 1000
560
The conditions are satisfied
1790
1338
1000
750
Stage 2
Lest find input speed for the

lowest output speed set.
For the
first condition,
possible input speeds are
1338 & 1790
For the second condition,
560
Nmin
425
Ni/p
315
Nmax
236
Ni/p
180
Stage 1
Stage - 1
560
= 0.41
0.25
= 0.74
1338
= 1000
1338
The conditions are satisfied
Step - 4 Kinematic Arrangement

1
5
Shaft - 1 / Input
7
9
11
Shaft - 2 / Intermediate
4
6
Shaft - 3 / Output
10
12
Step - 5 Calculation of number of

number of teeth in gears
Start from the final stage
First find the number of teeth for maximum
speed reduction pair.
Assume the number of teeth in the driver
gear (It should be above 17)
The sum of number of teeth in meshing
gears in a stage is always equal.
Stage - 2 First Pair - Maximum Speed Reduction

Assume number of teeth in driver = 20
z11
z12
N12
N11
20
180
=
z12
560
z12 = 62.2 62
Stage - 2 Second Pair - Minimum Speed Reduction

z7
z8
N8
z7
N7
z8
z7 = 0.76 z8
425
560
Stage - 2 Third Pair - Maximum Speed Increment

z9
z10
N10
z9
N9
z10
z9 = 1.78 z10
1000
560
Stage - 2
z7 + z8 = z9+ z10 = z11+ z12
z11 = 20
z7 + z8 = z9+ z10 = 20 + 62 = 82
z12 = 62
z7 + z8 = 82
z7 = 0.76 z8
0.76 z8 + z8 = 82
z9 = 1.78 z10
z8 = 46.5 46
z7 = 36
z9+ z10 = 82
1.78 z10+ z10 = 82
z10 = 29.49 30
z9 = 52
Stage - 1 First Pair - Maximum Speed Reduction

Assume number of teeth in driver = 20
z5
z6
N6
N5
20
560
=
z6
1338
z6 = 41.8 42
Stage - 1 Second Pair - Minimum Speed Reduction

z1
z2
N2
z1
N1
z2
z1 = 0.56 z2
750
1338
Stage - 1 Third Pair - Maximum Speed Increment

z3
z4
N4
z3
N3
z4
z3 = 0.74 z4
1000
1338
Stage - 1
z1 + z 2 = z 3 + z 4 = z 5 + z 6
z5 = 20
z1 + z2 = z3+ z4 = 20 + 42 = 62
z6 = 42
z3 + z4 = 62
z1 = 0.56 z2
0.74 z4 + z4 = 62
z3 = 0.74 z4
z4 = 35.63 36
z3 = 26
z1 + z2 = 62
0.56 z2 + z2 = 62
z2 = 39.74 40
z1 = 22
Solution
z1 = 22
z7 = 36
z2 = 40
z8 = 46
z3 = 26
z9 = 52
z4 = 36
z10 = 30
z5 = 20
z11 = 20
z6 = 42
z12 = 62

Design of 9 Speed Gear Box

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Design of 9 Speed Gear Box

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How is the step ratio calculated?

How is the step ratio calculated?

How are the standard speeds selected?

How are the standard speeds selected?

Design of Gear Box

Using PSG Design Data Book

Step - 1 Calculation of Step ratio

Refer PSG Data Book P. No : 7.20 to check

Since its not a std. value, Lets find a multiples

Multiples of 1.06 gives nearest value of 1.333

Step - 2 Selection of Speeds

The speeds are;

lets calculate the allowable deviation and actual

= (Nmax actual - Nmax) x

= (1790 - 1800) x 180

Since the deviation is within the allowable

The selected standard speeds are;

Step - 3 Structural formula & Ray

Selected speeds are;

Lets group the final

Lets select the input speed of stage 2. For that the

Lest find input speed for the

The conditions are satisfied

Lest find input speed for the

The conditions are satisfied

Step - 4 Kinematic Arrangement

Step - 5 Calculation of number of

Stage - 2 First Pair - Maximum Speed Reduction

Stage - 2 Second Pair - Minimum Speed Reduction

Stage - 2 Third Pair - Maximum Speed Increment

Stage - 1 First Pair - Maximum Speed Reduction

Stage - 1 Second Pair - Minimum Speed Reduction

Stage - 1 Third Pair - Maximum Speed Increment

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