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    Design of Gear Box

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    SUMIT MALUSARE
    The document summarizes the design of a 12-speed gearbox with an input speed range of 160-2000 RPM from a motor with 1600 RPM. It involves calculating the required step ratio of 1.258, selecting standard step ratios of 1.12, and determining the standard speeds from 100-1973 RPM. The structural formula of 3(1)2(3)2(6) is used. Number of teeth are calculated for each gear starting from the output gear and moving back through each stage. The final solution lists the number of teeth for each gear.

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    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd

    Design of Gear Box

    Uploaded by

    SUMIT MALUSARE
    380 views19 pages
    The document summarizes the design of a 12-speed gearbox with an input speed range of 160-2000 RPM from a motor with 1600 RPM. It involves calculating the required step ratio of 1.258, selecting standard step ratios of 1.12, and determining the standard speeds from 100-1973 RPM. The structural formula of 3(1)2(3)2(6) is used. Number of teeth are calculated for each gear starting from the output gear and moving back through each stage. The final solution lists the number of teeth for each gear.

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    design of gear box

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    design of gear box

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    The document summarizes the design of a 12-speed gearbox with an input speed range of 160-2000 RPM from a motor with 1600 RPM. It involves calculating the required step ratio of 1.258, selecting standard step ratios of 1.12, and determining the standard speeds from 100-1973 RPM. The structural formula of 3(1)2(3)2(6) is used. Number of teeth are calculated for each gear starting from the output gear and moving back through each stage. The final solution lists the number of teeth for each gear.

    Copyright:

    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd
    Download as ppsx, pdf, or txt
    380 views19 pages

    Design of Gear Box

    Uploaded by

    SUMIT MALUSARE
    The document summarizes the design of a 12-speed gearbox with an input speed range of 160-2000 RPM from a motor with 1600 RPM. It involves calculating the required step ratio of 1.258, selecting standard step ratios of 1.12, and determining the standard speeds from 100-1973 RPM. The structural formula of 3(1)2(3)2(6) is used. Number of teeth are calculated for each gear starting from the output gear and moving back through each stage. The final solution lists the number of teeth for each gear.

    Copyright:

    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd
    Download as ppsx, pdf, or txt
    of 19

    Design of Gear Box

    Using PSG Design Data Book


    Sample Problem
    Design a gearbox with 12 speeds from a source of
    motor with a speed of 1600. The required speed
    range is from 160 rpm to 2000 rpm.
    Given:
    n = 12
    Nmin = 160 rpm
    Nmax = 2000 rpm
    Step - 1 “Calculation of Step ratio”
    Nmax
    = Ø n-1
    Nmin

    2000 = Ø 12-1
    160
    Ø = 1.258
    Referring PSG Data Book P. No : 7.20 the
    calculated step ratio is not a std. value
    Since its not a std. value, Using multiples of
    std. value the required step ratio is calculated
    1.6 - Cannot be used
    1.25 - Cannot be used
    1.12 - 1.12 x 1.12 = 1.254
    1.06 - 1.06 x 1.06 x 1.06 x 1.06 = 1.238
    Multiples of 1.12 gives nearest value of 1.258
    As 1.06 is multiplied 1 times we skip 1 speed
    Hence std. Ø = 1.12 & R 20 series is selected
    Step - 2 “Selection of Speeds”

    100 112 125 140 160 180 200 224 250 280 315 355 400 450 500

    560 630 710 800 900 1000 1120 1254 1404 1573 1762 1973 2210

    The obtained speeds are;


    160,200,250,315,400,500,630,800,
    1000,1254,1573,1973

    Check for deviation


    The allowable deviation and actual deviation is
    calculated,

    Allowable deviation = ± 10 (Ø - 1) %
    = ± 10 (1.258 - 1) %
    = ± 2.58 %
    Nmin
    Actual deviation = (Nmax actual - Nmax) x
    Nmax

    = (1973 - 2000) x 160


    2000
    = - 2.16 %
    Since the deviation is within the allowable
    range we can design for standard speeds.

    The selected standard speeds are;


    160, 200, 250, 315, 400, 500, 630, 800,
    1000, 1254, 1573, 1973
    Step - 3 “ Structural formula & Ray
    Diagram ”
    The structural formula for 12 speed gear box is
    3 (1) 2 (3) 2 (6)
    Stage 1 - Single input is splitted into 3 speeds
    Stage 2 - 3 input is splitted into 6 speeds
    ie., each input is splitted into 2 speed
    Stage 3 - 6 input is splitted into 12 speeds
    ie., each input is splitted into 2 speed
    3 (1) 2 (3) 2 (6) Stage - 3
    1973
    Nmin 160
    = = 0.4 ≥ 0.25
    1573 Ni/p 400
    1254 Nmax 630
    = = 1.57 ≤2
    1000 Ni/p 400
    800 Stage - 2
    Nmin 400
    630 = = 0.63 ≥ 0.25
    Ni/p 630
    500 Nmax
    = 800
    = 1.27 ≤2
    400 Ni/p 630
    315 Stage - 1
    Nmin 630
    250 = = 0.40 ≥ 0.25
    Ni/p 1573
    200
    Nmax
    = 1000 = 0.63 ≤2
    160 Ni/p
    Stage 1 Stage 2 Stage 3 1573
    Step - 4 “ Kinematic Arrangement ”
    3
    1 5
    Shaft - 1 / Input

    9
    7
    Shaft - 2 / Intermediate
    2 4
    6
    11
    13
    Shaft - 3 / Intermediate
    8 10

    12 Shaft - 4 / Output
    14
    Step - 5 “ Calculation of number of
    number of teeth in gears ”
    Stage - 3 “First Pair - Lowest speed o/p

    Assume number of teeth in driver, z13 = 20

    z13 N14 20 160


    = =
    z14 N13 z14 400

    z14 = 50
    Stage - 3 “Second Pair

    z11 N12 z11


    630
    = =
    z12 N11 z12 400
    z11 = 1.575 z12
    z11 + z12 = z13+ z14
    z11 + z12 = 20+ 50 = 70

    1.575 z12 + z12 = 70

    z12 = 27 .18 ≅ 27
    z11 = 43
    Stage - 2 “First Pair - Lowest speed o/p

    Assume number of teeth in driver,z7 = 20

    z7 N8 20 400
    = =
    z8 N7 z8 630

    z8 = 31.5≅ 32
    Stage - 2 “Second Pair

    z9 N10 z9
    800
    = =
    z10 N9 z10 630
    z9 = 1.269 z10
    z7 + z8 = z9+ z10
    20+ 32 = z9 + z10 = 52

    1.269 z10 + z10 = 52

    z10 = 22.9 ≅ 23
    z9 = 29
    Stage - 1 “First Pair - Maximum Speed Reduction”
    Assume number of teeth in driver, z5 = 20
    z5 N6 20 630
    = =
    z6 N5 z6 1573

    z6 = 49.9 ≅ 50
    Stage - 1 “Second Pair”

    z1 N2 z1 800
    = =
    z2 N1 z2 1573

    z1 = 0.50 z2
    Stage - 1 “Third Pair”

    z3 N4 z3 1000
    = =
    z4 N3 z4 1573

    z3 = 0.63 z4
    Stage - 1

    z1 + z2 = z3+ z4 = z5+ z6 z5 = 20
    z1 + z2 = z3+ z4 = 20 + 50 = 70 z6 = 50
    z3 + z4 = 70 z1 = 0.50 z2
    0.63 z4 + z4 = 70 z3 = 0.63 z4
    z4 = 42.94 ≅ 43 z3 = 27
    z1 + z2 = 70
    0.50 z2 + z2 = 70
    z2 = 46.6 ≅ 47 z1 = 23
    Solution
    z1 = 23 z7 = 20 z13 = 20

    z2 = 47 z8 = 32 z14 = 50

    z3 = 27 z9 = 29

    z4 = 43 z10 = 23

    z5 = 20 z11 = 43
    z6 = 50 z12 = 27

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