CHAPTER 5

GEAR TRAINS
Harold L Johnson, Ph.D.
Associate Professor Emeritus
School of Mechanical Engineering
Georgia Institute of Technology
Atlanta, Georgia

5.1 ORDINARY GEAR TRAINS / 5.1

5.2 GEAR TYPE SELECTION / 5.3
5.3 PLANETARY GEAR TRAINS / 5.5
5.4 DIFFERENTIAL TRAINS / 5.14
REFERENCES / 5.16

5.7 ORDINARYGEARTRAINS

Gear trains consist of two or more gears meshed for the purpose of transmitting
motion from one axis to another. Ordinary gear trains have axes, relative to the
frame, for all gears making up the train. Figure 5.1a shows a simple ordinary train in
which there is only one gear for each axis. In Fig. 5.1b, a compound ordinary train is
seen to be one in which two or more gears may rotate about a single axis.
The ratio of the angular velocities of a pair of gears is the inverse of their num-
bers of teeth. The equations for each mesh in the simple train are
N2 N3 N4 /C1,
n3 = — n2 n4 = —-n3 n5 = —-n4 (5.1)
N3 N4 N5
where n is in revolutions per minute (r/min) and N = number of teeth. These equa-
tions can be combined to give the velocity ratio of the first gear in the train to the last
gear:
„ W4 N3 N2

Note that the tooth numbers in the numerator are those of the driving gears, and
the tooth numbers in the denominator belong to the driven gears. Gears 3 and 4
both drive and are, in turn, driven. Thus, they are called idler gears. Since their tooth
numbers cancel, idler gears do not affect the magnitude of the input-output ratio,
but they do change directions of rotation. Note the directional arrows in the figure.
Idler gears can also produce a saving of space and money. In Fig. 5.2, the simple
train of the previous figure has been repeated. In dotted outline is shown a pair of
gears on the same center distance as gears 2 and 5 and having the same input-
output ratio as the simple train.
Finally, Eq. (5.2) is simplified to become
 FIGURE 5.1 Ordinary gear trains, (a) Simple; (b) compound.

«5 = - ^ « 2 (5.3)

where the minus sign is now introduced to indicate contrarotation of the two gears.
The compound train in Fig. 5.1Z? has the following velocity ratios for the pairs of
driver and driven gears:

n3 = - — n2 and n5 = -^-n4 (5.4)

and, of course, n4 = n3. Combining the equations yields

 FIGURE 5.2 Gears 2' and 5' are required if idler gears are not used.

n
> = -NiNsn2 (5 5)
'
and the thing worthy of note here is that the numbers of teeth of all gears consti-
tuting a mesh with a compounded pair are required to determine the velocity ratio
through the system. Compound gear trains have an advantage over simple gear
trains whenever the speed change is large. For example, if a reduction of 12/1 is
required, the final gear in a simple train will have a diameter 12 times that of the
first gear.

5.2 GEAR TYPE SELECTION

The disposition of the axes to be joined by the gear train often suggests the type of
gear to choose. If the axes are parallel, the choices can be spur gears or helical gears.
If the axes intersect, bevel gears can be used. If the axes are nonparallel and nonin-
tersecting, then crossed helicals, worm and gear, or hypoid gears will work. In
Fig. 5.3, a train having various types of gears is shown. Gears 2 and 3, parallel helical
gears, have a speed ratio

»3 = - ^ « 2 (5-6)

Gears 4 and 5, bevel gears, have a speed ratio

TV4 /c _.
n5 =--^n4 (5.7)

Gears 6 and 7, worm and gear, are considered in a slightly different manner. A worm
is generally spoken of as having threads, one, two, three or more (see Chap. 12). A
 FIGURE 5.3 Various gears used in a train.

worm with one thread would have a lead equal to the pitch of the thread. A worm
with two threads would have a lead equal to twice the pitch of the thread. Thus
number of threads on 6 /c ox
H1 = — n6 (5.8)
Joining Eqs. (5.6), (5.7), and (5.8), we find

where Af6 represents the number of threads of the worm gear.

To determine the direction of rotation of gear 7, an inversion technique can be
used. Fix gear 7 and allow the worm to translate along its axis as it rotates. Here it is
necessary to note the hand of the worm, which can be either right or left. In the fig-
ure, gear 6 rotates in the same direction as gear 5 and, having a right-hand thread,
will move downward (in the drawing). Now, inverting back to the original mecha-
nism, the worm is moved in translation to its proper position, and by doing so, gear 7
is seen to rotate clockwise.
5.3 PLANETARYGEARTRAINS

Planetary gear trains, also referred to as epicyclic gear trains, are those in which one
or more gears orbit about the central axis of the train. Thus, they differ from an ordi-
nary train by having a moving axis or axes. Figure 5.4 shows a basic arrangement that
is functional by itself or when used as a part of some more complex system. Gear 2
is called a sun gear, gear 4 is a. planet, link 3 is an arm, ox planet carrier, and gear 5 an
internal-toothed ring gear.
Planetary gear trains are, fundamentally, two-degree-of-freedom systems. There-
fore, two inputs are required before they can be uniquely analyzed. Quite frequently
a fixed gear is included in the train. Its velocity is zero, but this zero velocity consti-
tutes one of the input values. Any link in the train shown except the planet can serve
as an input or an output link. If, for example, the rotations of link 2 and link 5 were
the input values, the rotation of the arm would be the output. The term link refers to
the individual machine elements comprising a mechanism or linkage, and gear trains
are included in this broad array of systems. Each link is paired, or joined, with at
least two other links by some form of connection, such as pin points, sliding joints, or

FIGURE 5.4 A basic planetary train.

direct contact, a pairing that is prevalent in cam-and-gear systems. An explanation
and an illustration of the joint types are found in Refs. [5.1] and [5.2] as well as others
(see Chap. 3).
There are several methods for analyzing planetary trains. Among these are
instant-centers, formula, and tabular methods. By instant centers, as in Ref. [5.3] and
on a face view of the train, draw vectors representing the velocities of the instant
centers for which input information is known. Then, by simple graphical construc-
tion, the velocity of another center can be found and converted to a rotational speed.
Figure 5.5 illustrates this technique.

LINE OF CENTERS VELOCITY GRADIENT

FIGURE 5.5 Instant-centers method of velocity analysis.

Calculate VICIA a n d VIC45 from

V=rco (5.10)
where r = radius dimension and co = angular velocity in radians per second (rad/s).
Draw these vectors to scale in the face view of the train. Then yIC24 and VIC45 will
emanate from their instant-center positions. Now draw a straight line through the
termini of the velocity vectors.1 The velocity of IC34 will be a vector perpendicular
to the line of centers and having its terminus on the velocity gradient. Determine co
of link 3 by using Eq. (5.10). Thus,

Vic24 = r2uk and ViC 45 = >5CO5

Choose a scale and construct the two vectors. Next, draw the gradient line and
construct V1C34. Scale its magnitude and determine n3 according to

„3 = ^ 6 0 (5.11)

where r3 = radius of the arm and n3 is in revolutions per minute.

If gear 5 is fixed, then VIC45 = 0; using VIC24, connect the terminus of FIC24 and IC45
with a straight line, and find VIC34 as before. See Fig. 5.6.

f
This line can be called a velocity gradient for link 4.

FIGURE 5.6 Gear 5 is fixed.

 By formula, the relative-motion equation will establish the velocity of the gears
relative to the arm; that is,
n23 = n2-n3 (5.12)
«53 = n5-n3 (5.13)
Then, dividing (5.13) by (5.12), we see that
«51= nlznL
n23 n2 - n3
which represents the ratio of the relative velocity of gear 5 to that of gear 2 with both
velocities related to the arm. The right-hand side of the equation is called the train
value. If the arm should be held fixed, then the ratio of output to input speeds for an
ordinary train is obtained.
The equation for train value, which is seen in most references, can be written

e=nL^nA (515)
nF-nA
where nF = speed of first gear in train
nL = speed of last gear in train
nA = speed of arm
The following example will illustrate the use of Eq. (5.15).
Example 1. Refer to the planetary train of Fig. 5.4. The tooth numbers are N2 =
104, N4 = 32, and TV5 = 168. Gear 2 is driven at 250 r/min in a clockwise negative direc-
tion, and gear 5 is driven at 80 r/min in a counterclockwise positive direction. Find
the speed and direction of rotation of the arm.
Solution. nF = n2 = -250 r/min nL = n5 = +80 r/min

\ N4)[N5) [ 32 A 1 6 8 / 21
In Eq. (5.15),
13 80-«3 .,. . .
~^V= o^n " 3= 46 2 r / m m
~ -
21 -250 - n3
By tabular method, a table is first formed according to the following:
1. Include a column for any gear centered on the planetary axis.
2. Do not include a column for any gear whose axis of rotation is fixed and differ-
ent from the planetary axis.
3. A column for the arm is not necessary.
4. The planet, or planets, may be included in a column or not, as preferred.
Gears which fit rule 2 are treated as ordinary gear train elements. They are used
as input motions to the planetary system, or they may function as output motions.
The table contains three rows arranged so that each entry in a column will con-
stitute one term of the relative-motion equation
 TABLE 5.1 Solution by Tabulation

Step Gear 2 Gear 5

1. Gears locked «3 «3
2. Arm fixed n2 — n3 N2 (N4\

3. Results Ai2 «5

ny + nxy = nx (5.16)
This is best shown by example. Using the planetary train of the previous example,
we form Table 5.1, and the equation from the column for gear 5 is

Rearranging and canceling Af4, we find

*(••£)-«•£-"• < 517 >

This is the characteristic equation of the planetary train, as shown in Fig. 5.4.
Note that three rotational quantities appear—n3, n2, and n5. There must be two
input rotations in order to solve for the output. This is easily done when the input
rotations and the tooth numbers are inserted. When a positive sense is assigned to
counterclockwise and a negative sense to clockwise rotation, the sign of the output
rotation indicates its sense of direction.
Note that planet 4 was not included in the table (it could have been); however,
gear 4 served its purpose by acting as an idler to change a direction of rotation. This
is evidenced by the presence of a negative sign in the second row of the column for
gear 5.
A convenient means of representing a planetary train was shown by Levai
[5.4]. Type A of Fig. 5.1a shows an edge view of the planetary train first seen in Fig.
5.4. It and the other 11 configurations represent all possible variations for
a planetary train. The equations in Table 5.2 are the characteristic equations of the
12 types.
An examination of the equations and their corresponding types reveals that cer-
tain ones are identical. Types C and D in Fig. 5.1b are identical because of the
arrangement of gears. Whereas in type C the meshes of 2 and 4 and of 7 and 8 are
external, the input and output meshes are internal in type D. The same relationship
can be seen in types G and H in Fig. 5.7c. Certain pair types are alike in equation
form but differ in sign. Compare types E and K and F and L in Fig. 5.1b and d, and
B and G (or B and H) in Fig. 5.7^ and c.
The speed of a planet gear relative to the frame or relative to the arm may be
required. If appreciable speeds and forces are involved, this information will facili-
tate the selection of bearings. Using type A as an example, set up Table 5.3. Row 2 in
the column for gear 4 is the speed of gear 4 relative to the arm, and row 3 in the col-
umn for gear 4 is its speed relative to the frame.
 FIGURE 5.7 Twelve variations of planetary trains.

Example 2. Figure 5.8 shows a planetary gear train with input at gear 2. Also, gear
6' is seen to be part of the frame, in which case its rotation is zero. For n2 = 100 r/min
clockwise (negative), find output rotation n6.
Solution. Gears 2,4,5, and 6 and arm 3 form a type B planetary train:

\ N4Ne) N4Ne
Solving for n3 yields
«3(i + i ) -HOO)(I) = O
100 , .
n3 = - —— r/min
For type G:
{^ N2N5] ( N2N5]

Then we solve type G for n6:

 TABLE 5.2 Characteristic Equations for 12 Planetary Trains
of Fig. 5.7

Type Equation

TABLE 5.3 Solution of Type A Train

Step Gear 2 Gear 4 Gear 5

1. Gears locked n3 n^ «3

2. Arm fixed Yt1-Yi1 - ~ (n 3 ~ "i) - 7 7 («3 - «2)

Jy4 Jy5
3. Results Yii n4 n5
 6'(FIXED) SHAFT 2

OUTPUT

SHAFT 1 INPUT
ARM 3 100 RPM
(c)

FRAME

FIGURE 5.8 (a) View of a gear train and (b) its symbolic notation.

n6 = -25.93 r/min

Example 3. Figure 5.9 shows a type I planetary train, Ref. [5.2]. Here, if n2 = 100
r/min clockwise and n3 = 200 r/min clockwise, both considered negative, determine
W4, n5, and n6.
 FIGURE 5.9 (a) Planetary train; (b) symbolic notation.

TABLE 5.4 Solution of Type I Train

Step Gear 2 Gear 4 Gear 5 Gear 6

1 #3 /?3 W3 //3

2 n2 - n3 - jf (n2 - n3) + ~ (n2 - n3) +j*(n2- n3)

3 n2 n4 ns n6
 Solution. To determine the angular speeds for the planet, form Table 5.4. The
speed of gear 4 can be found by writing the equation in the column for gear 4.
Thus,
Z1 N2] N2

-200(1+TI)-(-100)(TI)=-
M4 = -487.5 r/min
For gear 5,
/, N2 \ N2

n5 = +30 r/min
For gear 6,

_ 2 0 0 (l- if) + HOO)(If) = n6

n6 = -151 r/min

5.4 DIFFERENTIALTRAINS

Differential gear trains are useful as mechanical computing devices. In Fig. 5.10, if
CO4 and co6 are input angular velocities and VA and VB are the resulting linear veloc-
ities of points A and B, respectively, then the velocity of point C on the carrier is

VC = YA±YJL (5 . 18)

The differential gear train also finds application in the wheel-axle system of an
automobile. The planet carrier rotates at the same speed as the wheels when the
automobile is traveling in a straight line. When the car goes into a curve, however,
the inside wheel rotates at a lesser speed than the outside wheel because of the dif-
ferential gear action. This prevents tire drag along the road during a turn.

Example 4. See Ref. [5.2], page 329. The tooth numbers for the automotive differ-
ential shown in Fig. 5.11 are N2 = 17, N3 = 54, N4 = 11, and N5 = N6 = 16.The drive shaft
turns at 1200 r/min. What is the speed of the right wheel if it is jacked up and the left
wheel is resting on the road surface?
 FIGURE 5.10 (a) Top and (b) front views of a bevel-gear differential
used as a mechanical averaging linkage. Point A is the pitch point of
gears 4 and 5. Point B is the pitch point of gears 5 and 6.

Solution. The planet carrier, gear 3, is rotating according to the following

equation:

n3 = -^- /i2 = -^- (1200) = 377.78 r/min

Since the r/min of the left wheel is zero, the pitch point of gears 4 and 5 has a linear
velocity twice that of the pin which supports the planet. Therefore, the r/min of the
right wheel is twice that of the planet, or

n6 = 2n3 = 755.56 r/min

 DRIVE SHAFT

RING GEAR

TO REAR WHEEL TO REAR WHEEL

PLANET GEARS

FIGURE 5.11 Schematic drawing of a bevel-gear automotive differen-

tial.

REFERENCES

5.1 Richard S. Hartenberg and Jacques Denavit, Kinematic Synthesis of Linkages, McGraw-
Hill, New York, 1964.
5.2 J. E. Shigley and J. J. Uicker, Jr., Theory of Machines and Mechanisms, 2d ed., McGraw-
Hill, New York, 1995.
5.3 Virgil M. Faires and Robert M. Keown, Mechanism, 5th ed., McGraw-Hill, New York,
1960.
5.4 Z. L. Levai, "Theory of Epicyclic Gears and Epicyclic Change-Speed Gears," Technical
University of Building, Civil and Transport Engineering, Budapest, 1966.