CYCLOIDAL GEAR BOX

A Project Report On

DESIGN AND FABRICATION OF CYCLOIDAL GEAR BOX

Submitted in partial fulfilment of the requirements for the degree of
Bachelor of Engineering in Mechanical Engineering
By
Shambhudev lohte
Vivek singh
Rushikesh kadam
Under the guidance of
TRB.SANJAI KUMAR

Department of Mechanical Engineering

Pillai HOC College of Engineering and Technology
Rasayani– 410207

2016-2017
University of Mumbai

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Acknowledgement

We remain immensely obliged to TRB.SANJAI KUMAR sir for providing us with the moral
and technical support and guiding us. We would also like to thank our guide for providing us
with her expert opinion and valuable suggestions at every stage of project.

We would like to take this opportunity to thank Dr. M. D Nadar, Head of Mechanical
Engineering for his motivation and valuable support. This acknowledgement is incomplete
without thanking teaching and non-teaching staff of department of their kind support.

We would also like to thank Dr. Chelpa Lingam, Principal of Pillai HOC college of
Engineering and Technology, Rasayani; Dr. Charate, Dean of Pillai HOC college of
Engineering and Technology for providing the infrastructure and resources required for
project.

Group Members

Shambhudev lohte
Vivek singh
Rushikesh kadam

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Academic Year 2016-17

Mahatma Education Society’s

Pillai HOC College of Engineering & Technology, Rasayani – 410207

Department of Mechanical Engineering

CERTIFICATE
This is to certify that the project synopsis entitled DESIGN AND FABRICATION OF CYCLOIDAL
GEAR BOX

is successfully completed by following students:

Name Roll No

Shambhudev lohte 59

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Vivek singh 53

Rushikesh kadam 48

As per the syllabus & in partial fulfillment for the completion Bachelor’s degree in
Mechanical Engineering from University of Mumbai, it is also to certify that this is the
original work of the candidate done during the academic year 2016- 2017.

Project Guide Head of Department

Principal

Project Report Approval for B. E.

This dissertation/project report entitled DESIGN AND FABRICATION OF CYCLOIDAL
GEAR BOX by Shambhudev lohte,Vivek singh,
Rushikesh kadam isapproved for the degree of Bachelor of Engineering.

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Examiners
1.---------------------------------------------

2.---------------------------------------------

Date:

Place:

Declaration

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I declare that this written submission represents my ideas in my own

words and where others' ideas or words have been included, I have

adequately cited and referenced the original sources. I also declare that I

have adhered to all principles of academic honesty and integrity and have

not misrepresented or fabricated or falsified any idea/data/fact/source

in my submission. I understand that any violation of the above will be

cause for disciplinary action by the Institute and can also evoke penal

action from the sources which have thus not been properly cited or from

whom proper permission has not been taken when needed.

----------------------------- ---------------------------

Shambhudev lohte-59 Vivek singh-B-53

-----------------------------------------

Rushikesh kadam-48

Date:

Place:

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INDEX
PAGE.NO NAME OF THE TOPIC PAGE
NO.
1

10

11

12

13

14

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INDEX

Sr. Title Pg No.

No.
1 Abstract 5
2 Introduction 6
3 Literature survey 8
4 Problem Defination 9
5 Objective 10
6 Methodology 11
7 Scope Of Work 12
8 Cost Estimation 13
9 Advantages 14
10 Disadvantages 15
11 Images &Referances 16
12 Research Paper 22

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ABSTRACT

The word Cycloid, with its adjective Cycloidal, is derived from Hypocycloid which describes
the curve traced by a point on the circumference of a smaller circle rotating inside the
circumference of a larger fixed circle.  Just like words such as helical, worm, spur, and bevel,
cycloidal is a generic adjective; it merely describes the gearing mechanism inside the speed
reducer. 
A cycloid speed reducer is one of the rotational speed regulation devices of the machinery.
It has advantages of the higher reduction ratio, the higher accuracy, the easier adjustment
of the transmission ratio, high shock load absorption capacity and the smaller workspace
than any other kinds of the reducer. This paper proposes a simple and exact approach for
the lobe profile design of the cycloid plate gear, which is a main part of the cycloid reducer.

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1INTRODUCTION

Speed reducers are used widely in various applications for speed and torque conversion purposes.
Among them, a cycloid reducer has been used for decades owing to their smooth and high
performance, high reliability, long service life, compactness, exceptional overload capacity, low to
zero backlash through rolling tooth engagement in the contact mechanism, and other advantages.
Therefore it makes an attractive candidate for limited space applications today.

A cycloid plate gear, which is a main part of the cycloid reducer, meshes in all teeth or lobes at
any one time with the roller gear (or ring gear) consisted of several rollers on the circular pitch
line. Generally, it is classified into four types of the cycloid drives by the lobe profile of the cycloid
plate gear and the roller gear_s motion: the stationary ring gear type epicycloid reducer, the rotating
ring gear type epicycloid reducer, the stationary ring gear type hypocycloid reducer and the
rotating ring gear type hypocycloid reducer.

• In the picture above the central gray colored shaft is the input shaft. The same shaft is
shown yellow in the picture below. It is made with an eccentric cam at the end of the
shaft. The cam sits inside the center of the cycloid disc. As it rotates the cam moves the
cycloid disc in a circular orbit. The outer fixed pins and rollers restrain the disc and force
it to roll around inside the ring of fixed pins. As the disc rolls it moves the inner set of
pins and roller attached to the output shaft.

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• One rotation of the cam moves the cycloid disc over one outer pin. As the disc rotates the
inner pins are forced around with it at the speed of the disc. This means that there is a
reduction in gearing and the output turns at slower revolutions than the input shaft.

• The
nature of the design makes their size much smaller than a conventional toothed gear drive
for the same gearing ratio. This means you need less space to mount them. They weigh less
and are more easily maneuvered by installation and repair personnel. The smaller internals
and sliding action of the rotating components makes the gearbox quieter than conventional
gearboxes.

• They are ideal where shock loads are expected because all the parts are in compression
and not in tension, as is the case with conventional gearbox teeth. Their quietness makes
them ideal to use where operators need to work close to equipment or for equipment
located near offices, hospitals and the like. Their reliability and longevity is outstanding!

LITERATURE REVIEW

According to Kennedy_s theorem [8–10], the three instant velocity centers shared by three rigid
bodies in relative motion to one another (whether or not connected) all lie on the same straight
line. Fig. 2 shows the construction necessary to find instant velocity centers. In Fig. 2 links 2
and 3 are in direct contact. All pin joints (IC 12, IC13) are permanent instant centers. If the point
of contact does not lie on the line of centers IC12–IC13, these tangential components will not be

equal, and sliding exists. Hence the only relative motion which links 2 and 3 can have at their
point of contact is in the direction of the common tangent, and their center of relative rotation,

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instant velocity center IC23, must then lie along the common normal. However, by Kennedy_s theorem
instant velocity center IC23 must lie along line IC12–IC13. Hence instant velocity center IC23
lies at the point of the intersection of the common normal and the line of centers IC 12–IC13.
Fig. 3 is a schematic of a stationary ring gear type epicycloid reducer. This mechanism employs
a crank ðO1OCÞ to devote the epicycloidal plate gear that orbits about the center (O1) of the input
shaft due to the eccentricity of the shaft. At the same time, the cycloidal plate gear rotates about
its own center (OC) in the opposite direction of the input shaft, due to the engagement with the
stationary ring gear. The resulting motion of the cycloidal plate gear is a compound motion.
We can consider that it consists of three links in kinematics: the frame corresponding to O1OR
(here rollers being attached to the stationary ring gear) as Link 1, the eccentric distance O1OC
as Link 2, and the cycloid plate gear as Link 3. By Kennedy_s theorem, we can easily determine
the three instant velocity centers, i.e. a point O1 as IC12, a point OC as IC23 and a point M as IC13,
respectively, as shown in Fig. 3. Here we will denote the eccentricity O1OC corresponding to the
eccentric bearing of the input shaft as E, O1M as Q which is an unknown to be determined below,
and O1OR as R, respectively (Fig. 4). The center distance (or crank length) E, the number of rollers
N, the roller radius Rr, and the radius of the roller gear R are usually assigned design parameters.
From the definition of the instant center, both links sharing the instant center will have identical
velocity at that point. In Fig. 4, the angular velocity x2 of the input shaft (Link 2) and the angular
velocity x3 of the output cycloid plate gear (Link 3) are illustrated in the same direction
(counterclockwise).
The magnitude of the velocity ~V 23 of the point IC23 as shown in Fig. 4 can be determined
By

It means that the actual orientation of x2 and x3 is in the opposite direction to each other.
Pollitt [11] showed how to find the point of contact between the cycloid plate gear (planetary
gear) and the cylindrical rollers which make up the teeth of the stationary ring gear (sun gear)

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3. Rotating ring gear type epicycloid reducer

The situation envisaged is the same that of Section 2 but ring gear rotating at constant speed
(Fig. 8). It is also modeled kinematically into three-link and three-joint mechanism: the frame
corresponding
to O1OC as Link 1, the roller gear attached to the rotating ring gear as Link 2, and the
epicycloid plate gear as Link 3. Three instant velocity centers are given by the point O1 as IC12, the
point OC as IC13 and the point M as IC23, respectively (Fig. 9). From Fig. 9, the speed V23 at the
point of IC23 and the angular velocity ratio mV for this epicycloid reducer are given by

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PROBLEM DEFINATION AND PROJECT OBJECTIVE

The normal gear box is worm shaft and worm wheel type used for high speed reduction and
torque increment. But it is not having collinear shaft and is big in size also cannot be fitted on
motor mounting. Further high speed reduction is not possible in it.

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OBJECTIVE

The objective of our project is to develop affordable, wearable, light weight, user friendly
chairless chair which can enable the worker, back pain, arthritis patients to have the ability to
move around with absolute ease, with the use of a chairless chair.

1. Rolling Contact - All major torque transmitting components roll; they do

not slide.  Rolling motion contributes to minimal friction and high
efficiency.  Single stage efficiency approaches 93%, and double stage
efficiency approaches 86%.

2. Torque transmitting elements experience COMPRESSION; they do not

shear -  Unlike involute gear mechanism which has only 1 or 2 teeth to absorb the
entire shock load with possible gear teeth breakage, at least 66% of ring gear
rollers and cycloidal disc lobes share the shock load under compression (Frame

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size B10 and above with twin disc design).  In addition, major torque transmission
components inside the DARALITM Cycloidal Reducers are made of 52100 (JIS
SUJ2) bearing grade steel and heat treated to Rockwell Hardness of H RC 61~63. 
The end result is that DARALITM Cycloidal Reducers are capable of withstanding
intermittent shock load up to 500% of its catalog torque rating.

3. Compactness - Unlike helical speed reducers which require additional stages to

achieve higher reduction ratio (increased size/weight, decreased efficiency, more
bearings and gears to maintain), changing the ratio of DARALI TM Cycloidal
Reducers (up to 87:1) involves only the changing of ring gear rollers, cycloidal
disc lobes, and eccentric bearing.  The physical dimensions of speed reducers
remain the same.

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4. Excellent performance against worm gear reducers - Rolling motion creates

minimal friction.  Minimal friction contributes to minimal wear and minimal heat
generation.  Worm gear reducers performance are greatly limited by thermal
rating.  DARALITM Cycloidal Reducers with rolling components internally, enjoy
minimal heat loss.  The thermal capability of each frame size and ratio of
DARALITM Cycloidal Reducers exceed its mechanical capability.  Worm gear
reducers are characterized by lower efficiency;  you can select a smaller size
DARALITM Cycloidal Reducer and still enjoy larger output power.  The end result
is longer service life and tremendous energy saving !!

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1.4 METHODOLOGY

WORKING PRINCIPLE

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As the input shaft turns, the eccentric bearing goes into a rocking motion.  This rocking motion
exerts an outward radial force on the cycloidal disc Confined inside the ring gear housing with
pins/rollers, the cycloidal disc goes into a planetary motion as the eccentric bearing turns.   Refer to
Figure 2, as a smaller circle rotates inside the circumference of a larger circle, the smaller circle
goes into a planetary motion.  Relative to its own center, the smaller circle is rotating in the CCW
direction.  However, relative to the center of larger circle, the smaller circle is advancing in the CW
direction. (Figure 2, left)  Cycloidal mechanism works the same way.  The smaller circle as
described earlier is now almost as large as the larger circle and has the shape of a cycloidal disc.  
The larger circle now has the shape of a ring gear with pins/rollers. (Figure 2, right)  As the
eccentric bearing drives the cycloidal disc, the cycloidal disc rotates in one direction relative to its
own center.  However the cycloidal disc advances in the opposite direction relative to the center of
the speed reducer.  This planetary motion looks almost like the wobbling movement of hula hoops.

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As the eccentric bearing turns one revolution, the cycloidal disc advances in the opposite direction
by (360/L) degrees or (P/L) pitches of pins/rollers. (Figure 3)  The output direction of cycloidal
reducer with single stage reduction equals to the opposite of input direction.

In order to convert the wobbling motion of a cycloidal disc into the smooth concentric movement of
output shaft, several output shaft rollers are placed inside the small circles of a cycloidal disc. 
These rollers are also attached to the output shaft pins.  The difference (2C) between the diameter
of output shaft roller and the small circle is exactly twice the eccentricity (C) of eccentric bearing. 
This distance (2C) is also the radial difference between the valley and crest of a cycloidal disc lobe.

With the arrangement above, the mechanism is capable of converting the rocking motion of an eccentric
bearing into the wobbling planetary motion of a cycloidal disc.  This motion is then transformed to the
smooth concentric movement of output shaft through the output shaft rollers.  The speed reduction is
achieved, and torque transmission is accomplished.

To understand the operating principle, you should first know how to determine the reduction ratio of a
cycloidal reducer.

Ratio = (P-L) / L

Where  P = Number of ring gear pins/rollers

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            L = Number of lobes on a cycloidal disc

For example, please refer to drawing on the right, the number of ring gear pins/rollers (P) equals 12, and
the number of lobes (L) on the cycloidal disc equals 11. 

Ratio = (12-11) / 11 = 1 / 11 = 11:1 To understand the operating principle, you should first know how to
determine the reduction ratio of a cycloidal reducer.

Ratio = (P-L) / L

Where  P = Number of ring gear pins/rollers

            L = Number of lobes on a cycloidal disc

For example, please refer to drawing on the right, the number of ring gear pins/rollers (P) equals 12, and
the number of lobes (L) on the cycloidal disc equals 11. 

Ratio = (12-11) / 11 = 1 / 11 = 11:1

1.6 PROJECT MANAGEMENT

RAW MATERIAL & STANDARD MATERIAL

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SR.NO. NAME OF THE PART SPECIFICATION COST RS.

1. MOTOR ¼ HP 1440 RPM 1500

2. PULLY 10 “ & 2” 450

3. BELT V BELT 150

4. BASE C CHANNEL 250

5. MAIN SHAFT MS DIA 400

6. GEAR BOX CASING MILD STEEL 1800

7. CLAMPING BOLT 3/8 “ 150

8. MAIN ROLLER STD 2000

BEARING

9. CYCLOIDAL DISC MILD STEEL 800

10. PIN MILD STEEL 120

11 ECCENTRICITY MILD STEEL 300

12 OIL SEAL BEARING STD 160

TOTAL

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References

 [1] D.W. Botsiber, L. Kingston, Design and performance of the cycloid speed reducer,
Machine Design 28 (1956) 65–
69.
[2] S.K. Malhotra, M.A. Parameswaran, Analysis of a cycloid speed reducer, Mechanism
and Machine Theory 18 (6)
(1983) 491–499.
[3] J.G. Blanche, D.C.H. Yang, Cycloid drives with machining tolerances, ASME Journal
of Mechanisms,
Transmissions, and Automation in Design 111 (1989) 337–344.
[4] D.C.H. Yang, J.G. Blanche, Design and application guidelines for cycloid drives with
machining tolerances,
Mechanism and Machine Theory 25 (5) (1990) 487–501.
[5] F.L. Litvin, P.H. Feng, Computerize design and generation of cycloidal gearing,
Mechanism and Machine Theory
31 (7) (1996) 891–911.
[6] H.S. Yan, T.S. Lai, Geometry design an elementary planetary gear train with
cylindrical tooth-profiles, Mechanism
and Machine Theory 37 (8) (2002) 757–767.
[7] X. Li, W. He, L. Li, L.C. Schmidt, A new cycloid drive with high-load capacity and high
efficiency, ASME Journal
of Mechanical Design 126 (2004) 683–686.
[8] J.E. Shigley, J.J. Uicker Jr., Theory and Machines and Mechanisms, McGraw-Hill,
1980.
[9] J. Davidson, K.H. Hunt, Robots and Screw Theory, Applications of Kinematics and
Statics to Robotics, Oxford
University Press, 2004.
[10] J.S. Dai, D.R. Kerr, Geometric analysis and optimization of symmetrical Watt 6-bar
mechanisms, Journal of
Mechanical Engineering Science, Proceedings of IMechE 205 (C1) (1991) 275–280.
[11] E.P. Pollitt, Some applications of the cycloid machine design, ASME Journal of
Engineering for Industry 82 (1960)
407–414.
[12] F.L. Litvin, Gear Geometry and Applied Theory, PTR Prentice Hall, Englewood
Cliffs, 1994.

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