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Gears - Gear Efficiency PDF
Gears - Gear Efficiency PDF
Gears - Gear Efficiency PDF
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Gear Efficiency
Introduction
Important Note:
The equations used are mainly derived from the technical information provided in the SDP/SI technical library see links below.
I recommend that for serious work the linked information is more suitable.
Normal
Ratio Range
Pitch Line
Velocity (m/s)
Efficiency
Range
Spur
1:1 to 6:1
25
98-99%
Helical
1:1 to 10:1
50
98-99%
Double Helical
1:1 to 15:1
150
98-99%
Bevel
1:1 to 4:1
20
98-99%
Worm
5:1 to 75:1
30
20-98%
Crossed Helical
1:1 to 6:1
30
70-98%
Symbols
R g = Gear ratio
(%)
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sign of Rg term
External spur
cos a
(R g +1)
Internal Spur
(R g -1)
Single Helical
cos f n / cos 2
tan f n = tan a.cos
(R g +1)
= helix angle
Worm Gears
The theoretical efficiency of a worm gear is provided on page worm gears and is shown again below as.
= 0,04 v s -0,25
v s = sliding velocity (m/s)
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Epicyclic Gears
Consider the two meshing gears below which are part of an epicyclic gear train.This is provided as and example of a typical component
in an epicyclic gear. The two gears and the arms are rotating as shown .
Now it the arm was stationary the contact point P would have a instantaneous velocity = -?2 R2 . (velocities to the right are positive ).
Now if the whole system was rotating as a rigid assembly with the velocity of the arm the instantaneous velocity -?3 R2 .Combining these
two motions together, the linear velocity of the tooth engagement (gear 2 -> gear 1)is therefore
v 12 = - ( ?2 R 2 - ?3 R 2 ) = - (?2 - ? 3 )R 2
Now the magnitude of the transmitted tangential force F12 x the tooth engagement velocity v 12 is called the potential power and the
power loss due to tooth friction is proportional to this power.Generally for spur gears ( and helical gears) it is sufficient to estimate the
power loss as 1% of the potential power.For more accurate estimations the equations above can be used.
P = 0,01 F12 v 12
The potential power is not the actual power but is the but is the power transmitted by the same gears operating on fixed centres at angular
velocities of ( ?2 - ?3 ) for gear 2 and ( ?1 - ?3 ) for gear 2.
The actual pitch line velocity of the gear mesh is -(?2 ) and therefore the ration of the potential power to the actual power is
http://www.roymech.co.uk/Useful_Tables/Drive/Gear_Efficiency.html[19/08/2014 9:32:11]
Now in cases where the arm is rotating faster than the gear the potential power can be greater than the actual power and the losses
proportionally greater.
Example Epicyclic Gear efficiency calculation.
Consider the epicyclic gear chain shown below. The input speed = 250 RPM (ACW) and the input torque = 2.5 Nm
For the gear mesh between gear 3 and the fixed sun 2 the velocity of tooth engagement is calculated by the product of the angular
velocity of the arm 2 at pitch radius of R2. = ?2 R1 = 26,18.0,075 = 1,96m/s
The potential power relates to the gear pair operated in isolation in this case for gear 3 to be in equilibrium (With forces and moments)
F2.R3 + F3.R3 = 0 and F2.R3 + F3R3 = 0 therefore F3 = -F2 = 20N
The potential power of the mesh between the sun gear 1 and the planet gear 3
= the gear engagement velocity(1,96m/s) x the tangential force (F3= 20N) = 1,96.20 =3,92W
Allowing 1% loss on a typical spur gear engagement the power loss at this engagement = 0,39W.
For the gear engagement between the gears 4 and 5 the angular velocity of gear five =
The velocity of tooth engagement between gear (4) and gear (5) =
R5 ( ?5 - ?2 ) = 0,068(-5,95- 26,18)=-2.18 m/s
The potential power at this tooth engagement =
the gear engagement velocity (2,18 m/s). x the tangential force (F4 = -167N) = 2,18.167 = 364 W
Assuming 1% power loss then the loss at this tooth engagement = 3,64 W
The power input to the epicyclic gear = 65 W therefore the Gear efficiency = 100(1 - (3,64 + 0,39) /65 ) = 94%
http://www.roymech.co.uk/Useful_Tables/Drive/Gear_Efficiency.html[19/08/2014 9:32:11]
Gear Ratio
Worm Gear
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Drive Gear