1 Gear System

gear system gear system
GEAR SYSTEM
Mechanical Power Transmission
Power Input transmission Power Output

source mechanism point of application
cables/ pulleys, belts, chain, clutch, cams, ratchets, linkages, gears

depends on requirement and conditions
gear system
objective reduction or amplification of speed and torque
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gear box system

terminology and definition
output
input
gear box
Gear Ratio, n
output speed Noutput ω output 2πN
n= = = where ω= rad/s
input speed Ninput ω input 60
N [rpm]
Power, P [Watt] and Torque, T [N⋅m]
Pinput = Tinput ωinput
Poutput = Toutput ωoutput
Efficiency, η
Poutput Toutputω output Toutput Noutput Toutput
η= = = = n
Pinput Tinput ω input Tinput Ninput Tinput
since input and output torques are different, a holding torque TC is required to stop
gear box from rotating
ωoutput
ωinput ωinput ωoutput Toutput
Tinput
Tinput & ωinput ωinput & ωoutput Toutput & ωoutput
usually same direction depends on gear usually opposite direction
configuration
Toutput Toutput
TC TC
Tinput + TC + Toutput = 0
ωinput ωoutput ωinput ωoutput
Tinput TC Tinput TC
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example
A gear box has an input speed of 1500 rpm and output speed 300 rpm . Input
power is 20 kW, η = 70%. Determine
a. gear ratio, n
b. input torque, Ti
c. output power, PO
d. output torque, TO
e. holding torque, TC
solutions
No 300 1
a. n= = =
Ni 1500 5
2πNi
b. Pi = Ti ωi ωi =
60
60
Ti = 30 x 103 = 127.3 N⋅m same direction as ωi
2π (1500)
Po
c. η= PO = η Pi
Pi
PO = 0.7(20 x 103) = 14 kW
d. PO = TO ωO
60
TO = 14 x 103 = 445 6 N⋅m opposite direction to ωO
2π (300)
e. Ti + TC + To = 0
(+) 127.3 + TC + 445.6 = 0
TC = – 572.9 N⋅m
∴ TC = 572.9 N⋅m
exercise
A gear box has an input speed of 2000 rpm and output speed 500 rpm . Input
power is 50 kW, η = 60%. Determine
a. input torque, Ti
b. output power, PO
c. output torque, TO
d. holding torque, TC
ans (239 N⋅m , 30 KW, 573 N⋅m , 334 N⋅m )
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inside the gear box

Gear Terminology (in relation to the scope)
p pitch, p = distance between a point on

1 tooth to the same point on
the next tooth measured on
pitch diameter, d the pitch circle.

π d
p=
t
d = pitch diameter
t = no. of teeth
pitch circle
in order for two gears to mesh, pitch must be the same

π d1 π d2
=
t1 t2
t1 d1 r1
geometry relation = =
t 2 d2 r2
ω 2 N2 α 2
kinematics relation = =
ω1 N1 α 1
relation between the two
v is common to both gears
v = ω1 r1 = ω2 r2
ω2
ω1 r1 ω 2
=
r2 ω1
r1 r2
gear ratio, n
v ω 2 N2 α 2 t1 d1 r1
n= = = = = =
ω1 N1 α 1 t 2 d2 r2
power and efficiency

Po Toω o To
η= = = n
P i Ti ω i Ti
Ti ω N α t d r
∴ η =n= O = O= O= i = i = i
TO ωi Ni α i t O dO rO
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direction of rotation
external internal
opposite direction same direction

types of gear train
simple gear train
each gear is mounted on separate shaft gear ratio
ω2 t1 N2
ω1 n12 = =
t 2 N1
r1 r2
n13 = n12 x n23

ω3
ω1
r2 t1 t 2 t1
ω2 = x =
r3 t2 t3 t3
r1
n14 = n12 x n23 x n34

ω1
r1 r2 r3 r4 t1 t 2 t 3 t 1
ω2 ω3 = x x =
r1 ω4 t2 t3 t 4 t 4
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compound gear train

two or more gears mounted on the same shaft
gear ratio, n
t1 t 3
n14 = n12 x n34 = x
t2 t 4
1 3
2
4 general equation
(product of driver gears)teeth
n=
(product of driven gears)teeth
1 2
t1 × t 3
3 4 n14 =
t 2 × t4
reverted compound gear train

axes of input and output gears are in line
r1 r2
input similar to compound gear train

gear ratio, n
1 2 t1 t 3
n14 = n12 x n34 = x
t2 t 4
4 3
output
r4 r3
usually needed to find unknown gear teeth using the relationship

r1 + r2 = r3 + r4
∴ t 1 + t 2 = t3 = t4
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example
A simple train has 3 gears. Gear 1 is input,
t1 = 50 and N1 = 1500 rpm . Gear 3 is
output and t3 = 150. Calculate gear ratio, n
1
and N3. If T1 = 12 N⋅m and η = 75%, 2
3
calculate PO and TC.
solutions
t1 t 2 t1 50 1
gear ratio, n13 = n12 x n23 = x = = =
t 2 t 3 t 3 150 3
N3
n13 =
N1
1
∴ N3 = n13 N1 = (1500) = 500 rpm same direction as N1
3
Po
η=
Pi
∴ PO = η Pi = η Pi ωi
2π (1500)
PO = 0.75(12) = 1.414 kW
60
PO = TO ωO
Po 60
TO = =1.414 x 103 = 27 N⋅m opposite direction to ωO
ωO 2π (500)
Ti + TC + To = 0
(+) 12 + TC – 27 = 0
TC = 15 N⋅m
abdrahmanmusa2007
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example
A compound gear train is made up of gear 1
as input, gears 2 and 3 mounted on the same
2
shaft, and gear 4 as output. If N1 = 1200 rpm ,
1 3
T1 = 30 N⋅m and overall efficiency, η = 70%, 4
determine NO, PO and fixing torque TC.

given t1 = 50 t2 = 150 t3 = 30 t4 = 60
solutions
t1 t 3 50 30 1
gear ratio, n14 = n12 x n34 = x = x =
t 2 t 4 150 60 6
ω 4 N4
n14 = =
ω1 N1
1
N4 = n14 N1 = (1200) = 200 rpm same direction as N1
6
Po
η=
Pi
∴ PO = η Pi = η Pi ωi
2π (1200)
PO = 0.7(30) = 2.64 kW
60
PO = TO ωO
Po 60
TO = =2.64 x 103 = 126 N⋅m opposite direction to ωO
ωO 2π (200)
Ti + TC + To = 0
(+) 30 + TC – 126 = 0
TC = 96 N⋅m
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INPUT & OUTPUT TORQUES

taking into consideration friction torque and torque due to mass moment of inertia.
simple example for derivation purposes
Tf1 1
n12, η12
where
INPUT Tf1 and Tf2 = torque due to friction
n12 = gear ratio
OUTPUT η12 = gear mesh efficiency
Tf2
2
torque on gear 1, T1
T1 = Tinput – Tf1 – Tinertia1
T1 = Tinput – Tf1 – I1 α input
torque due to inertia
torque due to friction
input torque
torque on gear 2, T2
η12 T2ω 2 ω2
T2 = T1 this is from η12 = but = n12
n12 T1ω 1 ω1
T2
η12 = n12
T1
η12
thus T2 = T1
n12
substituting for T1 gives

η12
T1 = (Tinput – Tf1 – I1 α input)
n12
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output torque, Toutput

Toutput = T2 – Tf2 – I2 αoutput
η12
= (Tinput – Tf1 – I1 α input) – Tf2 – I2 αoutput
n12
rearranging
η  η  η 
Toutput = Tinput  12  – Tf1  12  – I1 α input  12  – Tf2 – I2 αoutput
 n12   n12   n12 
η   η   η 
= Tinput  12  –  Tf 2 + Tf1 12  –  I2α output + I1α input 12 
 n12   n12   n12 
relationship between αinput and αoutput
α output ω output
= n12 = (i.e. gear ratio)
α input ω input
η   η   α η 
= Tinput  12  –  Tf 2 + Tf1 12  –  I2α output + I1 output 12 
 n12   n12   n12 n12 
η   η   η 
Toutput = Tinput  12  –  Tf 2 + Tf1 12  –  I2 + I1 12  α output
 2 
 n12   n12   n12 
input torque friction torque torque due to moment of inertia

refer to output refer to output refer to output
general equation REFER TO OUTPUT

Toutput = Tinput −Tf − Tinertia
output output output
a similar derivation will result in

n   n   n2 
Tinput = Toutput  12  +  Tf1 + Tf 2 12  +  I1 + I2 12  α input
 
 η12   η12   η12 
input torque friction torque torque due to moment of inertia

refer to input refer to input refer to input
general equation REFER TO INPUT

Tinput = Toutput +Tf + Tinertia
input input input
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important notes
η n
1. refer to output : refer to input :
n η
2. refer to output start from output to input
refer to input start from input to output
BUT gear ratio is always from input to output
3. no friction/ neglecting friction Tf = 0
Tf refer to friction on the shaft!
4. ω constant (anywhere in the system) α = 0 → Tinertia = 0
Poutput1 + Poutput 2
5. 1 input → 2 outputs refer to input η overall =
Pinput
Poutput
2 inputs → 1 output refer to output η overall =
Pinput1 + Pinput 2
1 input → 1 output either refer to input or output
solution strategy by example
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example (refer to input and refer to output)

Determine the torque required by the motor raise the 6 tonne with an acceleration
of 0.4 m/s2. Determine also the overall efficiency of the power transmission system.
no. of teeth
4
t1 = 20 t2 = 80
t3 = 20 t4 = 100
drum
output
Z bearing friction torque
X 1 X = 50 N⋅m
φ 1.2 m
Y1 = Y2 = 90 N⋅m
Z = 300 N⋅m
motor
input
equivalent mass moment of inertia
Imotor = 5 kg⋅m2
6 tonne Ishaft 23 = 40 kg⋅m2

Y1 Y2 3
Idrum = 500 kg⋅m2
4.5 tonne gear mesh efficiency

2
η12 = η34 = 90%
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solutions
t1 20 1 t 3 20 1
gear ratios n12 = = = = 0.25 n34 = = = = 0.2
t 2 80 4 t 4 100 5
 n
REFER TO INPUT  
η 
main equation Tinput = Toutput/input + Tf/input + Tinertia/input
solving Tf/input
n  n n 
Tf/input = X + (Y1 + Y2)  12  + Z  12 34 
 η12   η12η 34 
 0.25   0.25   0.2 

= 50 + (90 + 90)   + 300   
 0.9   0.9   0.9 
= 50 + 50 + 18.5
= 118.5 N⋅m
solving Tinertia/input
Tinertia/input = Iequivalent/input αinput
solving Iequivalent/input solving αinput
 n2   n 2 n2  given a at drum
Iequivalent/input = Imotor + Ishaft 23  12  + Idrum  12 34 
 η η  αdrum
 η12   12 34 
 0.25 2   0.25 2   0.2 2 

= 5 + 40   +500    
 0.9   0.9   0.9 
= 9.323 kg⋅m2 rdrum
aoutput = 0.4 m/s2
aoutput = αdrum rdrum

0.4
αdrum = = 0.667 rad/s2
0 .6
gear ratio
α drum
n = n12 x n34 = (0.25)(0.2) =
α motor
α drum 0.667
αmotor = =
n12 n34 (0.25)(0.2)
=13.4 rad/s2
∴ Tinertia/input = Iequivalent/input αinput
Tinertia/input = 9.323 (13.4)
Tinertia/input = 124.9 N⋅m
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solving Toutput/input
n n 
Toutput/input = Toutput  12 34  Toutput = Tdrum
 η12η 34 
solving Tdrum kinetics analysis of the drum
drum
rdrum
aoutput = 0.4 m/s2
B
A
6 tonne
4.5 tonne
block A block B
Σ F = ma Σ F = ma
[FBD] = [kinetics diagram] [FBD] = [kinetics diagram]
Q1 Q2
A A 4.5 x 103 a B B 6 x 103 a
4.5 x 103 g
6 x 103 g
(+↑) Q1 – 4.5 x 103 g = – 4.5 x 103 a (+↑) Q2 – 6 x 103 g = 6 x 103 a

Q1 = 4.5 x 103 (g – a) Q2 = 6 x 103 (g + a)
Q1 = 4.5 x 103 (9.81 – 0.4) Q1 = 6 x 103 (9.81 + 0.4)
Q1 = 42345 N Q2 = 61260 N
Tdrum
(+)Σ MO = 0
rdrum
Tdrum + Q1 rdrum – Q2 rdrum = 0
O Tdrum = (Q2 – Q1)rdrum

Tdrum = (61260 – 42345)(0.6)
Q2 Tdrum = 11349 N⋅m
Q1
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n n 
but Toutput/input = Toutput  12 34  Toutput = Tdrum
 η12η 34 
 0.25   0.2 
Toutput/input = 11349    = 700.6 N⋅m
 0.9   0.9 
back to the main equation
Tinput = Toutput/input + Tf/input + Tinertia/input
Tinput = 700.6 + 118.5 + 124.9
Tinput = 944 N⋅m
overall efficiency, ηoverall
Poutput Tdrumω drum ω drum
ηoverall = = but = n12 x n34
Pinput Tmotor ω motor ω motor
11349
ηoverall = (0.25)(0.2) = 60.1%
944
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solutions
t1 20 1 t 3 20 1
gear ratios n12 = = = = 0.25 n34 = = = = 0.2
t 2 80 4 t 4 100 5
η 
REFER TO OUTPUT  
 n
main equation Toutput = Tinput/output – Tf/output – Tinertia/output
solving Tf/output
η  η η 
Tf/output = Z + (Y1 + Y2)  34  + X  34 12 
 n34   n34 n12 
 0 .9   0.9   0.9 
= 300 + (90 + 90)   + 50   
 0.2   0.2   0.25 
= 300 + 810 + 810
= 1920 N⋅m
solving Tinertia/output
Tinertia/output = Iequivalent/output αoutput
solving Iequivalent/output solving αoutput
η   η η12  given a at drum
Iequivalent/output = Idrum + Ishaft 23  34
2
 + Imotor  34
  n2 n 2

 αdrum
 n34   34 12 
 0.9   0.9   0.9 

= 500 + 40  2
 +5  2
 2

 0.2   0.2   0.25 
= 3020 kg⋅m2 rdrum
aoutput = 0.4 m/s2
aoutput = αdrum rdrum

0.4
αdrum = = 0.667 rad/s2
0 .6
∴ Tinertia/output = Iequivalent/output αoutput

Tinertia/output = 3020 (0.667)
Tinertia/output = 2014 N⋅m
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solving Toutput Toutput = Tdrum

solving Tdrum kinetics analysis of the drum
drum
rdrum
aoutput = 0.4 m/s2
B
A
6 tonne
4.5 tonne
block A block B
Σ F = ma Σ F = ma
[FBD] = [kinetics diagram] [FBD] = [kinetics diagram]
Q1 Q2
A A 4.5 x 103 a B B 6 x 103 a
4.5 x 103 g
6 x 103 g
(+↑) Q1 – 4.5 x 103 g = – 4.5 x 103 a (+↑) Q2 – 6 x 103 g = 6 x 103 a

Q1 = 4.5 x 103 (g – a) Q2 = 6 x 103 (g + a)
Q1 = 4.5 x 103 (9.81 – 0.4) Q1 = 6 x 103 (9.81 + 0.4)
Q1 = 42345 N Q2 = 61260 N
Tdrum
(+)Σ MO = 0
rdrum
Tdrum + Q1 rdrum – Q2 rdrum = 0
O Tdrum = (Q2 – Q1)rdrum

Tdrum = (61260 – 42345)(0.6)
Q2 Tdrum = 11349 N⋅m
Q1
abdrahmanmusa2007
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back to the main equation

Toutput = Tinput/output – Tf/output – Tinertia/output
11349 = Tinput/output – 1920 – 2014
Tinput/output = 15263 N⋅m
η η 
but Tinput/output = Tinput  34 12  Tinput = Tmotor
 n34 n12 
 0.9   0.9 
15263 = Tmotor    = 700.6 N⋅m
 0.2   0.25 
 0.2   0.25 
∴ Tmotor = 15263    = 943.4 N⋅m
 0.9   0.9 
overall efficiency, ηoverall
Poutput Tdrumω drum ω drum
ηoverall = = but = n12 x n34
Pinput Tmotor ω motor ω motor
11349
ηoverall = (0.25)(0.2) = 60.1%
943.4
abdrahmanmusa2007
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example 1
C
3
4
B D
5
6 o1
2
A
generator 5 kW
i 1
water wheel
7
at 15 rpm constant
E
8 9 G
F H
o2
grinder 15 kW
no of teeth bearing (friction) torque equivalent mass

moment of inertia
t1 = 400 A = 200 N⋅m Iwater wheel = 200 kg⋅m2
t2 = 80 B = 50 N⋅m I23 = 50 kg⋅m2
t3 = 200 C = 20 N⋅m I45 = 20 kg⋅m2
t4 = 50 D = 10 N⋅m Igenerator = 10 kg⋅m2
t5 = 250 E = F = 100 N⋅m I78 = 50 kg⋅m2
t6 = 50 G = H = 250 N⋅m Igrinder = 800 kg⋅m2
t7 = 100
t8 = 200 All gear mesh efficiency η = 80 %
t9 = 400
If 1 m3/s flowrate produces a 2000 N⋅m torque at the water wheel, determine the
required flowrate.
abdrahmanmusa2007
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solution 1 solving TI/i

1 INPUT 2 OUTPUT TI/i = Ieq/i α i = 0 because constant ω, α = 0
∴ REFER TO INPUT solving Tf/i
gear ratios n12 n12 n34 n12 n34 n56 n17 n17 n89
Tf / i = A + B +C +D + (E + F) + (G + H)
t1 400 η12 η12 η 34 η12 η 34 η 56 η17 η17 η 89
n12 = = =5
t2 80 note : friction torque acts on shaft !!
t3 200 5 5 4 5 4 5
n34 = = =4 Tf / i = 200 + 50 + 20 + 10
t4 50 0.8 0.8 0.8 0.8 0.8 0.8
t5 250 4 4 0.5
n56 = = =5 + (100 + 100) + (250 + 250)
t6 50 0.8 0.8 0.8
t1 400 Tf/i = 5653 N⋅m

n17 = = =4
t7 100
general equation
t 200 0
n89 = 8 = = 0 .5 Ti = To1/i + To2/i + Tf/i + TI/i
t9 400
= 6211 + 14 928 + 5653 = 26 792 N⋅m
given 2000 N⋅m torque ⇒ 1 m3/s flowrate

1
∴ 26 792 N⋅m torque ⇒ 26 792 ×
2000
= 13.4 m3/s flowrate
solving To1/i solving To2/i

given Po1 = 5000 W given Po2 = 15000 W
but Po1 = To1 ω o1 but Po2 = To2 ω o2
given Ni = 15 rpm given Ni = 15 rpm
No1 No2
knowing = n12 n34 n56 knowing = n17 n89
Ni Ni
No1 = (5)(4)(5) 15 = 1500 rpm No2 = (4)(0.5) 15 = 30 rpm

2πNo1 2π (1500) 2πNo2 2π (30)
∴ ω o1 = = = 157 rad/s ∴ ωo 2 = = = 3.14 rad/s
60 60 60 60
5000 15000
∴ To1 = = 31.8 N⋅m ∴ To2 = = 4777 N⋅m
157 3.14
n12 n34 n56 5 4 5 n17 n89 4 0.5

To1/ i = To1 = 31.8 To2 / i = To2 = 4777
η12 η 34 η 56 0.8 0.8 0.8 η17 η89 0.8 0.8
To1/ i = 6 211 N⋅m To1/ i = 14 928 N⋅m
abdrahmanmusa2007
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example 2
windmill 1
i1
B
4
3 2
Twm1 = 300 Nm A
1 o
windmill 2
6 5
generator
7
D
i2
E
Twm2 = 200 Nm
no of teeth bearing (friction) torque mass moment of inertia

t1 = 50 A = 5 N⋅m Igenerator = 4 kg⋅m2
t2 = t5 = 200 B = D = 10 N⋅m I23 = I56 = 10 kg⋅m2
t3 = t6 = 40 C = E = 12 N⋅m Iwm1 = Iwm2 = 40 kg⋅m2
t4 = t7 = 200
All gear mesh efficiency η = 80 %
Determine the power produced by the generator if Nwm1 = 30 rpm (i.e. it’s
maximum velocity)
abdrahmanmusa2007
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solution 2
2 INPUT 1 OUTPUT
∴ REFER TO OUTPUT
solving TI/o
gear ratios
TI/o = Ieq/o α o = 0 because constant ω, α = 0
t 200
n43 = 4 = =5
t3 40 solving Tf/o
t 2 200 η 21 η 21 η 43 η 51 η 51 η 76
n21 = = =4 Tf / o = A + B +C +D +E
t1 50 n21 n21 n43 n51 n51 n76
t 5 200 0.8 0.8 0.8 0.8 0.8 0.8

n51 = = =4 Tf / o = 5 + 10 + 12 +10 + 12
t1 50 4 4 5 4 4 5
Tf/o = 5 + 2 + 0.384+ 2 + 0.384 = 9.768 N⋅m
t 200
n76 = 7 = =5
t6 40
solving Ti2/o
general equation
given Ti2 = 300 N⋅m
0
To = Ti1/o + Ti2/o – Tf/o – TI/o
η 51 η76 0.8 0.8
Ti 2 / o = Ti 2 = 200
n51 n76 4 5
= 9.6 + 6.4 – 9.768 = 6.232 N⋅m
Ti 2 / o = 6.4 N⋅m
solving Po
knowing Po = To ω o
given Ni1 = 30 rpm solving Ti1/o
No given Ti1 = 300 N⋅m
knowing = n21n43
Ni1 η 21 η 43 0.8 0.8
Ti1/ o = Ti1 = 300
No = (4)(5) 30 = 600 rpm n21 n43 4 5
2πNo 2π (600) Ti1/ o = 9.6 N⋅m

∴ ωo = = = 62.83 rad/s
60 60
∴ Po = (6.232)(62.83) = 391.6 W
abdrahmanmusa2007
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example 3
drum 1 ∅ 1.0 m
D
1 o1 ⇒
drum 2 3 I4 50 kg
A
C
5
∅ 1.0 m o2 4
I1 I3 30o
2
B
I2
50 kg
i
power input
a = 0.5 m/s2
400 kg
no of teeth bearing (friction) torque mass moment of inertia

t1 = 200 A = 20 N⋅m I1 = 20 kg⋅m2
t2 = 40 B = 4 N⋅m I2 = 5 kg⋅m2
t3 = 160 C = 16 N⋅m I3 = 20 kg⋅m2
t4 = 50 D = 40 N⋅m I4 = 40 kg⋅m2
t5 = 250
all gear mesh efficiency η = 90 %
determine the torque required at input.
abdrahmanmusa2007
-1.23-
solution 3
1 INPUT 2 OUTPUT general equation
∴ REFER TO INPUT Ti = To1/i + To2/i + Tf/i + TI/i
gear ratios
t2 40 1
n21 = = =
t1 200 5
t2 40 1
n23 = = =
t 3 140 4 solving TI/i
t4 50 1 TI/i = Ieq/i α i
n45 = = =
t6 250 5 solving Ieq/i
2
solving Tf/i n21
Ieq / i = I2 + I1
η21
n21
Tf / i = B + A
η 21 2
n23 2
n23 2
n45
+ I3 + I4
η 23 η 23 η 45
n23 n23 n45
+ C +D
η 23 η 23 η 45  1
2
 
= 5 + 20  
1 5
Ieq / i
0.9
Tf / i = 4 + 20 5
0.9  1
2
 1  1
2 2
     
1 1 1
+ 20  4
+ 40    
4 5
+ 16 4 + 40 4 5 0.9 0.9 0.9
0.9 0.9 0.9
Ieq/i = 7.4 kg⋅m2
Tf/i = 15.35 N⋅m
solving α i
given a = 0.5 m/s2 at o2
a 0.5
∴ α o2 = = = 1 rad/s2
ro2 0.5
α o2
knowing = n21
αi
α o2 1
αi = = = 5 rad/s2
n21 1
5
TI/i = (7.4)(5) = 37 N⋅m
abdrahmanmusa2007
-1.24-
solving To1/i
n23 n45
To1/ i = To1
η 23 η 45
solving To1
kinematics analysis kinetics analysis

given ao2 = 0.5 m/s2 F = ma
a 0. 5 (FBD) = kinetics diagram
convert to α o2 = = = 1 rad/s2
ro2 0.5
Fo1 30o
mo1 g
α o2 mo1 ao1
knowing = n21
αi
=
α o2 1
αi = = = 5 rad/s2
n21 1 N
5
α o1
knowing = n23 n45 ( +) Fo1 – mo1 g sin 30o = mo1 ao1
αi
Fo1 = mo1 ao1 + mo1 g sin 30o
convert to α o1 = α i n23 n45
= mo1 (ao1 + g sin 30o)
11 = 50 (0.125 + 9.81 sin 30o)
α o1 = 5 = 0.25 rad/s2
45
= 251.5 N
convert to ao1 = αo1 ro1
ao1 = 0.25 (0.5) = 0.125 m/s2
o1 Fo1
To1 = Fo1 ro1 = 251 5 (0.5) = 125.75 N⋅m
1 1
n23 n45
To1/ i = To1 = 125.75 4 5 = 7.76 N⋅m
η 23 η 45 0.9 0.9
abdrahmanmusa2007
-1.25-
solving To2/i
n21
To2 / i = To2
η 21
solving To2
kinematics analysis
given ao2 = 0.5 m/s2
a 0. 5
convert to α o2 = = = 1 rad/s2
ro2 0.5
α o2
knowing = n21
αi
α o2 1
αi = = = 5 rad/s2
n21 1
5
Oy
To2
Ox =
Q1
Q2
kinetics analysis kinetics analysis

F = ma F = ma
(FBD) = kinetics diagram (FBD) = kinetics diagram
Q2
Q1
= 400a = 50a
50g
400g
(↑+) Q2 – 400g = 400 a (↑+) Q1 – 50g = – 50 a

Q2 = 400(g +a) = 400 (9.81 + 0.5) Q1 = 50(g –a) = 50 (9.81 – 0.5)
Q2 = 4124 N Q1 = 465.5 N
abdrahmanmusa2007
-1.26-
kinetics analysis
F = ma
(FBD) = kinetics diagram
Oy
To2
the term IGα is not
included because
Ox =
it has already been
considered when
calculating Ieq.
Q1
Q2
(+) To2 + Q1 ro2 – Q1 ro2 = 0

To2 = (Q2 – Q1) ro2 =(4124 – 465.5)(0.5)
To2 = 1829.25 N⋅m
n21
back to To2 / i = To2
η 21
1
To2 / i = 1829.25 5 = 406.5 N⋅m
0.9
back to general equation

Ti = To1/i + To2/i + Tf/i + TI/i
= 7.76 + 406.5 + 15.35 + 37 = 466.6 N⋅m
abdrahmanmusa2007
-1.27-
Question 1 (Q1 finals sem II, 00/01

Figure 1 shows a two stage reduction gear water wheel attachment for a waterfall
power generation system. The waterfall strikes the blades producing a torque. A
1 m3/s flowrate produces a 5000 N⋅m torque on the water wheel. The water wheel
is rotating at a constant speed of 15 rpm. Determine
a. the flowrate to achieve a maximum output power of 10 kW.
b. the power to overcome bearing friction
waterfall
5000 N⋅m/m3 Figure 1
R=2m
A B
D
4
water
1 3
wheel 2
C
data
no. of teeth: mass moment friction torque gear mesh
of inertia at bearings efficiency
t1 = 160 Iwater wheel = 2000 kg⋅m2 A = B = 50 N⋅m η12 = η34 = 90%
t2 = t4 = 40 I23 = 200 kg⋅m2 C = D = 20 N⋅m
t3 = 100 IO = 50 kg⋅m2
abdrahmanmusa2007
-1.28-
Question 1 (Q1 finals sem 1 05/06)

Figure 1a shows a three–stage gear system used to drive a pulley of a cable car.
The pulley requires 8 kN⋅m torque to move the cable. When the power source is
switched on, the time needed for the system to reach operating speed is 10
seconds, as shown in Figure 1b. Calculate the power of the power source
a. 8 seconds after the power source is switched on.
b. during operation, i.e. t ≥ 10 seconds.
G
pulley 0.25 m/s v (m/s)
φ2m starting–up
E cable
operation
5 6 0.25
F
4 3
D
C
2 8 10 t (seconds)
B
1
A
power Figure 1a Figure 1b
source
no of teeth bearing friction equivalent mass gear mesh efficiency

torque moment of inertia
t1 = 40 A = 20 N⋅m Ipulley = 400 kg⋅m2 η12 = η34 = η56 = 80%
t2 = 200 B = C = 30 N⋅m Ishaft 45 = 40 kg⋅m2
t3 = 50 D = E = 50 N⋅m Ishaft 23 = 20 kg⋅m2
t4 = 250 F = G = 120 N⋅m Ipower source = 10 kg⋅m2
t5 = 60
t6 = 300
abdrahmanmusa2007
-1.29-

The gear system in Figure 1 supports two drums, X and Y. Drum X is used to raise a
500 kg mass rail coach filled with 20 passengers with an average mass of 50 kg up
a 10o slope. Drum Y is used to raise a 100 kg mass lift. The lift is initially at rest and
raised with constant acceleration up to 50 m height. Determine the power
required by the power source for operation if the angular acceleration of drum X is
found to be 0.125 m/s2. The shaft of gears 6 and 7 is parallel to the shaft of gears 5
and 8.
A
1 6
power
source 7
B E F
C
drum Y
3
φ1m
J I
drum X
φ1m coach
D G H
10o
5
4 Figure 1
lift

t1 = 200 A = B = C = 5 N⋅m Ipower source = 20 kg⋅m2 η12 =η34 =η39 =η56 =η78 = 80%
t2 = 50 D = E = F = 10 N⋅m Ishaft 23 = 5 kg⋅m2
t3 = 50 G = H = 15 N⋅m Ishaft 45 = 10 kg⋅m2
t4 = 200 I = J = 10 N⋅m Ishaft 67 = 10 kg⋅m2
t5 = 100 Idrum X = 10 kg⋅m2
t6 = 250 Idrum Y = 40 kg⋅m2
t7 = 50
t9 = 100
abdrahmanmusa2007
-1.30-
Question 1 (Q1 T1 sem 1 05/06)

Figure 1 shows a gear box used for power transmission to raise a load at the drum.
Power is supplied by an electric motor generating a 40 N⋅m torque at a constant
speed of 300 rpm and a load is raised by cable at the drum. Determine
a. with a brief and clear explanation, secure the electric motor and drum to
their specific location at the gear box.
b. the overall gear ratio of the whole system.
c. the resulting torque at the drum.
d. the efficiency of the power transmission.
gear box
5 no. of teeth bearing friction torque

X
electric
E t1 = 80 A = 0.5 N⋅m
1 motor
t2 = 30 B = C = 1 N⋅m
6
t3 = 90 D = E = 2 N⋅m
2 D
t4 = 40 F = 4 N⋅m
A
t5 = 100
Y
t6 = 40
tX = 40
drum tY = 100
F
equivalent mass moment of inertia

B C
Ielectric motor = 1 kg⋅m2
4 I12 – I34 = I56 = 2 kg⋅m2
Idrum = 4 kg⋅m2
3
all gear mesh efficiency η = 90%
Figure 1
abdrahmanmusa2007
-1.31-

Figure Q1 shows a gear train system driving a dryer and a grinder. The dryer and
grinder torque requirements are 800 N⋅m and 400 N⋅m respectively. If the motor is
running at a constant speed 1200 rpm, determine
a. the power required by the motor.
b. overall efficiency of the gear system.
A 1 B
5
6
motor
F
3 7 8
H
G
C
grinder
dryer
E D 2
Figure Q1
equivalent mass gear mesh

no. of teeth moment of inertia bearing friction efficiency
t1 = 40 Imotor & shaft 15 = 100 kg⋅m2 A = B = 0.3 N⋅m η12 = 90%
t2 = 320 I23 = 50 kg⋅m2 C = 1.6 N⋅m η34 = 90%
t3 = 40 Idryer& shaft 4 = 200 kg⋅m2 D = E = 10 N⋅m η56 = 90%
t4 = 400 Ishaft 67 = 20 kg⋅m2 F = G = 1 N⋅m η78 = 90%
t5 = 50 Igrinder& shaft 8 = 800 kg⋅m2 H = 12 N⋅m
t6 = 250
t7 = 40
t8 = 320
abdrahmanmusa2007
-1.32-

Figure Q1 shows a gear train system driving two drums, D1 and D2. Determine the
torque required by the power source to raise the 400 kg mass at D1 with an
acceleration of 0.05 m/s2.
φD1 = 0.8 m
B
D1
power source A 5
1 50 kg
2 a = 0.05 m/s2
C
3 400 kg
4
Figure Q1
φD2 = 0.8 m
D Rajah S1
D2
smooth surface 50 kg
30o
permukaan licin
number of teeth equivalent moment of inertia bearing friction gear mesh efficiency
bilangan gigi gear momen inersia setara geseran di bearing kecekapan cantuman
t1 = 40 Ipower source = 5 kg⋅m2 A = 4 N⋅m η12 = η15 = η34 = 90%
t2 = 160 Igear23 = 20 kg⋅m2 B = 36 N⋅m
t3 = 50 ID1 = 20 kg⋅m2 C = 16 N⋅m
t4 = 250 ID2 = 40 kg⋅m2 D = 40 N⋅m
t5 = 200
soalan 1
Rajah S1 menunjukkan sistem gear berperingkat dengan dua gegendang, D1 dan
D2. Tentukan daya kilas yang diperlukan oleh punca kuasa supaya beban 400 kg
di D1 dapat dinaikkan dengan pecutan 0.05 m/s2.
abdrahmanmusa2007
-1.33-

The drum of a hoisting gear is driven by a motor through double reduction gearing
system as shown. The mass moments of inertia of the shafts and other attached
masses are, 2 kg⋅m2 for the motor, 9 kg⋅m2 for the intermediate and 65 kg⋅m2 for
the drum. The frictional torque in these shafts are, A = 20 N⋅m, B = 43 N⋅m and
C = 250 N⋅m. The drum diameter is 0.6 m and the load is 24 tonnes.
a. Find the torque required on the motor shaft to lift the load with an
acceleration of 0.8 m/s2.
b. Determine the overall efficiency of the system if the motor is rotating at
1500 rpm.
drum friction between pulley, cable and the drum can
(gegendang) be neglected.
Geseran di antara takal, kabel dan gegendang
motor 4
boleh diabaikan.
1 C
A
number of teeth
B 1 = 18
2 3 2 = 72
3 = 30
a = 0.8 m/s2 4 = 90 η12 = η34 = 80%
24 tonne
soalan 1
Gegendang mengangkat beban dipacu oleh motor melalui sistem gear dengan
pengurangan dua kali seperti dalam rajah. Momen inersia jisim pada syaf
termasuk jisim ialah, 2 kg⋅m2 untuk motor, 9 kg⋅m2 untuk syaf perantara dan
65 kg⋅m2 untuk gegendang. Daya kilas geseran pada syaf ialah masing–masing,
A = 20 N⋅m, B = 43 N⋅m dan C = 250 N⋅m. Diameter gegendang ialah 0.6 m dan
beban ialah 24 tan.
a. Dapatkan daya kilas yang diperlukan pada syaf motor untuk mengangkat
beban dengan pecutan 0.8 m/s2.
b. Tentukan kecekapan keseluruhan sistem tersebut sekiranya kelajuan motor
ialah 1500 rpm.
abdrahmanmusa2007
-1.34-

A hydro–turbine is driving a drum, dryer and generator transmission system shown
in the figure below. During steady state operation the turbine produces 20 kW
power while rotating at a constant speed 500 rpm. The dryer requires a 500 Nm
torque to operate. If the drum is required to raise the 400 kg mass, determine
a. the power at the drum and dryer
b. power at the generator
c. overall efficiency of the transmission system
4 5
D C E F
drum dryer 9
3
K generator
B
400 kg
2 1
A
hydro 8
turbine
G I
6 7
H J
equivalent mass gear mesh

no. of teeth moment of inertia bearing friction efficiency
t1 = 40 Iturbine = 40 kg⋅m2 A = G = H = 10 N⋅m η12 = 90%
t2 = 200 I23 = 20 kg⋅m2 B = 20 N⋅m η34 = 90%
t3 = 50 Idrum = 100 kg⋅m2 C = D = 40 N⋅m η35 = 90%
t4 = 200 Idryer = 100 kg⋅m2 E = F = 15 N⋅m η67 = 90%
t5 = 200 I78 = 20 kg⋅m2 I = J = 6 N⋅m η89 = 90%
t6 = 50 Igenerator = 80 kg⋅m2 K = 2 N⋅m
t7 = 250
t8 = 50
t9 = 250
abdrahmanmusa2007
-1.35-

Figure 1 shows a water wheel operating at a constant speed of 75 rpm used to
transmit power to drive the generator and grinder. The power output at both
generator and grinder are respectively 5kW and 15 kW. If a flowrate of 1 m3/kg will
generate a1500 N⋅m torque, calculate
a. the flowrate required to generate the power at generator and grinder.
b. overall efficiency of the system.
E
4
3
water wheel
D
A B C 5 F generator 5 kW
2 6
7
1
G I
8 9 J
H
grinder 15 kW

t1 = 40 A = B = 100 N⋅m Iwater wheel = 5 kg⋅m2 η12 =η34 =η56 =η17 =η89 = 90%
t2 = 80 C = D = 25 N⋅m Ishaft 23 = 50 kg⋅m2
t3 = 200 E = 25 N⋅m Ishaft 45 = 20 kg⋅m2
t4 = 50 F = 10 N⋅m Ishaft 78 = 50 kg⋅m2
t5 = 250 G = H = 50 N⋅m Igenerator = 10 kg⋅m2
t6 = 50 I = J = 250 N⋅m Igrinder = 800 kg⋅m2
t7 = 100
t8 = 200
t9 = 400
abdrahmanmusa2007
-1.36-
VEHICLE DYNAMICS
ωw
v
rw
kinematics analysis on wheel
gear box bearing
engine friction velocity v = ωw rw
front axle rear axle

ωw
gear ratio n=
ωe
transmission
where
n, η v 2π Ne
engine wheel ωw = and ωe =
INPUT OUTPUT rw 60
ANALYSIS
REFER TO INPUT
general equation Te = Tw/e + Tf/e + TI/e
where
TI/e = torque due to inertia refer to engine
= Ieq / eα e
 n2 
=  Ie + Iw  αe
 η 
Tf/e = bearing friction torque refer to engine

n
= Tfe + Tfw
η
Tw/e = wheel torque refer to engine
n
= Tw where Tw = FT rw
η
FT is the tractive force
found using kinetics analysis
abdrahmanmusa2007
-1.37-
REFER TO OUTPUT
general equation Tw = Te/w – Tf/w – TI/w
where
TI/w = torque due to inertia refer to engine
= I eq / w α w
 η 
=  Ie + Iw 2  α w
 n 
Tf/w = bearing friction torque refer to engine

η
= Tfw + Tfe
n
Te/w = wheel torque refer to engine
η
= Te where Tw = FT rw
n
FT is the tractive force
found using kinetics analysis
αw
aw
rw
kinematics analysis on wheel
acceleration aw = αw rw
kinetics analysis on vehicle

Σ F = ma
[FBD] = kinetics diagram
mg
ma
R
FT
N1 N2
solve for FT
abdrahmanmusa2007
-1.38-
example
The 1 tonne engine of a vehicle rotates at 3500 rpm while moving with velocity,
v = 120 km/h. Mass moment of inertia of the engine is equivalent to a 12 kg mass
at 150 mm radius of gyration, while for the wheel, equivalent to a 100 kg mass at
250 mm radius of gyration. Efficiency of transmission is 90%, wind drag = 1 kN and
wheel diameter = 0.75 m. Estimate the power produced by the engine when the
vehicle is travelling at velocity v = 100 km/h and acceleration a = 0.8 m/s2
a. on a flat road
b. up a 1 in 50 slope
solutions
120
ω v
solving gear ratio n = w ωw = = 3.6 = 88.89 rad/s
ωe rw 0.375
2π Ne 2π 3500
ωe = = =366.5 rad/s
60 60
88.89
n= = 0.2425
366.5
0
general equation Te = Tw/e + Tf/e + TI/e
solving TI/e
 n2 
TI/e = Ieq / eα e = Ie + Iw αe Ie = meke2 = 12(0.15)2 = 0.27 kg⋅m2
 η 
Iw = mwkw2 = 100(0.25)2 = 6.25 kg⋅m2

 0.2425 2 
= 0.27 + 6.25  8.78 aw = α w r w
 0.9 
aw 0.8
= 5.88 N⋅m αw = = =2.13 rad/s2
rw 0.375
αw
but n=
αe
αw 2.13
αe = = = 8.78 rad/s2
n 0.2425
abdrahmanmusa2007
-1.39-
a. solving Tw/e
n
Tw/e = Tw where Tw = FT rw
η
kinetics analysis flat road
Σ F = ma
1 x 103 g
ma = 1 x 103 (0.8) = 800
1000 N
FT
N1 N2
(→+) FT – 1000 = 800

FT = 1800 N
∴ Tw = FT rw = 1800 (0.375)= 675 N⋅m
n 0.2425
thus Tw/e = Tw = 675 =181.9 N⋅m
η 0 .9
0
back to general equation Te = Tw/e + Tf/e + TI/e
Te = 181.9 + 5.88
Te = 188 N⋅m
The engine torque is 188 N⋅m (constant)

The engine power at v = 100 km/h
100
v
Pe = Te ωe ωw = = 3.6 = 74.07 rad/s
rw 0.375
ωw
Pe = 188 (305.4) Knowing n=
ωe
ωw 74.07
Pe = 57 415 W ωe = = = 305.4 rad/s
n 0.2425
abdrahmanmusa2007
-1.40-
b. solving Tw/e
n
Tw/e = Tw where Tw = FT rw
η
kinetics analysis 1 in 50 slope
Σ F = ma
1 x 103 g θ ma = 1 x 103 (0.8) = 800

1000 N
=
1
sin θ =
FT 50
N1 N2
( +) FT – 1000 sin θ – 1000= 800

FT = 1000 + 800 + 20 = 1820 N⋅m
∴ Tw = FT rw = 1820 (0.375)= 682.5 N⋅m
n 0.2425
thus Tw/e = Tw = 682.5 =183.9 N⋅m
η 0.9
0
back to general equation Te = Tw/e + Tf/e + TI/e
Te = 183.9 + 5.88
Te = 189.8 N⋅m
The engine torque is 189.8 N⋅m (constant)

The engine power at v = 100 km/h
100
v
Pe = Te ωe ωw = = 3.6 = 74.07 rad/s
rw 0.375
ωw
Pe = 189.8 (305.4) Knowing n=
ωe
ωw 74.07
Pe = 57 965 W ωe = = = 305.4 rad/s
n 0.2425
abdrahmanmusa2007
-1.41-
exercise 1
A vehicle of mass 1000 kg has an engine producing maximum torque of 200 N⋅m.
It starts to climb a slope of 30o gradient at a speed of 90 km/h with the engine
running at 2500 rpm. If the motion of the vehicle is resisted by a constant force of
150 N, determine whether the vehicle can the vehicle reach the peak of the hill
which is at a distance of 100 m
a. if yes, calculate the time taken
b. if no, calculate the distance moved before it stopped
Mass moment of inertia of the engine = 4 kg⋅m2 and wheels (total) = 8 kg⋅m2
Equivalent bearing friction torque of the engine = 10 N⋅m and wheels = 20 N⋅m.
Gear meshing efficiency = 80% wheel radius = 0.2 m
exercise 2
A motorbike engine produced a torque of 30 N⋅m at speed of 2500 rpm. Each
wheel has a mass moment of inertia of 1 kg⋅m2 and the engine 0.2 kg⋅m2. the rear
wheel has an effective diameter of 620 mm and the total mass of the machine
and rider is 200 kg. if the reduction in speed from the engine to the rear wheel is
9:1 and the effect of resultant drag force and wind is assumed equivalent to a
force of 180 N, calculate the motorbike speed and acceleration at the rotational
engine speed of 2500 rpm.
ans : v = 32.5 km/h, a = 1.77 m/s2
abdrahmanmusa2007
-1.42-

1 Gear System

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1 Gear System

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gear system gear system

Power Input transmission Power Output

cables/ pulleys, belts, chain, clutch, cams, ratchets, linkages, gears

gear box system

ωinput ωinput ωoutput Toutput

inside the gear box

p pitch, p = distance between a point on

pitch diameter, d the pitch circle.

in order for two gears to mesh, pitch must be the same

power and efficiency

opposite direction same direction

n13 = n12 x n23

n14 = n12 x n23 x n34

compound gear train

reverted compound gear train

input similar to compound gear train

usually needed to find unknown gear teeth using the relationship

determine NO, PO and fixing torque TC.

INPUT & OUTPUT TORQUES

simple example for derivation purposes

substituting for T1 gives

output torque, Toutput

input torque friction torque torque due to moment of inertia

general equation REFER TO OUTPUT

a similar derivation will result in

input torque friction torque torque due to moment of inertia

general equation REFER TO INPUT

1 input → 1 output either refer to input or output

solution strategy by example

example (refer to input and refer to output)

6 tonne Ishaft 23 = 40 kg⋅m2

4.5 tonne gear mesh efficiency

 0.25   0.25   0.2 

 0.25 2   0.25 2   0.2 2 

aoutput = αdrum rdrum

aoutput = 0.4 m/s2

A A 4.5 x 103 a B B 6 x 103 a

(+↑) Q1 – 4.5 x 103 g = – 4.5 x 103 a (+↑) Q2 – 6 x 103 g = 6 x 103 a

O Tdrum = (Q2 – Q1)rdrum

 0.9   0.9   0.9 

aoutput = αdrum rdrum

∴ Tinertia/output = Iequivalent/output αoutput

solving Toutput Toutput = Tdrum

aoutput = 0.4 m/s2

A A 4.5 x 103 a B B 6 x 103 a

(+↑) Q1 – 4.5 x 103 g = – 4.5 x 103 a (+↑) Q2 – 6 x 103 g = 6 x 103 a

O Tdrum = (Q2 – Q1)rdrum

back to the main equation

no of teeth bearing (friction) torque equivalent mass

solution 1 solving TI/i

t1 400 Tf/i = 5653 N⋅m

= 6211 + 14 928 + 5653 = 26 792 N⋅m

given 2000 N⋅m torque ⇒ 1 m3/s flowrate

solving To1/i solving To2/i

No1 = (5)(4)(5) 15 = 1500 rpm No2 = (4)(0.5) 15 = 30 rpm

n12 n34 n56 5 4 5 n17 n89 4 0.5

To1/ i = 6 211 N⋅m To1/ i = 14 928 N⋅m

no of teeth bearing (friction) torque mass moment of inertia

t 5 200 0.8 0.8 0.8 0.8 0.8 0.8

2πNo 2π (600) Ti1/ o = 9.6 N⋅m

no of teeth bearing (friction) torque mass moment of inertia

determine the torque required at input.

kinematics analysis kinetics analysis