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1 Gear System
1 Gear System
BLOCK C15
ROOM NO 210
019-4272051
*NOTICE IN ADVANCE
BDA20303
Mechanics of Machines
1
Mechanism – mechanical portion of machine
that has function of transferring motion and
forces from a power source to an output.
2
Machine Structure
Transform energy to Not transform energy
do work
Motion Not move
Transmit motion and Transmit forces only
forces
3
Physical Principles
Force and Torque
4
Motion
Motion: a change of position or orientation.
5
Momentum and Conservation of
Momentum
Impulse
Momentum
Conservation of Momentum
Work
Power
Energy
CHAPTER 1
GEAR SYSTEM
6
1. Introduction to Gear System
2. Types of Gear system
3. Relationship between pitch diameter and pitch
circle
4. Gear Ratio
5. Gear Train
6. Gear Efficiency
7. Power Transmission in a Gear Train System
8. Equivalent Moment of Inertia
9. Gear Train Applications
10. Vehicle Dynamics
7
Gears being an important part of a machine have
immense usage within various industries.
8
9
10
3. Relationship between Pitch
Diameter and Pitch Circle
11
Pitch circle:
A right section of the pitch surface.
Addendum circle:
A circle bounding the ends of the teeth, in a right section of the gear.
Addendum:
The radial distance between the pitch circle and the addendum circle.
Dedendum:
The radial distance between the pitch circle and the root circle.
Clearance:
The difference between the dedendum of one gear and the addendum of
the mating gear.
Circular thickness :
The thickness of the tooth measured on the pitch circle. It is the
length of an arc and not the length of a straight line.
Tooth space:
The distance between adjacent teeth measured on the pitch circle.
Backlash:
The difference between the circle thickness of one gear and the
tooth space of the mating gear.
Circular pitch p:
The width of a tooth and a space, measured on the pitch circle.
Diametral pitch P:
The number of teeth of a gear per inch of its pitch diameter. A
toothed gear must have an integral number of teeth.
12
4. Gear Ratio
13
Gear ratio n is defined as ratio of speed of driven gear with the speed of driver gear.
w D N α
Gear ratio n is defined as ratio of speed of driven gear with the speed of driver gear.
w D N α
Gear ratio, n= 2 = 1 = 1 = 2
w1 D2 N 2 α 1
Where α 1 = angular acceleration of driver gear
n
α 2 =angular acceleration of driven gear
5. Gear Train
Gear trains consist of
two or more gears for the
purpose of transmitting
motion from one axis to
another.
14
A gear train may have several drivers and several
driven gears.
When gear A turns once clockwise, gear B turns 4
times counter-clockwise and gear C turns once
clockwise.
“For an EVEN
number of mating
gears, the rotation of
Driven gear is
REVERSE of Driver
Gear.”
15
1.6 Gear Efficiency
Gear efficiency is defined as the ratio of Output
Power from Driven Gear to the Input Power from
Driver Gear.
P2 T2ω 2 T2
Gear Efficiency, η G ,1− 2 = = = n
P1 T1ω1 T1
16
1.7 Power Transmission in a Gear Train
System
Consider a gear train consists of two sets of gear reducing arrangement. A motor
is attached to the system with I m is the moment of inertia of motor shaft, I T is moment of
inertia of middle shaft and I G is the moment of inertia of hoist which acts as the load of
the system. Gear ratio and gear efficiency of gear set 1-2 is n1 / 2 andη G1 / 2 , between gear
set 3-4 is n3 / 4 and η G 3 / 4 respectively. Let;
Tm = Torque of motor
TG = Torque of hoist
T X = Friction torque at bearing X
Draw the free body diagram and using Newton Second Law, ∑ T = Iα
Tm − T1 = I mα m
T2 − T3 = I T α T
Since there is gear mating between gear 1 and
For (C)
T4 − TX − TG = I Gα G ……………………….………………..………………………..
η
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Assume clockwise direction as positive value.
For (A)
Tm − T1 = I mα m ……………………………………………….…………… (1)
For (B)
T2 − T3 = I T α T …………………………………….………………………. (2)
Since there is gear mating between gear 1 and 2, thus, must include in the analysis its own gear
ratio and gear efficiency, and relate it to the inertia of middle shaft, I T .
T
Previously, η G1 / 2 = 2 n1 / 2 , thus it follows that
T1
η T
T2 = G1 / 2 1 ………………………………..……………………………….………. (3)
n1 / 2
For (C)
T4 − T X − TG = I Gα G ……………………….………………..……………………….. (4)
Tη
also T4 = 3 G 3 / 4 …………………………………………………………………………..(5)
n3 / 4
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1.8 Equivalent Moment of Inertia, I equiv
Consider a simple gear system as below Figure. In order for the driver gear A to start rotate, it
must have enough torque to overcome its own inertia, I A first, and then another additional
torque to start accelerate the driver gear B.
For a simple gear system, the solution is straightforward, but when it comes to complex gear
train design, it is useful to simplify / group together all inertia term in the system into a single
compact inertia expression.
1. Torque at B to overcome I B
TB = I B α B
ω
Refer α B to gear A side. Use gear ratio, n = B
αB
ωA = α A
Thus, TB = I B nα A
2. Gear efficiency is related to power and thus torque of the mating gears, thus
P T n
ηG = B = B
PA TA
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4. Therefore total torque at A to accelerate I A and I B is
TTOTAL = I Aα A + T A
I n2
TTOTAL = I A + B α A , Or in general form, TTOTAL = I equivα A (referred to motor side)
ηG
I n2
Thus I equiv = I A + B
ηG
The derivation of I equiv of this simple gear system can be extended to a double set of gear
reducing problem as in section 1.7. By neglecting the friction torque effect, T X , thus,
I ( n ) 2 I (n ) 2 (n3 / 4 ) 2
I equiv = I m + T 1 / 2 + G 1 / 2
η G ,1 / 2 (η G ,1 / 2 )(η G , 3 / 4 )
Calculate the torque of the motor needed to bring up the load with
acceleration 1.2 m/s2. Neglect friction effect.
20
Dia = 1.2 m
a) Consider for T M 1
IGn2
From I equiv = I M +
ηG
Thus I M = Motor shaft inertia
I M = mr 2 = 250 (0 . 1 ) = 2 . 5 kgm2
2
N1 20
Gear ratio, n = = = 0 .1
N2 200
275 (0 . 1 )2 2
Put into I equiv = 2 . 5 + = 5 . 55 kgm
0 .9
Acceleration of hoist, a G = α G rG
1 .2
Thus α G = = 2 rad/s
0 .6
αG 2
From the gear ratio, angular acceleration of motor, α m = = = 20 rad/s
n 0 .1
Now torque due to equivalent inertia, T M 1 = I equiv α m
T M 1 = 5 . 55 ( 20 ) = 111 . 1 Nm.
21
b) Consider for T M 2
Solution
Given that I M =5 kgm2, I T = 40 kgm2, I G =500 kgm2, n 1 / 2 = 1 , n3/4 = 1 , η G = 0 .9
3 .5 4 .5
Neglect friction effect.
22
a) Consider for TM 1
Recall that TM 1 = I equivα m , but for two set of gear system with friction effect is neglected,
I T (n1 / 2 ) 2 I G (n1 / 2 ) 2 ( n3 / 4 ) 2
I equiv = I m + +
η G ,1 / 2 (η G ,1 / 2 )(η G ,3 / 4 )
40( 1 ) 2 500( 1 ) 2 ( 1 ) 2
I equiv = 5 + 3.5 + 3 .5 4.5 = 11.116 Nm
0 .9 (0.9)(0.9)
11 . 349 (1 3 . 5 )(1 4 . 5 )
TM 2 = = 889 . 6 Nm
0 . 9 (0 . 9 )
Thus total torque at motor required is
T total = T M 1 + T M 2
T total = 116 . 72 + 889 . 6
T total = 1006 . 32 Nm.
23
a) Consider for TM 1
Previously, TM 1 = I equiv α m
For double set of gear reducing system,
I ( n ) 2 I ( n ) 2 ( n3 / 4 ) 2
I equiv = I m + T 1 / 2 + G 1 / 2
η G ,1 / 2 (η G ,1 / 2 )(η G ,3 / 4 )
20( 1 ) 2 100( 1 ) 2 ( 1 ) 2
I equiv = 5 + 3.5 + 3.5 4.5 = 7.312 kgm2
0.9 (0.9)(0.9)
From a = αr , thus
a a
αG = =
rG 0.45
αG 1
Also from gear ratio, = , thus
α m 15.75
a
α m = 15.75α G = 15.75 = 35a
0.45
Thus TM 1 = 7.312(35a )
TM 1 = 255.92a Nm
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b) Consider for TM 2 as in Figure 15;
From ∑ F = ma,
F1 F1 − FR − mg sin θ = ma
F1 = 5000a + 1000 + 5000(9.81) 1 ( 50)
FR Mg sinθ
F1 = (5000 a + 9.81) N
5000g Thus, torque to accelerate hoist
θ
TG = F1 r = (5000a + 9.81)(0.45)
TG = 2250 a + 891.45 Nm
F1
Use gear efficiency to relate TG with TM 2
r TG n1 / 2 n3 / 4
TM 2 =
η G ,1 / 2η G ,3 / 4
hoist
TM 2 = (176.4a + 69.876) Nm
Figure 15: inclined loading
c) Consider for TM 3
Friction effect can be grouped together to form TM 3 where;
T n T n n
TM 3 = X 1 / 2 + Y 1 / 2 3 / 4
η G ,1 / 2 η G ,1 / 2η G ,3 / 4
1 1 1
150 800
TM 3 = 3.5
+ 3.5 4.5
= 110.33 Nm
0.9 0.9 2
From Ttotal = TM 1 + TM 2 + TM 3
1500 = (255.92a ) + (176.4a + 69.876) + 110.33
Thus a = 3.1 m/s2
25
1.10Vehicle Dynamics
Wheel
v
wr
R
D/2
FT
Surface
Figure 16: Vehicle dynamics
For a moving vehicle as in Figure 16, some of the forces acting on it are;
• Friction due to the vehicle’s body (aerodynamic friction), R
• Forces due to friction from the engine to the wheel such as friction in bearing, shaft,
clutch and gears, RINT .
• Forces due the acceleration of the vehicle, which is called tractive force, FT considering
no slip between the wheel and the road surface.
We can estimate the speed of the moving vehicle by considering the speed of the wheel itself.
D
Vehicle speed, v = wr
2
Total mass for a two wheeled motorcycle including passenger is 190 kg. The engine produce
torque of 25 Nm at speed of 1800 RPM. Moment of inertia for each wheel is 1.4 kgm2 while for
other rotating parts in the engine is considered as 0.15 kgm2. The wheel’s effective diameter is
610 mm. If the motorcycle is moving on a road with a speed 23 km/hr at second gear, find
(i) Gear ratio for the second gear
(ii) Acceleration at speed 23 km/hr
Assume wind friction is 200 N and gear efficiency is 90%.
Solution
Given that m =190 kg, Ttotal =25 Nm at N =1800 PM, I R =1.4 kgm2, I int =0.15 kgm2, D =610
mm,
If v =23 km/hr at 2nd gear, with R =200 N, η G =90%.
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1st Step – Draw Free Body Diagram
Iint IR
Engine
Wheel
Gear system
Figure 17: Free body diagram
nd
2 Step
Total torque at engine, Ttotal
Ttotal = TM 1 + TM 2
Where TM 1 = Torque due to equivalent inertia of rotating parts in the engine.(referred to engine
side).
TM 2 = Torque to accelerate the wheel.
3rd Step
Convert all measurement to SI standard.
2πN 2π (1800)
Engine speed, wint = = = 188.5 rad/s
60 60
23(1000)
Wheel speed, v = 23km / hr = = 6.3889 m/s
3600
n= R =
w (
6 .3889 )
0 .305 = 1 (Where w = v
wint 188 .5 9
R (D 2 ) )
α
a ( )
α int = R = 0 .305 = 29 .508 a rad/s2
n 1
9
( )
Thus, T M 1 = I equiv α int = 0 .1884 (29 .508 a )
T M 1 = 5 .559 a Nm.
27
5th Step – Determine TM 2 as in Figure 18;
a
R
m=190 kg
FT
a = 1.374 m/s2
28
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