Subject Name ENGINEERING LABORATORY IV

Title of Experiment Gear Efficiency

Course Code BNJ 37301 Section

Semester and session

Lecturer/Instructor 1.Encik Wan Mohd Wardi Bin Wan Abdu

Name
2.
Group Members Matric
No. Assessment

Prakash A/L CN200153 Theory (C2) 10 %

1. Ramakrishanan
Shasmita Lakshmi A/P CN200211 Observation (P3) 20 %
2. Murualikaran
Muhammah Sholehin Bin DN210105 Results (P2) 15 %
3. Nordin
Calculation (P4) 10 %

Discussions 25 %
(C4&C5)

Date of Experiment Conclusion (C3) 15 %

4/1/2023 References (C1) 5%

Date of Submission TOTAL 100%

11/1/2023 TOTAL COGNITIVE

55%
Approved stamp
TOTAL 45%
PHYSCOMOTOR
1.0 INTRODUCTION

1.1 THEORY

A geared system's function is to alter rotational speed, increase torque, or change

the direction of rotation. Unfortunately, the process results in mechanical losses. The
power output of a perfect gear system would be equal to the power input, or 100
percent efficient. However, due to friction in the shaft bearings and between the
gears' meshing teeth, this is never the case. The use of very low friction bearings,
close tolerances, and fine surface finishes on moving parts can reduce friction, but
the added expense may outweigh the efficiency gain. In this experiment, the input
and output power of a straightforward geared system will be measured and driven
under a variety of loads [1].

To transmit motion or to change speed or direction, a gear is a toothed machine

component, such as a wheel or cylinder, that meshes with another toothed
component. Gears are another way to modify how quickly a machine shaft rotates [2].

Output Torque:

The output torque is the product of the force F and the lever arm on which the force
acts.[2]
Τ ab= F.l M ab in Nm, F in Τ and I in m

Ouput Power: The output power of a rotating shaft is the product of the torque Τ and
angular frequency ω.[2]

P ab = ω.Τ ab
And ω= 2.π. f
f =n P ab in W,Τ ab in Nm and n in rpm60s/ min

1.2 Objectives

1. Illustrate how different geared systems work and their relative advantages and
efficiencies.
2. Determine the performance of a simple and compound gear train.
3. Compare efficiency and synchronicity of each drive when set at a comparable
‘nominal tension’ and assess it in terms of its simplicity and noise.
4. Compare the non synchronous round belt drive with the other two synchronous
drives.
5. Find the efficiency of the gear drive from static tests and compare with those from
the dynamic tests.
2.0 EQUIPMENTS
3.0 SAFETY PRECAUTIONS

I. If the supply of lubricating oil to the gears fails, the gears should be stopped and
the cause located and remedied.

II. Unusual noises should be investigated at once, and the gears should be
operated cautiously stopped until the cause for the noise has been discovered
and remedied.
III. No inspection plate, connection, fitting, or cover which permits access to the
gear casing should be removed without the specific authority of the engineer
officer.

IV. Wearing the right safety boots will prevent from feet injury. Hands and fingers
are on the front lines so it is vital to protect their proper safety gloves.

V. A lab can be a very busy environment. Researchers are working side by side on
different projects that can have different hazards. It is important to be aware of
your surroundings and the work that is going on around you.

VI. Work with purpose. Labs can also be an environment filled with distractions.
When working with hazardous material it is critical that you focus on what you
are doing and try to eliminate distractions.

VII. Ensure all lab members are familiar with the lab's safety equipment.

4.0 PROCEDURES

1. The motor was placed along with the transmission, and brakes in the proper
positions on the frame, and secured them with the clamping levers at the
bottom.
2. Set up the line connection between the motor and the control and display unit.
The connection socket is located on the rear panel of the control unit.
3. Main cable had been plugged in. The drive unit was ready for use.
4. Motor is started.
5. The speed is set.
6. Cable is used to connect the display, control unit, and brake.
7. Repeat the steps for the second gear type.
8. Once done, the power was lowered gradually with the RPM and everything
was switched off and fixed back the gears and equipment in an orderly
manner.
5.0 OBSERVATION

For experiment 1, when we increase the value of current we have observe the minimum
output torque is 0.3 and the maximum output torque is 7.5 and the trend for this experiment
is decreasing. When we decreasing the value of current we have observe the minimum
output torque is 2 and the maximum output torque is 7.4 and the trend of this experiment is
increasing.

For experiment 2, when we increasing the efficiency of 2-stage spur gear the minimum
output is 3 and the maximum output is 75 and the trend is increasing. When the efficiency of
2-stage spur gear is decreasing the minimum output 2 and the maximum output is 75 and
the trend for this experiment is decreasing.

For experiment 3, when we increasing the efficiency of single-stage worm gear the minimum
output is 2.5 and the maximum output is 76 and the trend is increasing. When the efficiency
of single-stage worm gear is decreasing the minimum output 2 and the maximum output is
76 and the trend for this experiment is decreasing.
6.0 RESULTS & CALCULATION
EXPERIMENT 1: RECORDING A TORQUE VS. CURRENT CHARACTERISTIC
TABLE 1: THE INCREASING VALUE OF CURRENT
Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I [A] Force on the Lever Arm, F Output Torque, M [Nm]
[N]

0 3 0.3

0.05 8 0.8

0.1 18 1.8

0.15 33 3.3

0.2 45 4.5

0.25 63 6.3

0.3 74 7.4

TABLE 2: THE DECREASING VALUE OF CURRENT

Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I [A] Force on the Lever Arm, F Output Torque, M [Nm]
[N]

0.3 74 7.4

0.25 65 6.5

0.2 46 4.6

0.15 37 3.7

0.1 24 2.4

0.05 11 1.1

0 2 2
 EXPERIMENT 2: DETERMINE THE EFFICIENCY OF 2-STAGE SPUR GEAR
TABLE 2: EFFICIENCY OF 2-STAGE SPUR GEAR (INCREASE)

Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I Force on the Lever Arm, F Output Torque, M

[A] [N] [Nm]

0 3.25 3.0

0.05 4.0 7.0

0.1 5.5 18

0.15 7.75 31

0.2 9.75 45

0.25 12.25 62

0.3 14 75

TABLE 2: EFFICIENCY OF 2-STAGE SPUR GEAR (DECREASE)

Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I [A] Force on the Lever Arm, F Output Torque, M [Nm]
[N]

0.3 14 75.0

0.25 12.25 61

0.2 10.5 51

0.15 8.25 37

0.1 6.25 23

0.05 4.0 11

0 2.5 2
 EXPERIMENT 3: DETERMINE THE EFFICIENCY OF SINGLE-STAGE WORM GEAR
(1:15)

TABLE 3: EFFICIENCY OF SINGLE-STAGE WORM GEAR (INCREASE)

Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I [A] Force on the Lever Arm, F Output Torque, M [Nm]
[N]

0 2.75 2.50

0.05 4.00 8.50

0.1 6.00 19.00

0.15 8.00 32.00

0.2 10.75 47.00

0.25 13.50 62.00

0.3 16.25 76.00

TABLE 3: EFFICIENCY OF SINGLE-STAGE WORM GEAR (DECREASE)

Speed: 1500 rpm

Lever arm length: 100mm = 0.1m

Excitation Current, I [A] Force on the Lever Arm, F Output Torque, M [Nm]
[N]

0.3 16.25 76.00

0.25 14.25 66.0

0.2 12.00 52.00

0.15 8.75 39.00

0.1 6.25 25.00

0.05 4.00 11.00

0 2.25 2.00
4.0 CALCULATION
EXPERIMENT 1: RECORDING A TORQUE VS. CURRENT CHARACTERISTIC
5. Determine the output torque (M)
5.1 Output Torque (M) for Increasing Value of Current

5.2 Output Torque (M) for Increasing Value of Current

6. Plot the characteristic graphs for Excitation Current vs Force and Excitation Current vs
Torque

Graph 6.1: The Increasing Value of Current

Graph 6.3: The Decreasing Value of Current
 EXPERIMENT 2: DETERMINE THE EFFICIENCY OF 2-STAGE SPUR GEAR
(1:13.5)

4. Determine the Input Torque (M)

� = 0.05�

4.2 Input torque for decreasing value of current

 EXPERIMENT 3: DETERMINE THE EFFICIENCY OF SINGLE STAGE WORM GEAE (1:15)

4. Determine the Input Torque (M)

� = 0.05
7.0 DISCUSSION

From the graph plotted, we can say that the efficiency will increase as the input force
increases. At a certain point, the increase in efficiency is getting smaller as the input
force increases and eventually the efficiency will reduce if the input force keeps
increasing. From the graphs, we found that spur gear has better efficiency compared
to worm gear. This is done by referring to the line of the graph which is directly
proportional for spur gear; this shows that the increase in input force and efficiency is
at the same pace. Meanwhile, the line for worm gear shows a good increase at the
beginning of the experiment and the efficiency is decreasing at the end of the
experiment. The worm gear reaches its maximum efficiency during input force at 74N.

When an excitation current is used in a device, the current is used to operate the
device at some point. A certain amount of energy is needed to overcome the internal
resistance of the steel core. When the excitation current gives the motor its power,
the transmission is then converted to move the load.

After discussion with group members, we found that there are few errors involved
that affect our experimental result. One of the errors is parallax error. It means that
the student does not read the scale of spring balance and dynamometer
perpendicularly. In order to achieve an accurate result students should read the scale
perpendicularly and students can also take multiple readings to minimize the error.
Besides that, when taking the reading for output force students have to pull the load
back to its middle position and this is hard to do because the load is always moving
and causes the reading to be difficult. The higher the current the higher the force of
the load is and more harder for students to maintain the load to its middle position.
Therefore the results for output load might differ a bit from the theoretical result. And
finally is the error within the equipment itself. The equipment has been used for a
long time and some parts of the equipment might have worn out. This small error will
also affect the result. Besides, the longer the machine works, the hotter it will become.
Some of the output energy will be released in the form of heat and this will reduce the
efficiency of the machine.

8.0 CONCLUSION

At the end of the experiment we are able to determine the efficiency of a spur gear
system and worm gear system. After we have done the gear efficiency experiment,
we now know that the effectiveness of a power transmission can be measured by
finding their efficiency. Based on the experimental result that we obtained, which
clearly states that spur gear has better efficiency compared to worm gear. But the
efficiency is reduced as the input force increases. In conclusion, even though a spur
gear has an average efficiency better than worm gear, it can only operate at low input
force compared to worm gear which can be used to greatly increase torque.
REFERENCES

[1] Petrescu, R. V. (2019, November 21). Determining Gear Efficiency. Gear Solutions
Magazine Your Resource to the Gear Industry.
https://gearsolutions.com/features/determining-gear-efficiency/
[2] Gears- Gear Efficiency - Roy Mech. (n.d.).
https://roymech.org/Useful_Tables/Drive/Gear_Efficiency.html
[3] Fletcher, H. A. G.; and Bamborough, J.: Effect of Oil Viscosity and Supply
Conditions on Efficiency of Spur Gearing National Engineering Laboratory
Report No. 138.
[4] Merritt, H. E.: Efficiency and Testing. Gear Engineering, John Wiley & Sons,
Inc, pp. 345- 357.
[5] Fletcher, H. A. G.; and Bamborough, J.: Effect of Oil Viscosity and Supply
Conditions on Efficiency of Spur Gearing National Engineering Laboratory
Report No. 138.
APPENDIX