Project Report: Planetary Gearbox Motor

1. Introduction to Planetary Gearbox Motor

1.1 Uses and Basic Mechanism

Uses:

A planetary gearbox motor is a highly versatile mechanical system with widespread applications in
robotics, automotive transmissions, aerospace, and industrial machinery. It efficiently transmits
power, enabling speed reduction or increase while maintaining a compact and robust design.

Basic Mechanism:

The fundamental design of a planetary gearbox involves three primary components – the sun gear,
planetary gears, and an outer ring gear. The interaction of these elements creates a unique system
where the sun gear, planetary gears, and the ring gear work together to achieve specific
performance advantages. The planetary gearbox's operation includes simultaneous rotation and
orbiting of the planetary gears around the sun gear, providing multiple points of contact and load
distribution for enhanced efficiency, torque output, and space utilization.

1.2 Types of Planetary Gearboxes

Planetary Type:

In this configuration, the internal gear is fixed. The input is provided by the sun gear, and the
carrier serves as the output. This type is known for its simplicity and is commonly used in various
applications where compactness and efficiency are critical.

Solar Type:

In the solar type, the sun gear is fixed. The input is driven by the internal gear, and the carrier
serves as the output. This arrangement is advantageous in specific applications where a
stationary sun gear is desirable, and the rotation of the internal gear provides the desired
output.

Star Type:

In the star type, the carrier is fixed, and the planet gears rotate only on fixed axes. In a strict
definition, this configuration loses some features of a planetary system and resembles an
ordinary gear train. The sun gear becomes the input axis, and the internal gear is the output.
This type is suitable for applications where a fixed carrier is preferable.
2. Assembly Overview

Planetary Gearbox Extension Exploded view

Section 3

Section 2

Section 1
- The CAD model consists of three distinct sections, each contributing to the overall functionality of the
planetary gearbox motor.

- The first section includes a sun gear with 18 teeth, orchestrating the rotation of three planetary gears,
each possessing 39 teeth.

- These three planetary gears are intricately connected to a carrier.

- Within the carrier assembly, a second sun gear with 24 teeth is affixed, driving another set of three
planetary gears, each with 36 teeth.

- This second set of planetary gears is integrated into a subsequent carrier.

- The second carrier accommodates a third sun gear with 30 teeth.

- The third sun gear engages with three additional planetary gears, each featuring 33 teeth.

- The output is facilitated by the carrier of this third set of planetary gears, connecting to the output
shaft, equipped with a pulley.

- Simultaneously, the first sun gear is linked to a meticulously designed DC motor.

- The interconnected and synchronized components create a comprehensive and efficient planetary
gearbox motor.

DC Motor Internals Exploded view

Ring Gear/ Shell Orthographic view
3. Component Design

3.1 Spur Gears

All gears in the assembly are spur gears, and their design process involves several critical steps:

3.1.1 Gear Parameters

Parameters such as the number of teeth (N), module (M), and pressure angle (PA) are defined in the
model intent section.

reference_dia = module*no_of_teeth /*reference_dia

circular_pitch = pi*module /*circular pitch

addendum = module /*addendum

dedendum = 1.25*module /*dedendum

tip_dia = reference_dia+2*addendum /*tip diameter

root_dia = reference_dia-2*dedendum /*root_diameter

base_dia = reference_dia*cos(pressure_angle) /*base_diameter

root_fillet = 0.38*module /*root fillet radius

semitopping = 0.1*module

teeth_thickness = circular_pitch/2 /*teeth thckness

Equations for crucial geometric properties like reference diameter, circular pitch, addendum,
dedendum, tip diameter, root diameter, base diameter, root fillet radius, semitopping, and teeth
thickness are established in the relations section.

Root Dia
Tip Dia
Ref Dia Base Dia
 3.1.3 Involute Equation

The involute equation is utilized to generate a curve starting from the base diameter. This curve is
then mirrored onto a new datum plane, projected, and patterned around the circumference to
create teeth.

theta = 90*t

angle_ratio = theta/360

S = angle_ratio*pi*base_dia

base_radius = base_dia/2

Xc = base_radius*cos(theta)

Yc = base_radius*sin(theta)

X = Xc+(S*sin(theta))

Y = Yc-(S*cos(theta))

Z=0

3.1.4 Gear Generation

The gear generation process involves creating a curve, mirroring it, and projecting it to form teeth.
Subsequent gears are produced by adjusting the number of teeth while maintaining the other
parameters.

3.1.5 Internal Spur (Ring) Gear

Similar to spur gears, the ring gear is created using extrude to form a hollow cylinder. Teeth are then
generated using extrude > remove material. The ring gear, with 96 teeth, serves as the stationary
outer shell.

3.2 DC Motor

The DC motor is modeled by creating a coil using the spline command, which is then patterned 360
degrees. Magnets and brushes are designed using simple extrude commands and datum planes.

4. Connection and Mechanism

Each section contains four gear mechanisms. One between the sun and the carrier and three between
the central sun and planetary gears, one each. All the spur gears are pin connected.
5. Gear Ratios and Conditions

5.1 Conditions for Planetary Gearbox

In order to determine the relationship among the numbers of teeth of the sun gear(za), the planet gears
(zb) and the internal gear (zc) and the number of planet gears N in the system, these parameters must
satisfy the following two conditions:

1. ZC=ZA+2ZB - Ensures matching center distances of gears.

2. (ZA+ZC)/N=Integer - Relationship among gear parameters for a stable gearbox.

5.2 Gear ratios

Gear ratios are calculate using the following equation:

(ZC/ZA) + 1
So,
(96/18)+1 : first section = 19/3
(96/24)+1 : second section = 5
(96/30)+1 : third section = 21/5

Total Transmission ratio: 15.5

6. Conclusion

In conclusion, the designed planetary gearbox motor demonstrates the principles of planetary gear
systems. The comprehensive design and assembly considerations, coupled with an understanding of
different planetary gearbox types, showcase the versatility and adaptability of such systems in various
engineering applications. This project provides valuable insights into the complexity and practicality of
designing mechanical systems using CREO Parametric.