Single objective optimization of spur gear train

Objective Function
Our objective is to minimize the total span (length) of the given gear train below.
Let S be this ‘span’ function.
𝑑2 𝑑3
Then 𝑆 = 𝑑1 + + + 𝑑4
2 2
𝑚.𝑧2 𝑚′ .𝑧3
= 𝑚. 𝑧1 + + + 𝑚′. 𝑧4
2 2
5
= 2𝑚. 𝑧1 + 2 𝑚′ . 𝑧3 (1)
This is the objective function that we wish to minimize.
And m, Z1, m’ and Z3 are the decision variables.

The gear train is expected to transmit 5KW of power from 500 rpm to 125 rpm as shown in the figure.
The rpm of the intermediate shaft is 250 rpm.
Constraints
Some of the constraints that must be taken into account are as follows:
Minimum number of teeth
The number of teeth on each gear should not be less than 18.
𝑍1 ≥ 18 (2)
𝑍3 ≥ 18 (3)
Number of gears of gears 2 and 4 are twice that of 1 and 3, so they are automatically taken into
consideration by the above constraints.
Beam strength of gear tooth
The effective bending force on the gear tooth should be less than the maximum allowable bending force.
𝑆𝑏 ≥ 𝐹𝑂𝑆 . 𝑃𝑒𝑓𝑓
Let the factor of safety be 2.
This gives
60 𝑋 106 . 𝑃. 𝐶𝑠
𝑚𝑏𝜎𝑏 𝑌 ≥ 2.
𝜋𝑚𝑧𝑛𝐶𝑣
Now for the pinion gear 1 we have
Module, m=m
Face width, b=10m
𝑆𝑢𝑡 600
Permissible bending stress, 𝜎𝑏 = = = 200𝑀𝑃𝑎
3 3
𝑌 = 0.0565𝑍1 − 0.11 (Result of linear regression)
Power, P=5KW
Speed, n=500 rpm.
Service factor, 𝐶𝑠 = 1.5
3 3
Velocity factor, 𝐶𝑣 = 3+𝑣 = 𝜋𝑚𝑧𝑛
3+
60 𝑋 103

This gives the following constraint

60 𝑋 106 . 5. (1.5)
𝑚. 10𝑚. 200. (0.0565𝑍1 − 0.11) ≥ 2.
3
𝜋𝑚𝑍1 . 500. 𝜋𝑚𝑍1 𝑛
3+
60 𝑋 103
18 𝑋 105
113𝑚2 𝑍1 − 220𝑚2 ≥ 5000 + (4)
𝜋𝑚𝑍1

Similarly for the pinion 3 applying the same formula we get the following constraint:
36 𝑋 105
113𝑚′2 𝑍3 − 220𝑚′2 ≥ 5000 + (5)
𝜋𝑚′𝑍3

Wear strength of gear tooth

The effective force on the gear tooth should be less than the maximum allowable wear force on the tooth.
𝑆𝑤 ≥ 𝐹𝑂𝑆 . 𝑃𝑒𝑓𝑓
Let the factor of safety be 2.
This gives
60 𝑋 106 . 𝑃. 𝐶𝑠
𝑏𝑄𝑑𝑝 𝐾 ≥ 2.
𝜋𝑚𝑧𝑛𝐶𝑣
Now for the pinion gear 1 we have
Module, m=m
Face width, b=10m
2𝑍𝑔
Ratio factor, 𝑄 = 𝑍
𝑔 −𝑍𝑝
𝐵𝐻𝑁 2
The constant, 𝐾 = 0.156( ) = 0.156 𝑋 1.32 = 0.264
100
Power, P=5KW
Speed, n=500 rpm.
Service factor, 𝐶𝑠 = 1.5
3 3
Velocity factor, 𝐶𝑣 = 3+𝑣 = 𝜋𝑚𝑧𝑛
3+
60 𝑋 103
This gives the following constraint

4 60 𝑋 106 . 5. (1.5)
10𝑚. . 𝑚𝑍1 . 0.264 ≥ 2.
3 3
𝜋𝑚𝑍1 . 500. 𝜋𝑚𝑍1 𝑛
3+
60 𝑋 103
18 𝑋 105
3.52𝑚2 𝑍1 ≥ 5000 + 𝜋𝑚𝑍 (6)
1

Similarly for the pinion 3 applying the same formula we get the following constraint:
36 𝑋 105
3.52𝑚′2 𝑍3 ≥ 5000 + (7)
𝜋𝑚′𝑍3

Equations 2 to 7 are the six constraints that should be considered for the optimization problem.
Matlab code
Objective Function

Non-Linear Constraints

Optimization function ‘fmincon’

Result
Running the Matlab code has given the following results.
𝑚 = 11.136
𝑍1 = 18
𝑚′ = 12.597
𝑍3 = 18
These are the optimum values of the decision variables. The minimum value of the length of gear train is
5
𝑆 = 2𝑚𝑍1 + 𝑚′𝑍2 = 967.77𝑚𝑚 = 96.7 𝑐𝑚
2