DESIGN OF AUTOMATIC SLIDING GATE

A Study / Design Report

Presented to

ENGR. JAIME P. HONRA

Professor of the School of Mechanical & Manufacturing Engineering

MAPÙA UNIVERSITY
Muralla St., Intramuros, Manila

Submitted in Partial Fulfillment of the Requirements for the Subject ME151P-2 – Machine
Design 2 in the Degree
Bachelor of Science in Mechanical Engineering

Carpena, Ferdinand Lauren F. – 2018100352

Ibuyan, Joseph D. – 2018102419
Mabanta, Benjamin Zachary C. – 2018110365
Reyes, Ezekiel John S. – 2018104028
Villarama, Vincent R. – 2014101260

February 5, 2022
Table of Contents
Chapter 1: Introduction ................................................................................................................... 1
1.1 Description of Machine ......................................................................................................... 1
1.1.1 Description of Machine Utilities .................................................................................... 1
1.2 Statement of the Problem ...................................................................................................... 3
1.3 Objectives .............................................................................................................................. 3
1.4 Scope and Limitations ........................................................................................................... 3
Chapter 2: Review of Related Literature ........................................................................................ 4
2.1 Related Studies ...................................................................................................................... 4
Chapter 3: Design and Calculations ................................................................................................ 8
3.1 Calculations ........................................................................................................................... 8
3.1.1 Symbols Used in Calculation ......................................................................................... 8
3.1.2 Worm Gear Set ............................................................................................................. 11
3.1.3 Chain Drive................................................................................................................... 17
3.1.4 Shafts and Bearings ...................................................................................................... 22
3.2 Automatic Sliding Gate Model ........................................................................................... 29
Chapter 4: Design Considerations ................................................................................................ 34
4.1 Health, Safety and Welfare ................................................................................................. 34
4.2 Social Factors ...................................................................................................................... 34
4.3 Global and Cultural Sensitivity and Awareness .................................................................. 35
Chapter 5: Discussions of Results................................................................................................. 36
Chapter 6: Conclusion and Recommendations ............................................................................. 37
References ..................................................................................................................................... 38
Chapter 1: Introduction
1.1 Description of Machine
Tracked sliding gates operate over a fixed track, with the entirety of the gate's
weight supported by wheels. The track is built along the entrance and runs at the base of
the gate, and the gate is usually operated automatically. Sliding gates with tracks might be
single, paired leaf, or telescopic. Tracked sliding gates have the advantage of being space-
efficient, making them ideal for sites with limited area beyond the gate. They can span very
large openings and are suited for high and hefty gate designs. They can also have a lower
profile when viewed from the ground. Tracked sliding gates offer high security since they
are difficult to force open and have only a few vulnerable parts in their structure. They are
particularly dependable in difficult weather circumstances, including heavy wind, due to
their robust design. Although tracked sliding gates are mechanically easier to operate than
cantilever sliding gates, specifiers should keep in mind that tracked sliding gates require
more maintenance. The track must be carefully maintained, cleaned on a regular basis, and
free of debris in order for the gate to function properly. They are also not suitable for places
with a lot of uneven ground.

In a nutshell, presented in this paper is the automatic sliding gate which is a mix of
convenience and automation. An automatic sliding gate is a type of barrier that may be
rolled one way or the other. Automatic sliding gates offer landscape with a convenient,
safe, secure, and noticeable gateway. The bottom of a sliding gate is a flexible barrier with
bearings. It is simple to open and close since it has no turning circle.

1.1.1 Description of Machine Utilities

An automatic sliding gate consists of basic components namely sliding gate, chains,
chain bracket, limit switch, socket and plug, and gate operator. For this design, these are
the following machine utilities to make the sliding gate function:

1. Motor
AC, or alternating current, means that the gate motor is being powered
directly via the 230V mains supply from a distribution board in your house. AC
motor has a slip ring commutator which allows the current to continuously
change direction in the coil of the ac motor, the power supply supplies

1
 alternating current instead of a direct current which allows the rotor to rotate in
one direction in a magnetic field. The ac power supply can be produced by a
device called an AC generator.
2. Worm gear set

A worm gear is a cylindrical helical gear with one or more threads and
resembles a screw thread. A worm wheel or worm gear is a cylindrical gear
with flanks cut in such a way as to ensure contact with the flanks of the worm
gear. The worm wheel is analogous to a nut that fits on the screw thread of the
worm. If the worm is restrained axially within its housing, then if the worm is
rotated, the worm gear will also rotate. They are widely used for non-parallel,
non-intersecting, right angle gear drive system applications where a high
transmission gearing ratio is required.

3. Chain drive
A chain can be defined as a series of links connected by pin joints.
Moreover, A chain drive consists of an endless chain wrapped around two
sprockets. The sprockets are toothed wheels over which an endless chain is
fitted. Chains can also be used as a guide to support material transported on rails
or routes, which is common in conveyors and bucket elevators. Both driving
and conveyor applications employ roller chains.

2
1.2 Statement of the Problem
An automatic sliding gate is a moveable barrier that is set in the entrance of a room
or building to restrict access, make opening a door easier, or offer visual privacy. Human
nature expects more comfort in his existence as a result of increased civilization and
technology. They search for relevant for ways to do things efficiently and simply
(Abraham-Attah & Zungeru, 2013).

Thus, the design for automatic sliding gates, which is a machine that utilizes two
types of gear drives namely worm gear drive and chain drive, is required. The chain drive
must be able to hold and support a gate that is 950 kg and 6 m long.

1.3 Objectives
The main objective of this paper is to design a sliding gate with accordance to the
design specification and parameters. Moreover, the following are the aims of this paper:

1. To provide an overview and background about the sliding gate.

2. To understand the significance of using sliding gate.
3. To determine the design calculation and parameters for each component.
4. To create 3D models of the components using Fusion 360.

1.4 Scope and Limitations

The focus of this study is to design an automatic sliding gate. Chain drives, motor,
worm gear set and gate itself are the components that will be designed in this study. It will
not cover other components, such as the safety sensors of the sliding gate. Standard gates
and typical speed of gates will be used as the basis of calculation. Conditions for the design
will revolve over typical household gate conditions. Gate rollers will also come from the
gate manufacturer which excludes it from being part of the design. Electrical components
as well as control panels or switches for opening and closing the gates are also out of the
scope of the study.

3
Chapter 2: Review of Related Literature
The review of related literature will include research that have already been completed.
This will assist researchers in gathering information on the aspects and characteristics involved in
building the chain and gear drives of sliding gates.

2.1 Related Studies

Automatic Sliding Gate (Desai et al., 2018)

Automatic gates are highly beneficial in businesses, industries, colonies,

colleges, and schools. A gate can be operated by a sliding on screw or a rack and
pinion, a piston, a rotary, or a chain sprocket. Design is accessible for some types
of operations, and it is also the most expensive even when installation and
maintenance costs are not yet considered. Most of the things we consume in our
nation are imported from other countries. The goals of this paper are to research,
analyze, and create a novel mechanism that is inexpensive, safe, and easy to install.
Various types of mechanisms are employed to operate the gate in this case. These
approaches include finite element modeling as well as mechanical design concepts
and theories. Thus, they must choose the material, the size of the material, and the
right installation. As a result, the durability evaluation results are important for
lowering costs and improving product reliability. Vibration factor is considered,
and more features are offered, to improve the constructed mechanism.

A Digital Automatic Sliding Door with a Room Light Control System (Abraham-
Attah & Zungeru, 2013)

An automatic door is a moveable automated barrier installed in the entrance

of a room or building to restrict access, make it easier to open a door, or give visual
seclusion. Human nature expects more comfort in his existence as a result of
improved civilization and technology. The man seeks ways to do things easily and
which saves time. As a result, automatic gates are one of the instances that human
nature devised to provide comfort and convenience in its everyday existence. To
meet the requirements, they modeled an automated sliding door with a room light

4
management system. This was accomplished by factoring in aspects including cost,
component availability, and research materials, as well as efficiency, compatibility,
and portability, as well as durability, during the design process. The system's
performance after testing was within the design parameters. A photodiode detects
an infrared beam of light, which is broken by this mechanism. It is made up of two
infrared diodes that transmit and two photodiodes that receive. The first is for
someone who is entering the room, while the second is for someone who is leaving
it. When the beam is broken, the photodiodes are coupled to comparators, which
provide a lower output when the beam is disrupted and a high output when the beam
is transmitting normally. The presence of an intruder entering via the door, as well
as how near he or she is to the entrance, affects the overall operation and execution
of the job. The door is designed to open automatically, however forcing it open in
the event of a power outage might harm the unit's mechanical control system. The
total project was completed with a created work that was tested and found to be
fully functional.

Main trends in the development of slide-gate systems (Kononov et al., 2011)

The three stages of slide-gate system development are examined in this

article. The presence of elastic components and reliable plate fastening
distinguishes the contemporary sliding gate. The various ways for attaching the
refractory plates in the carriage of the sliding gate are explored. The gate's reliable
functioning is ensured by the drive and auxiliary parts, which were developed to
account for the unique characteristics of metal casting while using slide gates.
Hydraulic drives have proven to be the most efficient in Russia and across the
world. The forms of refractory slide-gate plates are also discussed in the paper,
which aid to limit fracture propagation and make the plates more trustworthy in
service. The current generation of slide-gate plates, which are produced using
carbon-based, oxygen-free, or cermet binders, is now widely used.

5
Features of design and calculation of sliding gates of industrial buildings and
structures (Popovyan, 2021)

The study addresses the design elements of sliding gates, reviews patents
from 1983 to the present, and examines cantilever sliding gate recommendation
techniques. It has been established that sliding gate designs must meet the
requirements for the first and second groups of limiting conditions for gates as a
building structure, specific requirements for the operation of structures (reduced
deflections, roll, and bends), and the minimum weight of the movable part of the
gate for the use of a lower-power opening mechanism.

Automatic Sliding Gate System using Tap Water Pressure (Ali et al., 2021)

Automatic gates are currently controlled by an electrically driven motor,

which is relatively expensive in terms of installation, operation, and maintenance,
raising the cost of automatic gates. For this, a novel automatic gate control system
has been designed that employs a direct supply of tap water pressure to run the
movement of the gate, which is controlled by fluid power valves and cylinders. Tap
water is immediately linked to the system, so there is no need for a separate pump
to boost the pressure. The essential components of this device are a double acting
cylinder, solenoid valves, and a remote-control switch. Swing and sliding gates are
the two types of gates considered in this research. For the sliding gate type, an extra
mechanism that can expand the piston cylinder's maximum reach is required. It's
because the piston cylinder's length is insufficient to open the gate. After selecting
the best design from a number of options, the chosen design was further analyzed
and simulated using CAD software. The CAD program might then calculate the
motion by simulating the distance that the gate could move or travel. The proportion
of inaccuracy in comparing simulation data to actual data was 24.68 percent, which
relates to the movement or distance of gate traversed. Finally, both types of gates
relate to swing and sliding gates that may be operated with tap water. Finally, the
newly created automatic gate control for each kind is less expensive to install and
operate.

6
Optimization of the Sultartangi sliding gates in Iceland (Kravanja, 2002)

Over time, structural optimization research has resulted in the development

of methods and algorithms for the simultaneous solution of topological,
geometrical, and size issues, resulting in structures that are optimal in terms of cost
and weight. The sliding gates, tunnel intake bulkheads, and draft tube gates that
were produced for the Sultartangi project in Iceland in 1999 were optimized in this
study. The optimization was carried out at the Faculty of Civil Engineering's
Laboratory for Structural Analysis in Maribor, Slovenia.

7
Chapter 3: Design and Calculations

3.1 Calculations

3.1.1 Symbols Used in Calculation

Symbol Definition Units

𝐹𝑇 Total load to move the gate N
𝐹𝑠 Force to overcome static friction N
𝐹𝑟 Force to overcome rolling friction N
𝐹𝑁 Normal force N
𝐹𝑤 Force due to the weight of the gate N
𝜇𝑟 Coefficient of rolling friction -
𝜇𝑠 Coefficient of static friction -
𝑚𝑔 Gear ratio -
𝐶𝑤𝑔 Center distance of the worm gear set mm
𝑁𝑤 Rotational speed of worm RPM
𝑑𝑚𝑎𝑥 Maximum pitch diameter of worm mm
𝑑𝑚𝑖𝑛 Minimum pitch diameter of worm mm
𝑑𝑤 Pitch diameter of worm mm
𝑑𝑔 Pitch diameter of worm gear mm
𝐿𝑤 Lead of worm mm
𝜆 Lead angle °
𝜙 Pressure angle °
𝑝𝑤 Pitch of worm mm
𝑎 Addendum mm
𝑏 Dedendum mm
𝐹𝑊𝑤𝑔 Face width of worm gear mm
𝑉𝑝𝑤 Pitch line velocity of worm m/s
𝑉𝑝𝑤𝑔 Pitch line velocity of worm gear m/s
𝐶𝑠 Materials Factor -
𝐶𝑚 Ratio correction factor -
𝑉𝑡 Tangential Velocity m/s
𝐶𝑣 Velocity factor -
𝑊𝑡 Tangential load N
𝑓 Coefficient of friction -
𝑊𝑓 Friction force N
𝑃𝑜 Power output kW (hp)
𝑃𝑙𝑜𝑠𝑠 Power loss kW
𝑃𝑖𝑛 Power input kW (hp)
𝑇𝑤𝑔 Torque produced in the worm gear N-m
𝑇𝑤 Torque produced in the worm N-m
𝜇 Efficiency of the worm gear set %

8
𝑊𝑇 𝑤𝑔 Tangential force on the worm gear N
𝑊𝐴𝑤𝑔 Axial force on the worm gear N
𝑊𝑅 Radial force on the worm/ worm gear N
𝑊𝐷 Dynamic load N
𝑦 Lewis Form Factor -
𝜎𝑤𝑔 Stress on the worm gear teeth psi
𝑁𝑠 Rotational speed of the sprocket RPM
𝑇𝐻𝑃 Transmitted horsepower hp
𝑣 Linear velocity of chain in/s
𝐷𝐻𝑃 Design horsepower hp
𝑝𝑐 Pitch of chain in
𝐷𝑠 Pitch diameter of sprocket in
𝑇𝑟 Torque required to move the gate N-m
𝐷𝑟 Diameter of chain roller in
𝐷𝑝 Diameter of chain pin in
𝐿𝑃𝑇 Link plate thickness in
𝐷𝑠𝑐 Seating curve diameter in
𝑀𝐻𝐷 Maximum hub diameter in
𝐵𝐷 Bottom diameter of sprocket in
𝑝𝑠𝑡 Transverse pitch of sprocket in
𝑡𝑠 Thickness of sprocket flange in
𝐶𝑐 Center distance of chain drive in
𝐾 Number of chain link Chain links
𝐿𝑐 Length of chain in
𝑏𝑤 Worm dedendum mm
𝐷𝑖𝑠 Idler shaft diameter mm
𝐷𝑤𝑠 Worm shaft diameter mm
𝐷𝑔𝑠 Gear shaft diameter mm
𝑆𝑢 Ultimate strength Psi
𝑆𝑦 Yield strength Psi
𝐾𝑠 Shearing factor -
𝐾𝑚 Bending factor -
𝑆𝑠𝑑 Design stress Psi
𝑆𝑠𝑑′ Design stress with keyway Psi
𝑤 Width of key mm
𝑡 Thickness of key mm
𝐿 Length of key mm
𝑉 Rotation factor -
𝑓0 Factor -
𝑖 No. of rows of balls in any one bearing -
𝑋 Radial load factor -
𝑌 Axial load factor -
𝑊𝑅𝑤 Worm radial load N

9
 𝑊𝑅𝑤𝑔 Worm gear radial load N
𝑊𝑅𝑖𝑠 Idler shaft radial load N
𝑊𝐴𝑤 Worm axial load N
𝑊𝐴𝑤𝑔 Worm gear axial load N
𝑊𝐴𝑖𝑠 Idler shaft axial load N
𝐶0𝑟 Basic load rating N
𝐶 Basic dynamic load rating N
𝑊 Equivalent dynamic load N
𝐿 Service life in revolution revolution
𝐿𝐻 Service life in hours hours
𝐷𝑜 Ball bearing outside diameter mm
𝐷𝑖 Ball bearing inside diameter mm
𝐵 Ball bearing width mm
The gate that is moved to open and close will be the basis of calculations. The

chosen gate weighs 950 kg while the length of the gate is 6 m.

The rollers and rails are made of hardened steel. The amount of force to be able to

move the gate could be taken from the equation below.

𝐹𝑇 = 𝐹𝑠 + 𝐹𝑟

𝐹𝑠 = 𝜇𝑠 𝐹𝑁
𝐹𝑟 = 𝜇𝑟 𝐹𝑁
𝑊ℎ𝑒𝑟𝑒:
𝐶𝑂𝐹 𝑆𝑡𝑎𝑡𝑖𝑐 (ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙 𝑡𝑜 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙), 𝜇𝑠 = 0.78
𝐶𝑂𝐹 𝑅𝑜𝑙𝑙𝑖𝑛𝑔, 𝜇𝑟 = 0.007
𝑚
𝐹𝑤 = 950 𝑘𝑔 × 9.81 = 9319.5 𝑁
𝑠2
𝐹𝑇 = 𝜇𝑠 𝑁 + 𝜇𝑟 𝑁 = (0.78 × 9319.5 𝑁) + (0.007 × 9319.5 𝑁) = 7334.45 𝑁

10
3.1.2 Worm Gear Set

A series of iterations were conducted to find the optimal initial conditions as well

as to achieve the desired conditions. Worm gear set calculations started by using a 40-gear

ratio, a center distance of 100 mm, and a single start worm. These conditions were the

optimal values for the worm gear set.

Initial Conditions

𝑚𝑔 = 40

𝐶𝑤𝑔 = 100 𝑚𝑚

𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡 = 1

𝑁𝑤 = 1200 𝑅𝑃𝑀

Worm Pitch Diameter

0.875
𝐶𝑤𝑔 (100)0.875
𝑑𝑚𝑎𝑥 = = = 52.56 𝑚𝑚
1.07 1.07
0.875
𝐶𝑤𝑔 (100)0.875
𝑑𝑚𝑖𝑛 = = = 18.74 𝑚𝑚
1.6 1.6

The pitch diameter that could be chosen according to AGMA standards is between

the diameters above. The middle value was taken as the pitch diameter.

𝑑𝑤 = 36 𝑚𝑚

Worm Gear Pitch Diameter

𝑑𝑔 = 2𝐶 − 𝑑 = 2(100) − 36 = 164.35 𝑚𝑚

Lead

𝜋𝑑𝑔 𝑁𝑤 𝜋𝑑𝑔 𝜋(164)

𝐿𝑤 = = = = 12.9 𝑚𝑚
𝑁𝑔 𝑚𝑔 40

11
Lead Angle

𝐿𝑤 12.9
𝜆 = tan−1 = tan−1 = 6.57°
𝜋𝑑𝑤 𝜋 × 36

Based on AGMA 6034-B92, self-locking mechanism could be achieved when the

lead angle is less than the static friction angle of the materials used. It also mentioned that

for hardened steel worm and a bronze worm gear, the static friction angle is assumed to be

between 8 degrees to 9 degrees. Since lead angle is lower for the said material, self-locking

could be achieved using these.

Pressure Angle

AGMA has a table of suggested values corresponding to the pressure angle and the

minimum number of teeth of the worm gear as shown below.

𝑛𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 = 𝑚𝑔 × 𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡 = 40 × 1 = 40

Common pressure angles vary from 14.5 and 20, to be safe, a pressure angle of 17.5

was used.

𝜙 = 17.5°

Worm Pitch

𝐿𝑤 12.9 𝑚𝑚
𝑝𝑤 = = = 12.9 𝑚𝑚
𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡 1

Addendum and Dedendum

𝑎 = 0.3183𝑝𝑤 = 0.3183 × 12.9 = 4.11𝑚𝑚

12
 𝑏 = 0.3683𝑝𝑤 = 0.3683 × 12.9 = 4.75 𝑚𝑚

Face width

𝐹𝑊𝑤𝑔 = 0.67𝜆 = 0.67 × 6.57° = 23.89 𝑚𝑚

Pitch Line Speed

𝜋𝑑𝑤 𝑁𝑤 𝜋 × 36 × 1200 𝑚
𝑉𝑝𝑤 = = = 2.2619
60000 60000 𝑠

𝜋𝑑𝑔 𝑁𝑔 𝜋 × 164.35 × 30 𝑚
𝑉𝑝𝑤𝑔 = = = 0.2582
60000 60000 𝑠

Empirical Factors

Based on AGMA 6034-B92, for any method of casting, for 𝑑𝑤 < 63.5 𝑚𝑚,

materials factor, 𝐶𝑠 , is equal to 1000.

𝐶𝑠 = 1000

Ratio correction factor, 𝐶𝑚 , depends on the gear ratio. From the same standard, for

20 ≤ 𝑚𝑔 ≤ 70, the value could be expressed as shown below.

0.5
𝐶𝑚 = 0.0107(56𝑚𝑔 + 5145 − 𝑚𝑔2 ) = 0.0107(56 × 40 + 5145 − 402 )0.5

𝐶𝑚 = 0.8138

The velocity factor, 𝐶𝑣 , is dependent on the tangential velocity, 𝑉𝑡 .

𝑁𝑤 𝑑𝑤 1200 × 36 𝑚
𝑉𝑡 = = = 2.2549
19098𝑐𝑜𝑠𝜆 19098 × cos (6.57) 𝑠
𝑚 𝑚
From AGMA 6034-B92, for 0 ≤ 𝑉𝑡 ≤ 3.556 value could be obtained from the
𝑠 𝑠

equation below.

𝐶𝑣 = 0.659𝑒 −0.2165𝑉𝑡 = 0.659𝑒 −0.2165×2.2549

𝐶𝑣 = 0.4045

Tangential Load

13
 𝐶𝑠 𝐶𝑚 𝐶𝑣 𝑑𝑔0.8 𝐹𝑊𝑤𝑔 1000 × 0.8138 × 0.4045 × 164.350.8 × 23.89
𝑊𝑡 = =
75.948 75.948

𝑊𝑡 = 6133 𝑁

Coefficient of friction

The coefficient of friction also depends on the tangential velocity of the gear set.
𝑚
Based on AGMA 6034-B92, for 𝑉𝑡 > 0.0508 𝑠 , the coefficient of friction can be taken

based on the equation below.

0.45 0.45
𝑓 = 0.103𝑒 −1.185𝑉𝑡 = 0.103𝑒 −1.185×2.2549 = 0.01866

Friction Force

𝑓𝑊𝑡 0.01866 × 6133

𝑊𝑓 = = = 120.7598 𝑁
𝑐𝑜𝑠𝜆𝑐𝑜𝑠𝜙 cos(6.57) cos (17.5)

Rated Power Output

𝑁𝑤 𝑊𝑡 𝑑𝑔 1200 × 6133 × 164.35

𝑃𝑜 = =
1.91 × 107 𝑚𝑔 1.91 × 107 × 40

𝑃𝑜 = 1.5831 𝑘𝑊

1 ℎ𝑝
𝑃𝑜 = 1.5831 𝑘𝑊 × = 2.12 ℎ𝑝
0.746 𝑘𝑊

Torque Produced

𝑊𝑡 𝑑𝑔 6133 × 0.164
𝑇𝑤𝑔 = = = 504 𝑁 − 𝑚
2 2

Power Loss

𝑉𝑡 𝑊𝑓 2.2549 × 120.7598
𝑃𝑙𝑜𝑠𝑠 = = = 0.2723 𝑘𝑊
1000 1000

Power Input

𝑃𝑖𝑛 = 𝑃𝑜 + 𝑃𝑙𝑜𝑠𝑠 = 1.5831 + 0.2723 = 1.8554 𝑘𝑊

𝑃𝑖𝑛 = 1.8554 × 1.341 = 2.4871 ℎ𝑝 ≈ 2.5 ℎ𝑝

14
Worm Torque

60𝑃𝑖𝑛 60 × 1860
𝑇𝑤 = = = 14.76 𝑁 − 𝑚
2𝜋𝑁𝑤 2 × 𝜋 × 1200

Efficiency

𝑐𝑜𝑠𝜙 − 𝑓𝑡𝑎𝑛𝜆 cos(17.5) − 0.01866tan (6.57)

𝜂= × 100 = = 85.3%
𝑐𝑜𝑠𝜙 + 𝑓𝑐𝑜𝑡𝜆 cos(17.5) + 0.01866cot (6.57)

Worm / Wormgear Force

Worm axial force is equal in magnitude with the worm gear tangential force. The

worm tangential force is equal in magnitude with the worm gear axial force. Radial force

on the worm and worm gear are equal in magnitude.

2000𝑇𝑤𝑔 2000 × 504

𝑊𝑇𝑤𝑔 = = = 6132.57 𝑁
𝑑𝑔 164.35

2000𝑇𝑤 2000 × 14.8

𝑊𝐴 𝑤𝑔 = = = 828.3 𝑁
𝑑𝑤 36

𝑊𝑇𝑤𝑔 𝑡𝑎𝑛𝜙 6133.25 × tan (17.5)

𝑊𝑅 = = = 1946.39 𝑁
𝑐𝑜𝑠𝜆 cos (6.57°)

Stress in Worm Gear

1200 + 𝑉𝑝𝑤𝑔 1200 + 0.2582 × 196.86 6132.57

𝑊𝐷 = × 𝑊𝑇𝑤𝑔 = × = 1437.04 𝑙𝑏
1200 1200 4.44822

From Mechanical Elements in Mechanical Design by Mott, a table for the Lewis

Form Factor (y) was obtained. Interpolation between 14.5 and 20 pressure angles was

conducted to get the Lewis Form Factor as a pressure angle of 17.5.

15
 𝜙1 − 𝜙𝑥 14.5 − 17.5
y = y1 − × (y1 − y2 ) = 0.1 − × (0.1 − 0.125)
𝜙1 − 𝜙2 14.5 − 20

𝑦 = 0.1136

𝑊𝐷 1437.04
𝜎𝑤𝑔 = = = 9552.14 𝑝𝑠𝑖
yFWwg 𝑝𝑤 𝑐𝑜𝑠𝜆 0.1136 × 23.89 × 36 × cos (6.57)
25.4 25.4

16
3.1.3 Chain Drive

Sliding gates could be considered as uniform load especially at low speeds. Its

operation is also less than five hours per day. This gives the service factor to be 1. Typical

speed of sliding gates is around 10 cm/s. Values from the worm gear set calculation was

used for the design of the chain drive.

Initial Conditions

𝑁𝑠 = 30 𝑅𝑃𝑀

𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝑇𝐻𝑃) = 2.1ℎ𝑝

𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟 = 1

𝑣 = 3.94 𝑖𝑛/𝑠

Design Horsepower

𝐷𝐻𝑃 = 𝑇𝐻𝑃 × 𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 2.1 × 1 = 2.1 ℎ𝑝

Chain Pitch

Standard roller chains chart from Rexnord was used for the determination of chain

pitch.

17
 RC60 chain was taken given the design horsepower, the rotational speed of the

sprocket, and a 4 stranded configuration.

𝑝𝑐 = 0.75 𝑖𝑛

Sprocket Teeth

Rexnord also has charts for the different chain numbers. For RC60, the chart is

shown below. The power delivered from the worm gear is very high. Using 4 strands of

chain drives is the best option.

𝑇𝐻𝑃 2.1
𝐷𝐻𝑃 = = = 0.6364 ℎ𝑝
𝑚𝑢𝑙𝑡𝑖𝑝𝑙𝑒 𝑠𝑡𝑟𝑎𝑛𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 3.3

18
 The design horsepower falls at 11 teeth sprockets or higher for 4 strands. The

chosen number of teeth is 11 as well.

𝑛𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 = 11

Sprocket Pitch Circle Diameter

𝑝𝑐 0.75
𝐷𝑠 = = = 2.626 𝑖𝑛
180 180
sin ( ) sin ( 11 )
𝑛𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡

𝐷𝑠 = 2.5 × 2.54 = 0.0676 𝑚

Torque Required

The torque required to open and close the gate depends on the load from the gate

and the sprocket pitch as this is the machine element that pulls the gate.

𝑇𝑟 = 𝐹𝑇 𝐷𝑠 = 7334.45 × 0.0676 = 495.8 𝑁 − 𝑚

The torque required (𝑇𝑟 ) is less than the torque produced by the worm gear (𝑇𝑤𝑔 ).

This means that the design is capable of moving the sliding gate.

19
Roller Diameter

5 5
𝐷𝑟 = 𝑝𝑐 = × 0.75 = 0.4688 𝑖𝑛
8 8

Pin Diameter

𝐷𝑟 0.4688
𝐷𝑝 = = = 0.2344 𝑖𝑛
2 2

Link Plate Thickness

𝑝𝑐 0.75
𝐿𝑃𝑇 = = = 0.09375 𝑖𝑛
8 8

Seating Curve Diameter

𝐷𝑠𝑐 = 1.005𝐷𝑟 + 0.003 = 1.005 × 0.4688 + 0.003 = 0.4741 𝑖𝑛

Maximum Hub Diameter

180°
𝑀𝐻𝐷 = 𝑝𝑐 (cot ( ) − 1) − 0.03
𝑛𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡

180°
𝑀𝐻𝐷 = 0.75 (cot ( ) − 1) − 0.03
11

𝑀𝐻𝐷 = 1.77 𝑖𝑛

Bottom Diameter

𝐵𝐷 = 𝐷𝑠 − 𝐷𝑟 = 2.626 − 0.4688 = 2.1572 𝑖𝑛

Sprocket Transverse Pitch

ASME B291 standard has a chart for standard chain dimensions where the nominal

chain width was taken, and other dimensions were confirmed.

20
 𝑊𝑐 = 0.5 𝑖𝑛

𝑝𝑠𝑡 = 𝑊𝑐 + 4.22𝐿𝑃𝑇 = 0.5 + 4.22 × 0.094 = 0.8967 𝑖𝑛

Sprocket Flange Thickness

According to ASME B291 standard, the thickness for a four-strand chain and higher

follows the equation below. Tolerance thickness for RC60 is 0.036

𝑡𝑠 = 0.86𝑊𝑐 − 0.012 − 𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.86 × 0.5 − 0.012 − 0.036

𝑡𝑠 = 0.382 𝑖𝑛

Center Distance

The center distance will simply depend on the width of the gate. By adding an

allowance of 20 cm, the center distance could be obtained.

6.2 𝑚
𝐶𝑐 = 6 + 0.2 = = 244 𝑖𝑛
0.0254

Length of Chain

The sprockets on both sides are just the same. Their diameters and number of teeth

are equal.

2𝐶𝑐 2 × 244
𝐾 = 𝑛𝑡 + = 11 + = 662 𝑐ℎ𝑎𝑖𝑛 𝑙𝑖𝑛𝑘𝑠
𝑝𝑐 0.75

𝐿𝑐 = 𝐾𝑝𝑐 = 662 × 0.75 = 496.5 𝑖𝑛

21
3.1.4 Shafts and Bearings

Worm Shaft

Shaft Length = 11 in
Bending Load = 2.56 lb-in
Torque = 4460.78 lb-in = 504 N-m
𝑑𝑤 = 36 𝑚𝑚
𝑏𝑤 = 4.75 𝑚𝑚
𝐷𝑤𝑠 = 𝑑𝑤 − 2𝑏𝑤
𝐷𝑤𝑠 = 36 𝑚𝑚 − 2(4.75 𝑚𝑚) = 26.5 𝑚𝑚
Use smaller shaft diameter for standard ball bearing
𝐷𝑤𝑠 = 25 𝑚𝑚
Worm Gear - Sprocket Shaft
Shaft Length = 12 in
Length Between A and B = 2.2 in
Length Between B and C = 7.8 in
Length Between C and D = 2 in
Assumed Forces: A = 3.71 lbf, B = 11.24 lbf, C = 28.3 lbf, D = 20.77 lbf
Bending Load = 52.71 lb-in
Torque = 4460.78 lb-in = 504 N-m
Material = AISI C1020 as rolled
Ductile material, thus use maximum shear stress theory
𝑆𝑢 = 65000 𝑝𝑠𝑖
𝑆𝑦 = 48000 𝑝𝑠𝑖

𝐾𝑠 = 1.0
𝐾𝑚 = 1.5
Solve for design stress
𝑆𝑠𝑑 = 0.3𝑆𝑦 = 0.3(48000) = 14400 𝑝𝑠𝑖

𝑆𝑠𝑑 = 0.18𝑆𝑢 = 0.18(65000) = 11700 𝑝𝑠𝑖

22
 Use smaller design stress
Shaft with keyway
𝑆𝑠𝑑′ = 0.75𝑆𝑠𝑑 = 0.75(11700) = 8775 𝑝𝑠𝑖
Solve for shaft diameter
16
𝑆𝑠𝑑′ = 3
√(𝐾𝑠 𝑇)2 + (𝐾𝑚 𝑀)2
𝜋𝐷𝑔𝑠

Substituting

3 16√[(1)(4460.78)]2 + [(1.5)(52.71)]2 3
𝐷𝑔𝑠 = √ = 1.373 𝑖𝑛 = 1 𝑖𝑛 = 34.925 𝑚𝑚
𝜋(8775) 8

Use larger shaft diameter for standard ball bearing

𝐷𝑔𝑠 = 35 𝑚𝑚

Key for Gear - Sprocket Shaft

Square Sunk Key
Material = AISI C1020 as rolled
𝐷𝑔𝑠 34.925
𝑤= = = 8.73125 𝑚𝑚
4 4
𝐷𝑔𝑠 34.925
𝑡= = = 5.82083 𝑚𝑚
6 6
Key material is the same as that of shaft
𝐿 = 1.571𝐷𝑔𝑠 = 54.86718 𝑚𝑚

Idler Sprocket Shaft

Shaft Length = 6 in
Assumed Force: A = 20.77 lbf, B = 20.77 lbf
Bending Load = 124.62 lb-in
Torque = 0 lb-in
Material = AISI C1020 as rolled
Ductile material, thus use maximum shear stress theory
𝑆𝑢 = 65000 𝑝𝑠𝑖
𝑆𝑦 = 48000 𝑝𝑠𝑖

23
 𝐾𝑠 = 1.0
𝐾𝑚 = 1.5
Solve for design stress
𝑆𝑠𝑑 = 0.3𝑆𝑦 = 0.3(48000) = 14400 𝑝𝑠𝑖

𝑆𝑠𝑑 = 0.18𝑆𝑢 = 0.18(65000) = 11700 𝑝𝑠𝑖

Use smaller design stress
Solve for shaft diameter
16
𝑆𝑠𝑑 = 3 [𝐾𝑚 𝑀 +
√(𝐾𝑠 𝑇)2 + (𝐾𝑚 𝑀)2 ]
𝜋𝐷𝑖𝑠
Substituting

3 16 [(1.5 × 124.62) + √[0]2 + [(1.5)(124.62)]2 ] 9

𝐷𝑖𝑠 = √ = 0.546 𝑖𝑛 = 𝑖𝑛
𝜋(11700) 16
= 14.2875 𝑚𝑚
Use larger shaft diameter for standard ball bearing
𝐷𝑖𝑠 = 15 𝑚𝑚
Worm (A and B) Angular Contact Ball Bearing (Face-to-Face)
𝑉(𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟) = 1
𝑘 = 3 (𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠)
𝑊𝑅𝑤 = 1946.39 + 1.42 = 1947.81 𝑁
𝑊𝐴𝑤 = 6132.57 𝑁
𝑖𝑓0 𝑊𝐴𝑤 1 × 15.5 × 6132.57
= = 9.23
𝐶0𝑟 10300
𝑊𝐴𝑤 6132.57
= = 3.1484 > (𝑒 = 0.68)
𝑊𝑅𝑤 1947.81
𝑋 = 0.67
𝑌 = 1.41
Equivalent dynamic load
𝑊 = 𝑋𝑉𝑊𝑅 + 𝑌𝑊𝐴
𝑊 = (0.67 × 1 × 1947.81 𝑁) + (1.41 × 6132.57 𝑁) = 9951.96 𝑁

24
Basic dynamic load rating
𝐿𝐻 = 500 ℎ𝑜𝑢𝑟𝑠
𝐿 = 60𝑁𝐿𝐻 = 60 × 35.1543 𝑟𝑝𝑚 × 500 ℎ𝑜𝑢𝑟𝑠 = 1054629 𝑟𝑒𝑣
1 1
𝐿 𝑘 1054629 3
𝐶 = 𝑊 ( 6 ) = (9951.96 𝑁) ( ) = 10129.98 𝑁
10 106
Selection of ball bearing
𝐷𝑜 = 42 𝑚𝑚
𝐷𝑖 = 25 𝑚𝑚
𝐵 = 9 𝑚𝑚
𝑊𝑖𝑑𝑡ℎ = 2𝐵 = 2 × 9 = 18 𝑚𝑚

Thus, take Bearing No. 7905 A5 DF

Gear – Sprocket (A) Single-Row Deep Groove Ball Bearing
𝑉(𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟) = 1
𝑘 = 3 (𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠)
𝑊𝑅𝑤𝑔 = 1946.39 + 16.50 = 1962.89 𝑁

𝑊𝐴𝑤𝑔 = 828.3 𝑁
𝑓0 𝑊𝐴𝑤𝑔 16.7 × 828.3
= = 3.374
𝐶0𝑟 4100
𝑊𝐴𝑤𝑔 828.3
= = 0.422 > (𝑒 = 0.38)
𝑊𝑅𝑤𝑔 1962.89

𝑋 = 0.56
𝑌 = 1.15
Equivalent dynamic load
𝑊 = 𝑋𝑉𝑊𝑅 + 𝑌𝑊𝐴
𝑊 = (0.56 × 1 × 1962.89 𝑁) + (1.15 × 828.3 𝑁) = 2051.76 𝑁

25
Basic dynamic load rating
𝐿𝐻 = 500 ℎ𝑜𝑢𝑟𝑠
𝐿 = 60𝑁𝐿𝐻 = 60 × 30 𝑟𝑝𝑚 × 500 ℎ𝑜𝑢𝑟𝑠 = 900000 𝑟𝑒𝑣
1 1
𝐿 𝑘 900000 3
𝐶 = 𝑊 ( 6 ) = (2051.76 𝑁) ( ) = 1980.95 𝑁
10 106
Selection of ball bearing
𝐷𝑜 = 47 𝑚𝑚
𝐷𝑖 = 35 𝑚𝑚
𝐵 = 7 𝑚𝑚

Thus, take Bearing No. 6807

Gear – Sprocket (C) Single-Row Deep Groove Ball Bearing

𝑉(𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟) = 1
𝑘 = 3 (𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠)
𝑊𝑅𝑤𝑔 = 1946.39 + 125.88 = 2072.27 𝑁

𝑊𝐴𝑤𝑔 = 828.3 𝑁
𝑓0 𝑊𝐴𝑤𝑔 16.7 × 828.3
= = 3.374
𝐶0𝑟 4100
𝑊𝐴𝑤𝑔 828.3
= = 0.4 > (𝑒 = 0.38)
𝑊𝑅𝑤𝑔 2072.27

𝑋 = 0.56
𝑌 = 1.15

26
Equivalent dynamic load
𝑊 = 𝑋𝑉𝑊𝑅 + 𝑌𝑊𝐴
𝑊 = (0.56 × 1 × 2072.27 𝑁) + (1.15 × 828.3 𝑁) = 2113.02 𝑁
Basic dynamic load rating
𝐿𝐻 = 500 ℎ𝑜𝑢𝑟𝑠
𝐿 = 60𝑁𝐿𝐻 = 60 × 30 𝑟𝑝𝑚 × 500 ℎ𝑜𝑢𝑟𝑠 = 900000 𝑟𝑒𝑣
1 1
𝐿 𝑘 900000 3
𝐶 = 𝑊 ( 6 ) = (2113.02 𝑁) ( ) = 2040.10 𝑁
10 106
Selection of ball bearing
𝐷𝑜 = 47 𝑚𝑚
𝐷𝑖 = 35 𝑚𝑚
𝐵 = 7 𝑚𝑚

Thus, take Bearing No. 6807

Idler Sprocket Single-Row Deep Groove Ball Bearing
𝑉(𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟) = 1
𝑘 = 3 (𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠)
𝑊𝑅𝑖𝑠 = 92.39 𝑁
𝑊𝐴𝑖𝑠 = 0 𝑁
𝑋 = 1.0
𝑌 =0

27
Equivalent dynamic load
𝑊 = 𝑋𝑉𝑊𝑅 + 𝑌𝑊𝐴
𝑊 = (1 × 1 × 92.39 𝑁) + 0 = 92.39 𝑁
Basic dynamic load rating
𝐿𝐻 = 500 ℎ𝑜𝑢𝑟𝑠
𝐿 = 60𝑁𝐿𝐻 = 60 × 30 𝑟𝑝𝑚 × 500 ℎ𝑜𝑢𝑟𝑠 = 900000 𝑟𝑒𝑣
1 1
𝐿 𝑘 900000 3
𝐶 = 𝑊 ( 6 ) = (92.39 𝑁) ( ) = 89.20 𝑁
10 106
Selection of ball bearing
𝐷𝑜 = 24 𝑚𝑚
𝐷𝑖 = 15 𝑚𝑚
𝐵 = 5 𝑚𝑚

Thus, take Bearing No. 6802

28
3.2 Automatic Sliding Gate Model

A. Worm Gear Set

29
B. Chain Drive

30
C. Bearing

31
D. Automatic Sliding Gate Assembly

32
E. Exploded View of the Automatic Sliding Gate Assembly

33
Chapter 4: Design Considerations
4.1 Health, Safety and Welfare
Automatic gates, like all other moving machinery, are required to comply with
the Machinery Directive. Manufacturers of machinery must analyze the hazards posed
to users of their equipment and take all reasonable precautions to reduce such risks,
according to this regulation. The British standard BS-EN13241-1 defines the state-of-
the-art for automated gates. The risk assessment is the first stage in starting a new
installation or bringing an existing installation up to safety requirements. The
installation must be inspected, and any potential sources of damage must be identified.
Additionally, the following must be applied for safety:

1. Intelligent drive units to provide inherent force control by causing the gate to
reverse when an obstruction is detected.
2. Safe edges are touch-sensitive rubber switching strips that transmit a signal to
the gate controller to reverse the gate's movement when contact is detected.
3. The placement of a light or radar curtain in front of dangerous regions. The gate
will reverse direction if the curtain is penetrated while it is working. This may
be installed primarily to protect automobiles, but it will also protect people from
accidental contact.
4. The "hold-to-run" which means that the gate can only be opened or closed by a
person standing in a safe place and applying constant pressure to a controller.

4.2 Social Factors

1. This unique design of a sliding gate features design choices that could prolong
the lifespan of the components within, thus reducing long-term cost. For
example, the chain drive is designed to be positioned buried under the road
rather than the typical rack-and-pinion setup that is exposed to environmental
elements such as weather and dust buildup.
2. This design is for both ease-of-use as well as long-lasting and durable
applications as they do not require complicated operations to function.
3. The design of the gate, specifically the motor and gearbox setup, does not
excrete harmful chemicals or substances to the environment.

34
4.3 Global and Cultural Sensitivity and Awareness
1. The sizing of the components as well as the gate was determined and designed
to accommodate a wide array of vehicle sizes to broaden the applications of this
gate design from private suburban properties to industrial plant entrances.
2. People with any sort of disabilities may be able to use the full function of this
gate as the design has no specific physical requirements to be operated.
3. The gate itself may be interchanged to accommodate the desired privacy for
different applications and cultural environments such as a fence gate for
factories and a solid sheet gate for civilian homes or religious spaces.

35
Chapter 5: Discussions of Results

A series of iterations were conducted by modifying the input parameters between the worm
gear set and the chain drive. These main input parameters were the gear ratio of the worm gear set,
the rotational speed of the sprocket which is also the rotational speed of the worm gear, and the
center distance of the worm gear set. The load to move a gate and the velocity of the gate when
opening and closing were initially chosen to be 7334.45 N and 10 cm/s respectively and these were
the basis for the design. From this, optimal design parameters were generated using standards such
as AGMA and ASME. There are main parameters that were critical in modifying the initial
conditions. One of them is the input power on the worm which is 2.5 hp. This was not too low to
provide the amount of torque required and not too high to spend so much electricity when using
it. Another parameter was the lead angle and for this case, it was 6.57°. The lead angle would
determine if the drive is self-locking or not. The design met the conditions for a self-locking worm
gear set. Another parameter is the torque provided by the worm gear set which is 504 N-m. This
has to be higher than the torque required to move the gate. The pitch diameter of the sprocket was
also important as larger would require higher torque from the worm gear set.

The main setup of the sliding gate starts with the motor rotating the worm gear. The worm
transmits power to the worm gear and converting the high speed into low speed with higher torque.
The worm gear is directly connected to the 4-strand chain drive through the sprocket. The sprockets
spin with high torque, pulling the chain drive around the sprockets. An idler sprocket is present at
the end of the gate and the gate is locked on a portion of the chain drive which will allow the gate
to move along with the chain.

36
Chapter 6: Conclusion and Recommendations

Conclusion

A design of an automatic sliding gate using machine design standards and principles was
achieved in this study. The objectives of the study were achieved as well. Sliding gates and their
principles were introduced. Similar systems of automatic gates were also discussed. The
mechanisms, the components, and the arrangement of typical sliding gates were also highlighted.
The importance in ease of work that automatic sliding gate systems provide were mentioned as
well. The main components of an automatic sliding gate such as the chain drive and worm gear set
as well as the supporting components including the bearing and the shafts were calculated to get
the optimum design. Using Fusion 360, 3D models of the mechanical configuration were generated
in accordance with the design.

Recommendation

It is recommended that before creating a sliding gate design, the group must plan and
investigate what are the various components and parts of a sliding gate. With this, the group must
do research and develop a design methodology for the calculation part of these components. The
group must also consider the gate's weight and length in order to determine what parameters are
required for the computation and sizes of the various sliding gate components. Finally, in order to
provide a good output and design, the group must develop a systematic approach for studying,
planning, and in designing the sliding gate.

37
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