There are three gear systems used, listed below y y 2 Planetary gear systems 1 Transmission gear system

Planetary Gear Systems Planetary gear systems are used for the synchronized rotation of both the hangers with the angular position of the arms. Hangers are supported at both ends by arms as shown in the design of the Falkirk wheel. Each arm of the Falkirk wheel supports both hangers at one end. This way both arms together support both hangers. The problem arises when the arms rotate along the axis shaft. With changing angular position of arms, the orientation of hangers would change if the hangers were simply attached to the arms. To overcome this problem, each arm is provided with a planetary gear system that keep the hangers parallel to the ground at any angular position of the arms. Each Planetary gear system consists of y y 1 Sun gear (which remains stationary) G1 4 Planet gears (Rotating) o 2 Small G2, G3 o 2 Large G4, G5

The outer Rim is physically not present but the arms serve as the outer Rim. The Gears are attached in a way that the Sun gear (G1) is attached to the two Small gears (G2 & G3) which in turn are attached to Large gears (G4 & G5).The gear ratios are adjusted in a way that when the arms rotate, G1 remains stationary while the other gears rotate. G2 and G3 are added to the system so that the gears G1, G3, G4 all rotate in same direction and hence the sun gear remains stationary with respect to the arms, however it rotates with respect to G2 or G3 which cannot be visualized by observers but can be observed with respect to the rotating gears G2 & G3.

Specifications and Calculations Number of teeth for each gear is specified as y y y G1 40 teeth G4 & G5 24 teeth G2 & G3 8 teeth

To synchronize both the gears that support the hanger (G4 & G5) the velocities of both gears must be same, which means their gear ratios must be same. The gear ratios are taken as

G1 : G2 : G3 : G4 : G5 40 : 24 : 24 : 8 : 8 Simplifying gives 5:3:3:1:1

The gears G2 & G3 are 24 teeth, 20 full depth Involute, modulus 167mm and face width 0.5m. The calculations are given as Load = 300 Tons Force = 2667119 N Velocity = 0.046m/s = 10.7 MPa Factor of Safety = 5 (working) = 53.5 MPa so material used is Cast Iron Similarly stresses for G1, G4, G5 can be calculated

Transmission Gear System A Transmission gear system is required to transmit torque from motor to the axis shaft of the arms of the Falkirk Wheel. A pinion is mounted to the motor shaft and a gear is mounted to the axis shaft of the arms. The gear ratios are adjusted in a way that the torque requirements and angular velocities match. Pinion is 8 teeth, 20 degree full depth involute with modulus 12.5mm The Calculations are given as RPM of motor = 1 rpm Power Generated = 22.5 kW Velocity = 0.046 Diameter of Pinion = 31mm

Tangential Load = 469130 N = 126 MPa Factor of Safety = 3 (Working) = 378MPa The material used is Alloy Steel-Heat Treated