BANGALORE

BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

DESIGN AND ANALYSICS OF GEAR

AND PINION USED IN
E-RICKSHAW
Internal Guide:
Dr.MANJUNATHA.M.C
ASSOCIATE PROFESSOR

Department of Mechanical Engineering

Bangalore Institute of Technology, Bengaluru-04

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 1

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
INDEX

 ABSTRACT
 INTRODUCTION
 LITERATURE SURVEY
 OBJECTIVES
 METHODOLOGY
 DESIGN AND ANALYSIS
 RESULT AND CONCLUSION
 SCOPE FOR FUTURE WORK

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 2

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
ABSTRACT

 E-rickshaws are typically designed as three-wheeled vehicles with a seating arrangement for passengers at
the rear and a small cabin for the driver at the front. They are equipped with an electric motor, a
rechargeable battery, and a control system that regulates the speed and power output.

 The design of a single-stage gear box is a critical aspect of mechanical engineering, aiming to transmit and
control power efficiently between input and output shafts.

 The process begins with determining the desired gear ratio based on torque and speed requirements. The
selection of gear types, such as spur, helical, or bevel gears, is crucial.

 In conclusion, the design of a single-stage gear box involves various considerations, including gear ratio
selection, gear sizing etc .

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 3

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
INTRODUCTION

 An electric rickshaw, also known as an E-rickshaw or electric tricycle, is a mode of transportation that operates on
electricity instead of conventional fuels like petrol or diesel.

 E-rickshaws are equipped with an electric motor, a rechargeable battery, and a control system that regulates the speed
and power output.

 One of the primary advantages of E-rickshaws is their low operational cost. Electric power is generally cheaper
compared to fossil fuels, allowing e-rickshaw owners to save on fuel expenses

 The increasing popularity of E-rickshaws has led to technological advancements in battery technology, motor efficiency,
and overall vehicle design.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 4

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

 A “gearbox” is a complex structure of circulating machines that can control the speed and torque of a motor. In simple
words, it is a system of gears in a vehicle. It is also known as transmission due to its transmitting capacity.

 The gearbox is a complex structure consisting of various components with their respective functions. All the components
are interdependent and work collectively .The four main parts are Input Shaft ,Output Shaft ,Gears.

 It is used to transmit power, speed, and torque. It is the most reliable and experimentally proven method for the
transmission of power. We can’t use a direct engine to transmit the power, so we must use a gearbox for transmission.

 It accomplishes this by employing a single set of gears with a fixed gear ratio, providing a straightforward and efficient
power transmission solution for various applications.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 5

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
LITERATURE SURVEY

AUTHOR’S TITLE DESCRIPTION

1.Vaidehi Techno-economic assessment
of various motors for three-
wheeler E-auto rickshaw.
2.Neeraj Patel, Tarun Methodology for Designing a
Gupta Gearbox and its Analysis.
In their research,have studied that three-wheeler auto-rickshaws form a major
part of the public transportation sector in developing countries like India, as they
provide cost-effective and convenient mobility. Switching to electric auto-
rickshaws will significantly reduce emissions besides being cost-effective. Also,
in contrast to the gas-powered vehicles, electric auto rickshaws for public
transport aid a big aid to the national economy by benefitting the power grids,
PSUs & customers. The ultimate intent of this present research work is to
identify the characteristics for a range of motors and to determine their attributes
that are optimal suited for large-scale deployment of electric auto-rickshaws in
the Indian transport scenario.
Studies identified that Robust and Axiomatic design, a property-based approach
in design, is applied and integrated into a new methodology for developing
Functional Requirements (FR) or Design Parameters (DP). The reliability of the
design structure and design components are used as a functional requirement of
the gearbox, in relation to the service and driving conditions, and also as a
design constraint in analytical relationships.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 6

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
LITERATURE SURVEY
AUTHOR’S TITLE DESCRIPTION

3.Rajveer Panesar
Design and Failure Analysis of
single-Stage Reduction Gearbox.
In their research have studied that single seater and moderated
weight are desirable by considering the service environment.
In this context, high torque is being employed while
designing this kind of automobile systems. Hence, two stage
reduction gearbox is a vital part of transmission in order to
obtain the necessary speed and torque. failure has been
eliminated through simulations carried out by Ansys 18.2 and
Kiss software

4.Kai Wu Multi-objective optimization of a single
stage helical gear transmission system.
This study attempts to propose an optimal design method of
the geometric parameters of gear transmission system under
the condition of meeting the requirements of gear strength
and shaft strength and performance. In this paper, the single-
stage reduction gear box is taken as the research object, and
the design objective is to minimize the volume, center
distance and power loss in the transmission system, and 12
parameters such as the number of gear teeth, module and
helix angle are taken as design variables.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 7

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

OBJECTIVES

 To Design and Analyze gear and pinion for the transmission gear box of E-Rickshaw.

 To Design for input and output shaft.

 To carry out analysis on the design model.

 To carry out analysis for the drive shaft and output shaft.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 8

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

METHODOLOGY

 Using empirical formula, the gear has been designed.

 By using empirical formula the gear and output shaft has been designed.

 The analysis has been carried out on the gear using KISS software.

 The analysis has been carried out on drive and output shaft using KISS software.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 9

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
INPUT SHAFT
The input shaft of a single-stage gearbox, also known as the primary shaft or driving shaft, is a component that transmits
rotational power from the motor to the gearbox. It is usually connected directly to the output shaft of the motor .The primary
function of the input shaft is to receive the rotational energy and transfer it to the gears within the gearbox. The input shaft
typically extends into the gearbox housing and is supported by bearings to ensure smooth and efficient operation.

The specifications used for designing Input Shaft are:

• Length:63.100mm
• Material :C45 (unalloyed, hardened Steel)
• Weight:91.997g
• Sense of rotation: Clockwise
• Power transmitted:0.3700kW driving(output)
• Torque: 2.456Nm
• Speed:1440.00rpm

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 10

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

Side View

ISO View

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 11

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF INPUT SHAFT USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 12

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
ANALYSIS OF INPUT SHAFT USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 13

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 14

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
OUTPUT SHAFT
The output shaft of a single-stage gearbox is the component responsible for transmitting power from the gearbox to the
external load or system. It is typically the final shaft in the gearbox's power transmission sequence .The output shaft is
designed to deliver the power and rotational speed required by the application. It may have various features and configurations
depending on the specific gearbox design and intended use . The size, material, and dimensions of the output shaft are
determined based on factors such as the torque, speed, and load requirements of the application.

The specifications used for designing Output Shaft are:

• Length:76.300mm
• Material :C45 (unalloyed, hardened Steel)
• Weight:148.00g
• Sense of rotation: Counter Clockwise
• Power transmitted:0.3700kW driving(output)
• Torque: 6.1341Nm
• Speed: 576.00rpm

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 15

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

Side View

ISO View

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 16

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF OUTPUT SHAFT USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 17

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

ANALYSIS OF OUTPUT SHAFT USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH

18
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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 19

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

HELICAL GEAR
The introduction of helical gears in a single-stage gearbox brings several advantages and design considerations. Helical gears
are a type of cylindrical gears with angled teeth that form a helix shape around the gear's circumference. This helical
arrangement of teeth provides several benefits over other gear types, such as spur gears.
The helical gears in a single-stage gearbox offer several advantages over other types of gears, such as spur gears. Some of these
advantages include:

 Smoother and quieter operation: The angled teeth of helical gears allow for gradual engagement and disengagement,
resulting in reduced noise and vibration compared to spur gears. This makes helical gears well-suited for applications that
require low noise levels, such as automotive transmissions.
 Increased load-carrying capacity: The helical design distributes the load over multiple teeth, allowing helical gears to handle
higher torque and power transmission compared to spur gears. This makes them suitable for applications that require high
torque, such as industrial machinery.
 Higher efficiency: The helical gear design provides greater contact area between the gear teeth, resulting in improved
efficiency compared to spur gears. This means that less power is lost as heat during gear operation.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 20

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

 Ability to transmit motion at an angle: The helical gears can transmit power between non-parallel shafts or intersecting
shafts that are not in the same plane. This feature allows for more flexible design options in certain applications.

However, helical gears also have some limitations, including increased axial thrust, which requires additional thrust bearings
or gear design considerations to counteract the axial forces. Additionally, the manufacturing process for helical gears is more
complex and costly compared to spur gears.

Overall, a single-stage gearbox with helical gears offers improved performance characteristics, such as smoother operation,
higher load capacity, and increased efficiency, making it suitable for a wide range of applications that require precise power
transmission.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 21

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

SPECIFICATION OF HELICAL GEAR

• Center distance : 54.00mm

• Material : 20MnCr 5, Case- carburized steel, case hardened
• Inner Diameter : 22mm
• Face Width : 10mm
• Normal Module : 0.75mm
• Helix Angle : 8°
• Number of Teeth : 100
• Power : 370 W
• Speed : 670rpm
• Torque : 6.134 Nm
• Sense of Rotation :Counter clockwise

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 22

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF HELICAL GEAR

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 23

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF PINION

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 24

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF HELICAL GEAR USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 25

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF HELICAL GEAR USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 26

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
DESIGN OF HELICAL GEAR USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 27

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

ANALYSIS OF HELICAL GEAR USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 28

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

ANALYSIS OF HELICAL GEAR USING KISS SOFTWARE

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 29

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering
ASSEMEBLY OF TRANSMISSION

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 30

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 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

RESULT AND CONCLUSION

 The Gear and pinion for transmission gear box has been successfully designed for E-rickshaw.

 The Input and output has been designed using empirical formula.

 Analysis has been carried out on the design gear and found to give safe working of the gear box.

 An analysis has been carried out on the shaft in order to check relatability of shaft . It is found to be satisfactory.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 31

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

SCOPE FOR FUTURE WORK

 Noise Reduction: Helical gears offer reduced noise and vibration levels compared to other gear types. By implementing a
single-stage gear box with helical gears in e-rickshaws, the noise generated during gear engagement and operation can be
minimized. This can contribute to a quieter and more comfortable ride for both passengers and drivers, enhancing the overall
user experience.

 Maintenance and Durability: Helical gears are known for their durability and load-carrying capacity. Implementing a single-
stage gear box using helical gears in e-rickshaws can result in a robust and long-lasting drivetrain system. This can potentially
reduce maintenance requirements and increase the longevity of the gear box, leading to lower operating costs for e-rickshaw
owners and operators.

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 32

USN 1BI20ME013 1BI20ME016 1BI20ME019 1BI20ME021
 BANGALORE
BANGALORE INSTITUTE
INSTITUTEOF OF
TECHNOLOGY
TECHNOLOGY
Department of Mechanical
Department Engineering
of Mechanical Engineering

THANK YOU

NAME OF THE STUDENT BHUVAN P DARSHAN H G DHANUSH R GAGAN SINGH 33

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