Design Brief

We are required to design a simple gear train that achieves a specified speed reduction ratio for a given input speed and power with the following specifications: Input and output shaft must turns in opposite direction Deep groove ball is chosen and should be able to last for 54000hours with 95% reliability. This specific gears and components are used for mass production. Completed gearbox includes 3=phase,DOL Brook Crompton motor and connected to a piston compressor. Uniform and steady load.

Idea Generation

R & D (Research & Development)

Lubrication for the Gearbox

Why Lubricate the Gearbox? 1) When Gear teeth meet each other, they will encounter friction. This friction then makes the teeth blunt. Lubricant is applied in the gearbox. 2) Also removes the heat generated from the gear operation.

To meet the lubrication needs of a modern enclosed industrial gear drives, a gear lubricant must possess the following key performance properties.

- Thermal and oxidative stability - Thermal durability - Compatibility with seal materials Protection against excessive gear and bearing wear

- High-temperature extreme pressure protection ( EP gear oils) - Gear and bearing cleanliness - Emulsibility Characteristics - Rust and Corrosion protection, especially to yellow metal components - Antifoaming Characteristics. => Method Of Lubrication Grease Lubrication. Grease lubrication is suitable for any gear system that is open or enclosed, so long as it runs at low speed. The grease should have a suitable viscosity with good fluidity especially in a enclosed gear unit. Grease is not suitable for high loads and continuous operation and there is virtually not cooling effect. The must be sufficient grease to ensure the gear teeth are lubricated but an excess can result in viscous drag and power losses.

Splash Lubrication.

Splash lubrication is the normal method for lubricating spur, helical, bevel and worm gears. The gears simply dip into a bath of oil as the rotate. Splash lubrication needs at least 3 m/s tangential speed gear speed to be effective. It is important that provisions are made to ensure the teeth are not immersed in the bath such that excessive losses result from the oil being churned up. The oil level should be monitored under static and dynamic conditions to ensure it is correct for the application

Spray Lubrication. or the higher speed units (10 to 20 m/s peripheral speed) engineered spray lubrication is genally provided using shaped nozzles with oil at a circulated pressure of about 0.7 barg. At higher speeds

the system for directing the oil at the teeth needs to be carefully engineering to ensure the oil actually reaches the contacting surfaces as centrifugal forces and escaping air flow will tend to deflect the oil jet.

Calculations.
Grp: 09 | V.R: 3:1 | Input Power(KW):3.0 | Input Speed: 2860Rpm | No. of Pinion teeth: 18 | Module: 3.00 | Motor Frame N.O : D100L Power: 3000rpm Speed: 2860rpm Total Length: 371mm Shaft Diameter: 28mm Normal Running Torque: 10.0Nm Starting Torque: 10 x 3.0 = 30Nm Breaking Torque: 10 x 3.5= 35Nm Noise Level at 1meter = 67dB

Coupling Service Factor: Ks = 0.9 Design Power = 3000 x 0.9 = 2700W Coupling Size = F40 Design Torque = Td = (2700x60)/(2 (2860) = 9.01 Nm Maximum Design Tourque : Tdmax = 9.01 x 3.5 = 31.5Nm Nominal torque = 24Nm > design torque, Td = 9.01Nm Maximum speed = 4500 rpm > speed of coupling, N=2860rpm Maximum Torque = 64 Nm > Maximum design torque, Tdmax = 31.5Nm The selected Coupling Size is Suitable. Maximum Bore Size, 32mm > motor shaft diameter: 28mm and gear shaft: 30mm Coupling Selected: F40 Type B. Gears Dpinion = M.n = 3 x 18 = 54mm V.R = nw/np= dw/dp = 3 nw/np = 3 nw/18 = 3 nw= 54 dw= 54 x 3 = 162 mm V.R = Nin/Nout= 3 2860/Nout = 3 Nout = 953 1/3 Rpm

Circular Pitch (P= M) N.o Of Teeth (n = D/m) Addendum (a = m) Dddendum (b=1.25m)

9.42 3 3.75 -

54

18 -

Outside Diameter (Do=(n+2)M) Root Diameter (Dr = (n-2.5)M) Base Diameter (Db = Dcos ) Circumference Thickness (t = P/2) Gear Details Working Depth (hk = 2a) Whole Deapth (ht = a+b) Clearance (c = b a) Centre Distance ((dp+dw)/2)

4.71 ALL 6 6.75 0.75 108 -

168 154.5 152.2 Wheel -

60 46.5 50.7

Pinion

Tin = 60 x Pin/ 2 Nin = 60 x 3000 / 2 (2860) = 10.01Nm Pinion = Ft =Tin/rp= 10/0.027 = 370.3N Fs = Ft x Tan20 = 134.778N Ftot = (134.778^2) + (370.3)^2 = 394.06

Tout = (60 x Pout)/(2 Nout)= (60 x 3000)/ (2 x 953 1/3) = 30.05 Nm Wheel = Ft = Tout/rw = 30.05/0.081 = 370.98 Fs = Ft X tan20 = 135.02N Ftot = 394.78N Shaft Ftot = 394.78N Ra = Rb = 394.78/2 = 197.39N Horizontal gear force, F = Ft = 394.78 N

Maximum bending moment acting on the shaft M = 197.39 x 0.55 = 108.56Nm For steady load take Kt = 1.0 Kb = 1.5 Allowable shear stress with keyway =  Torque acting on the shaft T=Ft.r= 394.78 x (162/2 x 10^-3) = 10.66Nm
 

d= = 0.02764 = 27.6mm

The required Shaft size is 30mm. (wheel)(OUTPUT) Torque acting on the shaft , T = Fr x r = 394.78 x (54/2 x 10 ^ -3) = 10.66Nm d= d = 0.02749m d = 27.5mm The required Shaft size is 30mm. (Pinion)(INPUT)
 

Bearing Total shaft length = 80 + 15 x 2 = 110mm Ftot = 394.78N Ra = Rb = 394.78 / 2 = 197.39N Service factor = 1.0 No axial load, Fa = 0 P = Fr = 197.39N Pe = P x Fz = 197.39 x 1 = 197.39N

L10h = 10 x 360 x 15 = 54000h L5h = (a1)95 x L10h 54000 = 0.63 x L10h = 85715h
   

85715= (C/197.39)^3 x (10^6/60(2860)) C = 4836.33 Bearing Type selected: SKF 16006 C = 11200 Co = 5850
   

85715= (C/197.39)^3 x (10^6/60(953.33)) C= 3353.32 Bearing type selected: SKF 16006 C= 11200 Co= 5850

Step By Step Gearbox Installation.

Step 1: First, we remove the cover of the gear case and fit in the pinion and wheel shafts halfway.

Step 2: Fit in the pinion and wheel gear to the respective shafts.

Step 4: Fit in the bearings into the respective shafts and knock it into place.

Step 5: Use the hubs to secure the shaft into place. Then, tighten the hubs using nuts and bolts.

Step 6: Close the cover and secure it by using the cover nuts.

Tolerance
NO. 1 Part: Bearing Bore Shaft Diameter 2 Gear Bore Shaft Diameter 3 Bearing outer diameter Housing diameter Input shaft


Fits Interference (H7/P6) Interference (H7/P6) Interference

Output shaft
 

Fits Interference (H7/P6) Interference (H7/P6) Interference (H7/P6)

(H7/P6)