Calculation of a two stage gearbox this tutorial shows the usage of mesys shaft calculation with systems of parallel shafts. Us6302356b1 helicopter two stage main reduction gearbox. The task for each team working on this project was to design a singlereduction spur gearbox which includes a housing, ball bearings, spur gears, mechanical keys and shafts to meet specifications given for each team. We started with the manufacturing process of two stage reduction gearbox, firstly we started searching for the gearbox manufacturer. Figure 1 double branched design the design allows for the reduction on speed, while increasing torque along two stages.
This is a step by step explanation for designing a 3dmodel of a multiplestage gearbox, the calculation of it and how to document the results. The gearbox is part of a system to test the idling characteristics of an automotive timing drive system. The objective of this paper is to design and analyze the various stresses acting on the. However the ratio of the second stage was chosen to be on the higher side so that the differential can be fitted into the.
Design and analysis of two stage reduction gearbox. Gearbox design contreras, marisol gregorio, kevin obdulio sosa, carlos alberto florida international university department of. Pdf design and analysis of two stage reduction gearbox for. Gearbox typical failure modes, detection and mitigation. The schematic illustration of two stage helical gear reduction unit is shown figure1. Kisssoft is a program for machine design calculations. Agnee gear motors, gear boxes and 3d printers 457,626 views 5. So, maximum torque available at wheels is 573 nm at 2800 rpm. Due to reduction in output speed, the torque of the system is increased. Calculate the number of steps or speed reduction stages for this range. As we have finished with all the theoretical part of the project, it is the time for the manufacturing. The frame in the middle, where the coordinate system is shown, is the design space of your gearbox. This places significant demands on the algorithm employed to search it, but successful optimization has the potential to yield considerably better designs than conventional heuristics, at the same time enabling a better understanding of the tradeoffs between various. Apr 26, 2017 such freedom allowed for more openended innovation.
Software to automate preliminary design of gearbox with spur helical and bevel gears was developed. A two stage reduction gearbox is a part of a transmission assembly which reduces the rotational speed at the input shaft to a slower rotational speed at output shaft. This gearbox manufacturing will result into quick availability to the students participating in various international events for which they require similar type of gearbox as well cost. The gearbox to be designed is of the double branched double reduction gearbox type, a sketch of which is shown in figure 1. Now you can start working on the dataset and also automatically overwrite it when saving. The novelty of this article consists in the complex and complete approach of the optimal design of gearings. Common mwscale wind turbine gearbox designs comprise three stages, one planetary and two helicalparallel stages with a ratio between 60 and 80 11, while an equivalent tidal turbine designs typically employs fourstage gearboxes with three planetary stages and one helicalparallel stage with a ratio of about 200 12. The strength design of the gear to allow for the use a grade 1 steel.
The first set of gears can cut the rpm by half and the second as well. Pdf on mar 1, 2018, l karikalan and others published design and analysis of two stage reduction gearbox for all terrain vehicles find, read. The gears and shaft design calculations are done with the help of kisssoft. The objective of the synthesis was to minimize the size of all gears from the mesh and speed ratio. In various embodiments, the first stage uses face gears, or bevel gears, with a reduction greater than 5. Design and optimization of 2stage reduction gearbox.
Design and draft 2 stage gearbox with given dimensions and. Design and analysis of a gearbox for an all terrain vehicle. The primary use is to multiply the amount of torque generated by an input power source to increase the amount of usable work. Active dataset now change to the 3dsurface to design the model. The design of the gearbox for the specified requirement is done, considering all the design specifications and objectives. Baja vehicles are the most famous off road vehicles in india. Hence to achieve the speed of 53kmph we required the gear reduction of gearbox as 10. The gearbox is being powered by a 5 hp, 60hz ac, electric motor with a speed of 1725 revmin. This chapter begins with a comparison of the merits of spiral bevel gears and hypoid gears when employed as the final drive in the automotive gearbox, ix. Pdf on mar 1, 2018, l karikalan and others published design and analysis of two stage reduction gearbox for all terrain vehicles find, read and cite all the research you need on researchgate. Reduction gear is an arrangement by which an input speed can be lowered for a requirement of slower output speed, with same or more output torque.
The difference between single stage and two stage gearbox. When operating, the input crank deflects the cycloidal disc such that the cycloidal disc orbits and wobbles about the center of the crank shaft because of the cranks eccentricity and meshing between the disc and rollers on the case. Design and optimization of 2stage reduction gearbox ijedr. In the software kisssoft we apply the problem with the. Speed reducers are mechanical devices generally used for two purposes. The gears and shafts present in the reduction gearbox undergo various forces acting over them. The optimization model of two stage helical gear reduction unit is formulated in this section, with minimum volume and maximum load carrying capacity as design objectives. An allterrain vehicle is an off road vehicle that has the ability to drive on any terrain without any difficulty. Design and optimization of 2stage reduction gearbox 1neeraj patel 2tarun gupta 3aniket wankhede 4vilas warudkar 1 23b. This is an instruction for designing a gearbox model followed by a kinematic calculation of single machine elements using the program mdesign gearbox. Lightweight design for planetary gear transmissions. Tutorial for gear design and calculation with mdesign gearbox. Rv cycloid gearbox which belongs to the closed encased type planet gear is one member of them. Uses 2 stage helical gear the design is simple and not complicated when compared with the existing gear box.
Design and analysis of two stage reduction gearbox for. The chosen objective function was the volume bounded by the inner surface of the reducer housing. They exclude delivery charges and customs duties and do not include additional. The gearbox design presented in this report is a result of considerable amount of experimental iterations based on stress analysis knowledge and the teams ability to manipulate the provided data into a feasible wellperforming solution. The company has planned to develop a series of singlereduction spur gearbox reducers. Automated optimal design of a twostage helical gear reducer. Stefanache abstractin this paper an optimal design of two stage speed reducer is presented. In order to do so, open the pulldown menu on the middle window and choose graphical input. Two different solutions for a 3stage gearbox are on the market today. Understanding, selecting and applying planetary gearheads. As it is a case of two stage gear reduction, the gear ratios between first pair.
Design of spur gears spur gear can be modeled similar. Determine the maximum and minimum speeds of the output shaft. Since differential itself is used as a gear reduction unit and we are eliminating the differential so we have to increase the final drive reduction through gearbox only. View pdf catalogues and other online documentation prices are pretax. Fixed transmission 2stage speed reducing mechanical gearbox. Planetary stage design, shaft design, bearing selection. Optimal design of two stage speed reducer using two phase evolutionary algorithm l. The singlestage reducer consists of a gear or a worm gear transmission. Estimate a center distance between gear axes of a one stage gear reducer with. Design of two stage speed reducer the overall reduction ratio obtained in previous step is split into two stages using the formula. Design component safety factor infinite life factor coupling key 2 l 1.
The reduction in co 2 emissions is by 15%, and up to 50% for nox emissions. Design of a twostage cycloidal gear reducer with tooth. The first step in the gearbox design process is to select the material. By using the given rotational speed of 1800 rpm, input power of 10 horsepower, gear ratio of 3. The two types of tooth that can be used for both parallel and angled drives are.
This depends on the application as well as space optimization. Calculat ion of a two stage gearbox this tutorial shows the usage of mesys shaft calculation with systems of parallel shafts. A twostage gearbox or a threestage gearbox can be achieved by simply increasing the length of the ring gear and with serial arrangement of several individual planet stages. Gearbox typical failure modes, detection and mitigation methods. Optimal design of twostage speed reducer using twophase. Sep 29, 2016 a gearbox that converts a high speed input into a single output it is called a single stage gearbox.
A gearbox that converts a high speed input into a single output it is called a single stage gearbox. Single speed, double reduction gearbox the same old two stage gearboxes teams have come to know and love. Methodology for designing a gearbox and its analysis. Twostage gear reducer, twostage gearbox all industrial. The design sequence is similar for variations of this particular transmission. It is divided into a twostage cast iron worm gear reducer and a twostage rv worm gear reducer. Design and analysis of two stage reduction gearbox for all terrain vehicles. Pdf design and analysis of two stage reduction gearbox for all.
Oct 27, 2015 worm gearbox, worm reduction gear box, worm speed reducer and gear motor manufacturer duration. Design, modelling and analysis of a 3 stage epicyclic planetary reduction gear unit of a flight vehicle k akhila1 and m amarnath reddy2 corresponding author. Reduces the cost of speed reducing gear box considerably. He made a design synthesis of a ninespeed gear drive. Procedure for optimum design of a twostage spur gear system article pdf available in jsme international journal series c 464.
The required reduction is achieved through two stages. The design achieves most of its initial goals except for the weight reduction requirement. The primary use is to multiply the amount of torque generated by an input power source to. Gear design in mdesign gearbox march 2012 driveconcepts gmbh, dresden 3. The design space of multistage transmissions is usually very large and heavily constrained. Pdf on mar 1, 2018, l karikalan and others published design and analysis of two stage reduction gearbox for all terrain vehicles find. We have also checked the design in various analysis software such as catia and ansys. The two stage reduction gearbox consists of three shafts and four gears two driver gears, two driven gears. First set of gears 800024000 second set of gears 400022000.
Two stage reduction gearbox reduces the speed on rotations and can help in many applications to reduce speed. Design of gears according to agma 2001d04 the intent of the agma strength rating formula is to determine the load which can be. Pdf procedure for optimum design of a twostage spur gear. Please start with the tutorial for shaft calculation to see how to introduce geometry and supports for single shafts. The menu on the right is the element explorer, where you can select the required machine elements. Such freedom allowed for more openended innovation. Single speed, double reduction gearbox vex robotics. The reduction ratio of the first and second stage was decided to be 2. The novelty of this work consists in the complex and complete approach of the optimal design of gearings.
Gear design in mdesign gearbox march 2012 driveconcepts gmbh, dresden in the graphical input you will find different categories. In general two stage gearbox means in which the torque is stepped down or up twice that is using two pairs of gears. Tutorial for designing and calculation of a multiplestage. A typical case would involve the design of the gearing for a hoist to raise a certain weight w ata uniform speed, when making use of a motor with a given horsepower hp running at a given speed rpm and driving through a pinion with number of teeth np, fig.
A typical twostage gear reduction box is been used to understand the design process. Design of gearbox free download as powerpoint presentation. Which stage is most critical in 2 stage reduction gearbox. In this paper, two stage reduction helical gearbox has been designed. Modeling and analysis of 2stage reduction gear box ijmetmr. Considerable cost reduction of gearbox compared with the existing gearbox. The latter unit is used to transmit the prime mover power to the working machine and to operate the working machine at the required speed.
These vehicles are designed to sustain any sort of extreme loads that act during off road driving. Pdf procedure for optimum design of a twostage spur. Single stage planetary gearheads provide possible gear ratios ranging from 3. However, due to the extreme loads caused by the gravel tracks and the. Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. Machineengineering design of gears, shafts, gearbox casing, bearing selection, vibrations caused due to the engine. Introduction heading 1 in this project we are going to manufacture a two stage reduction gearbox. Say the input rpm is 8000 and we want 2000 out put. The twostage reducer is also called a twostage worm gear reducer. Procedure for optimum design of a two stage spur gear system article pdf available in jsme international journal series c 464. Kisssoft have been incorporated with various calculation methods for the gear and shaft design separately. Design of twostage single speed gearbox for transmission. Each of the chapters will deal with aspecific problem which is encountered during the design phases and during operation.
In this paper an optimal design of twostage speed reducer is presented. Pdf design and analysis of two stage reduction gearbox. An allterrain vehicle is an offroad vehicle that has the ability to drive on any terrain without any difficulty. A gearbox that converts a high speed input into a number of different speed output it is called a multispeed gear box. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. After considering the space requirements a twostage constant speed reduction gearbox was decided. Here we tackle a twostage helical gear transmission design prob lem complete with the sizing and selection of shafts, bearings, housing, etc. The details can be observed on the picture below, the first stage is a simple planetary gear and the second stage is the cycloid gear. The high speed incoming motion from the wheel work is transmitted to the set of rotating gears, wherein the motion or torque is changed. A two stage gearbox or a three stage gearbox can be achieved by simply increasing the length of the ring gear and with serial arrangement of several individual planet stages. A reduction gear assembly consists of a set of rotating gears connected to a wheel work. The motor i have found has a shaft diameter of 48mm the design i proposed is a two stage reduction gear box using spur gears.