Achievement:

Gear box

A three stage gear box

has been design,
using AGMA gear
analysis

Generator

Generator was
selected from MAGNA
MAX company ,model
(431RSL4007).

Shafts

Shafts designed using

Goodman criterion .

Blades

A three blades with

60cm length will be
used.

Generator:
We are looking to find a generator that works for(4) kW .
From the marathon generator selection catalogue we found a
generator with
the following specifications :
Company : MAGNA MAX
* Base model : 431RSL4007
* Net weight : 6kg

Gearbox:
GEAR

DIAMETER(
mm)
Planet1
30
Ring gear 100

NUMBER
OF TEETH
20
52

FACE
WIDTH
10
10

Planet 2
Sun gear
Spur1

44
24
38

22
21
33

10
10
10

Shaft Design :
SHAFT

DIAMETER(
mm)

Output
15
shaft
Sun&spu 24
r1 shaft
Input
40
shaft

MATERIA FACTOR
L
OF
SAFETY
AISI1080 1.68
HR
AISI1080 1.6
HR
AISI1080 1.4
HR

Weights of each gear and shaft

COMPONENT NAME
Sun gear
Planet1
Planet2
Spur1
Spur2
Bearing:

WEIGHT(kg)
0.8
2.2
2.1
0.8
0.8

Th
e
out
put
sha
ft

C10
=1.
3

Taper
ed
roller
beari
ngs
singl
e row
(32/Q
)

Su
n
an
d
spu
r
sha
ft

C=1
.6

Thr
ee
inp
ut
sha
ft

C10
=1.
8

Taper
ed
roller
beari
ngs
singl
e row
(33/Q
)
Cylin
drical
roller
beari
ngs ,
high

capac
ity
(NUH
2212
ECMH
)
Mai
n
sha
ft

C10
=2.
3

Cylin
drical
roller
beari
ngs ,
high
capac
ity
(NUH
2234
ECMH
)

Small TWOER , BLADE :

Long
(m)

Mater
ial

Weig
ht
(kg)

Compone
nts name

0.4

AISI
1141
Q&T
steel

Small
Tower

0.6

Carbo
n
fiber

Blades

Manufacturing analysis:
First of all there should be an original blade model to make the
copies from, this is usually made from wood, then a carbon fiber
female mould is taken from the original, this mould is in two
halves. This mould can be used a number of times, The two
halves of the blade are then made separately using a number of
layers of carbon fiber, this is left to dry, these blade halves are
then carefully cut and the edges tapered to that the two halves fit
carefully together, then a wooden insert is fitted into the root of
the blade. This provides material for which to screw into and
provides some compressive strength, a stringer is fixed into one
blade half, and this is carefully cut down so that the other blade
half fits exactly on top, this stringer gives strength to the blade,
then we can put the two halves together (foam is used to fill in
the holes), by this step the manufacturing process is now finished.

The blade could be plated with cobalt which works as an

accelerator to speed up the hardening process.

Wind turbine calculations:

P=T*
T=14*103/4 = 3.7 kN.m
Planet torque=12*0.2/3 = 0.8 N.m
Choosing the module for the gear set as 5 mm from the standard
modules for spur gear.
Planet 1: N = 25 teeth, d=m*N where d is the gears diameter in
mm

d=20 mm
Planet 2: N=40 teeth, d=40 mm
Sun gear: N=21teeth, d=18 mm
Ring gear: N=50 teeth, d=40 mm
Spur 1: N=26 teeth, d=38 mm
Spur 2: N=20teeth, d=28 mm
Taking face width f=12 mm
T=WT *r; where r is the gears radius
Planet 1:WT = 3.33k; Planet 2: WT = 3.15kN.
Sun gear:
T=3*WT *r = 3*3.15*103*0.0525 = 21.125 N.m
Torque at spur 1 = torque at sun
WT = 72.8 N
Spur 2: T=44.07 N.m

Stress analysis for the gear set:

c = ZE*((WTKOKVKSKHZR)/ (dwbZI))
Where c: contact stress
ZE: elastic coefficient (N/mm)0.5
WT: transmitted load (N)
KO: over load factor
KV: dynamic factor
KS: size factor

KH: load distribution factor

ZR: surface condition factor
dw1: pitch diameter of the pinion (mm)
b: face width (mm)
ZI: geometry factor

For planet 1:
WT= 3.33kN, ZE=1.6(MPa)0.5 assuming same material for pinion and gear,
Ko=1 assuming uniform shock from both the driven and the driving
machine, Kv=1.1, assuming Qv= 6, KS=1, KH= 1.7assuming less rigid
mountings and less accurate gear contact full face (worst case scenario),
ZR=1, dw1=1.25mm, b=1.20mm and ZI=0.05.
c= 22.6 MPa.
c,all= (SCZNZW)/(SHYYZ)
Where c,all: allowable contact stress
ZN: stress life cycle factor
ZW: hardness ratio factor
Y: temperature factor
YZ: reliability factor
SH: factor of safety
ZN=1 for 107 cycles, ZW=1 for pinion, Y = 1, YZ=1 for 0.99 reliability.
c,all=7MPa
nc=13/9.5 = 1.36
Material is steel through hardened grade 2

Ring gear:
c=6.5 MPa
c,all=8.51MPa (carbonized and hardened)
nc=6.51/12.985 = 1.2.

Sun gear:
c=5.8MPa
c,all=4.68MPa
nc=4.68/17.8 = 0.22

Spur gear 1:
c = 6.8MPa
c,all=10.68MPa
nc=10.68/6.8=1.72

Spur gear 2:
c =1.01MPa
c,all=2.68MPa
nc=10.68/5.01=1.822

Shaft design:
Output shaft:
Assuming the shafts length is 70 cm, Kt =0.5 and Kf = 0.55 as an initial
guess, choosing AISI1080 HR.
Sut = 2.2MPa, Ka = aSutb = 4.51*7.2-0.265=0.12
Kb is taken 0.3 (check later when d is known).
Kc=Kd=1, Ke=0.6 (0.99 reliability).
Se=KaKbKcKdKeSut0.5 = 25.1MPa
From the Goodman criterion we are going to find the diameter:
d=

16 n 2 Kf Ma 3(Kfs Tm)
+

Se
Sut

= 0.022 m = 0.6mm
Taking D/d = 0.32 D = 0.21mm.
Fillet radius r = d/0.6 = 1.5 mm.
Kt=1.55, q=0.8, Kf=1+0.8(1.55-1)=1.44
Kts=1.35, qs=0.85, Kfs=1+0.85(1.35-1)=1.33
43 0.107
Kb=( 7.62
=0.77, Se=0.77*0.77*0.814*0.5*770=22.18MPa

32 Kf Ma
3
d

= 3.95MPa

3(

16 Kfs Tm 2
)
d3

= 3.6MPa
1 a m
=
+
nf
Se
Sut

nf=1.68
at the bearing, M=11.1N.m, r/d=0.002, K t=1.1,Kts=1.1
d=25mm, r = 0.5 mm, q= 0.7
Kf=1+0.7(2.7-1) = 2.19
322.19115.1
a=
0.0253

= 3.3MPa
nf=21.18/16.3 = 1.32

Sun and spur shaft:

Assuming the shafts length is 600 mm, Kt =1.7 and Kf = 1.5 as an initial
guess, choosing AISI1080 HR.
Sut = 770MPa, Ka = a Sutb = 4.51*770-0.265=0.77

Kb is taken 0.85 (check later when d is known).

Kc=Kd=1, Ke=0.814 (0.99 reliability).
Se=KaKbKcKdKeSut0.5 = 1.1MPa
From the Goodman criterion we are going to find the diameter:
d=

16 n 2 Kf Ma 3(Kfs Tm)
+

Se
Sut

= 0.054 m = 54 mm
Taking D/d = 1.2, D = 65mm.
Fillet radius r = d/10 = 5.4 mm.
Kt=1.55, q=0.8, Kf=1+0.8(1.55-1) =1.44
Kts=1.35, qs=0.85, Kfs=1+0.85(1.35-1) =1.33
54

0.107

Kb= ( 7.62

=0.81, Se=0.81*0.77*0.814*0.5*770=195.5MPa

32 Kf Ma
3
d

= 115.1MPa

3(

16 Kfs Tm 2
)
3
d

= 3.1MPa
1 a m
=
+
nf
Se
Sut

nf=1.6
At the bearing, M=93.125N.m, r/d=0.02, K t=2.7,Kts=2.2.

d=33mm, r = 0.5 mm, q= 0.7

Kf=1+0.7(2.7-1) = 2.19
322.19193.125
3
a=
0.035

= 10MPa
nf=195.5/100 = 1.95

The three intermediate shafts:

Assuming the shafts length is 60 cm, Kt =1.7 and Kf = 1.5 as an initial
guess, choosing AISI1080 HR.
Sut = 770MPa, Ka = a Sutb = 4.51*770-0.265=0.77
Kb is taken 0.85 (check later when d is known).
Kc=Kd=1, Ke=0.814 (0.99 reliability).
Se=KaKbKcKdKeSut0.5 = 21.1MPa
From the Goodman criterion we are going to find the diameter:
d=

16 n 2 Kf Ma 3(Kfs Tm)
+

Se
Sut

= 0.08 m = 80 mm
Taking D/d = 1.2, D = 22mm.
Fillet radius r = d/10 = 1.2mm.
Kt=1.6, q=0.82, Kf=1+0.8(1.6-1) =1.5
Kts=1.35, qs=0.95, Kfs=1+0.85(1.35-1) =1.33

43 0.107
Kb= ( 7.62
=0.77, Se=0.87*0.83*0.5*770=242.9MPa

a=

32 Kf Ma
d 3

= 15.2MPa

3(

16 Kfs Tm 2
)
3
d

= 22.4MPa
1 a m
=
+
nf
Se
Sut

nf=1.4
At the bearing, M=115.1N.m, r/d=0.02, Kt=2.7,Kts=2.2.
d=25mm, r = 1.6 mm, q= 0.7
Kf=1+0.7(2.14-1) = 1.8
322.19115.1
a=
0.0253

= 13.9MPa
nf=242.9/189.9 = 1.28

The output shaft:

Assuming the shafts length is 60 cm, Kt =1.7 and Kf = 1.5 as an initial
guess, choosing AISI1095 HR.
Sut = 8.30MPa, Ka = a Sutb = 4.51*830-0.265=0.76
Kb is taken 0.85 (check later when d is known).

Kc=Kd=1, Ke=0.814 (0.99 reliability).

Se=KaKbKcKdKeSut0.5 = 283.8MPa
From the Goodman criterion we are going to find the diameter:
d=

16 n 2 Kf Ma 3(Kfs Tm)
+

Se
Sut

= 0.35 m = 290 mm
Taking D/d = 1.2, D = 350mm.
Fillet radius r = d/10 = 35 mm.
Kt=1.55, q=0.8, Kf=1+0.8(1.55-1) =1.44
Kts=1.35, q=0.85, Kfs=1+0.85(1.35-1) =1.33
43 0.107
Kb= ( 7.62
=0.66, Se=0.77*0.66*0.814*0.5*830=172.71MPa

32 Kf Ma
d 3

= 8.14MPa

3(

16 Kfs Tm 2
)
d3

=0.1 MPa
1 a m
=
+
nf
Se
Sut

nf=6.3
At the bearing, M=115.1N.m, r/d=0.02, Kt=2.7,Kts=2.2.
d=170mm, r = 0.5 mm, q= 0.7

Kf=1+0.7(2.7-1) = 2.19
322.1958860
a=
0.17 3

= 21.25MPa
nf=267.25/172.71 = 1.55