SUBJECT

ENGINEERING LABORATORY IV (BDA 2721)

CODE

: BDA 2711

TOPIC

: COMPUTERIZED GEAR SYSTEM

OBJECTIVES :
i.

Describe the different type of gear system and some of their application

ii.

Calculate gear ratios, angular velocity, input and output torque.

iii.

Calculate the efficiency of the gears.

LEARNING OUTCOMES :
i.

Understand the concept of gear system, types of gears and its related function and
application.

ii.

Implement and analyze the required data collectively within member of group.

iii.

Produce good technical report according to the required standard

THEORY :
Gears are used to transmit motion, and therefore power, between one shaft and
another shaft. The function of a gear box is to transmit rotational motion from a
driving prime mover to a driven machine. Gear also know as a toothed wheel
designed to transmit torque to another gear or toothed component. Different size gears
are often used in pairs, allowing the torque of the driving gear to produce a large
torque in the driven gear at lower speed, or a smaller torque at higher speed. The large
gear known as wheel and the smaller gears as a pinion. Consider a simple schematic
of a gear box with an input and output shaft as shown in Figure 1.
N1
N2

Figure 1

And another theory of gear is a component within a transmission device that transmits
rotational torque by applying a force to the teeth of another gear or device. A gear is different
from a pulley in that a gear is a round wheel that has linkages ("teeth" or "cogs") that mesh
with other gear teeth, allowing force to be fully transferred without slippage. Depending on
their construction and arrangement, geared devices can transmit forces at different speeds,
torques, or in a different direction, from the power source.
The gear's most important feature is that gears of unequal sizes (diameters) can be combined
to produce a mechanical advantage, so that the rotational speed and torque of the second gear
are different from those of the first. In the context of a particular machine, the term "gear"
also refers to one particular arrangement of gears among other arrangements (such as "first
gear"). Such arrangements are often given as a ratio, using the number of teeth or gear
diameter as units.
Gear Types
internal gears

Spur gears

Bevel gears

Worms Gear

Gear ratio, G.R = Input Speed / Output Speed,

= N1 / N2

Gear ratio, G.R = (product of driven teeth)/(product of driving teeth)

Gear ratio, G.R = Input Speed / Output Speed,

= 1 / 2

The power transmitted by a torque,T (Nm) applied to the shaft rotating at N (rev/min) is
given by :Power,

P = T
P = [ 2NT] / 60

In the ideal gearbox, the input and output power are the same so,
[2N2T2] / 60 = [2N1T1] / 60
In a real gear box, power is lost through friction and the power output is smaller than the
power input.
The efficiency is defined as;
= Power Output / Power Input
= [2N2T2 x 60] / [2N1T1 x 60]
= T11 / T11
Note:Type
of
Gear
4Stage

4Stage

Class of
Gear

Same
Size

Different
Size

N speed in rev/min

angular velocity (rad/s)

Table 1 : Technical Specification for Equipment

Gear
Description
1
2
3
a. No of
18
78
78
teeth
b. Pitch
36
156
156
diameter
c. Outside
40
160
160
diameter
a. No of
18
38
78
teeth
b. Pitch
36
76
156
diameter
c. Outside
40
80
160
diameter

4
78
156
160
118
232
236

EQUIPMENT :

ITEM

NO

Unit of Gear Set

Control Panel

Computer Set

Printer

Protective Transparent Cover

Protective transparent cover

Control Panel

Unit of Gear set

Main Table
Equipment

Motor

Gear Set
Potentiometer

Motor Driver

Motor Display
Computer

Figure 2 : Connection Diagram

Speed Set

Control Panel
Protective transparent

Computer

Gear Set

Main Table

Table

Figure 3 : Overall System

CPU

PROCEDURES :
A.

EXPERIMENT FOR 4 STAGE GEAR WITH SAME SIZE GEAR - GEAR SET 1
1) Make sure gear set 1 is in place. If not, install the gear set 1 into the system according
to the following steps:i.
ii.
iii.
iv.
v.

Remove the transparent protective cover of the system.

Disconnect the sensor cable. Remove the locking bolts of the gear set.
Remove the gear set by lifting it using the handles.
Put the removed gear set lifting on storage table.
Take the new gear set and put it on system. Make sure the gear set is

vi.
vii.

completely in place.
Tighten the locking bolts. Connect the sensor cable.
Put the transparent protective cover of the system. The new set is ready to
operate.

2) Turn on the computer. Turn on the Infix gear software.

3) Turn on the system by pressing ON button. The controller and motor displays will
ON.
4) Slowly increase the speed until it reaches 100rpm. Record the motor speed into the
lab sheet accordingly.
5) Press RECORD on the monitoring page software. Let the system run and stabilize for
an about 10 seconds.
6) Slowly increase the speed until it reaches 200rpm. Record the motor speed into the
lab sheet 1.
7) Let the system run and stabilize for about 10 seconds.
8) Follow the step 5.1.6 to 5.1.7 for the speed adjustment of 300rpm, 400rpm, 500rpm,
600rpm, and 700rpm.
9) Turn OFF the potentiometer slowly.
10) Record all values into your lab sheet.

B.

EXPERIMENT FOR 4 STAGE GEAR WITH DIFFERENT SIZE GEAR GEAR

SET 2
1) 5.2.1. Make sure gear set 2 is in place. If not, install the gear set 2 into the system
according to the steps 5.1.1. (i vii).
2) 5.2.2. Turn on the computer. Turn on the Infix gear software.
3) 5.2.3. Turn on the system by pressing ON button. The controller and motor displays
will ON.
4) 5.2.4. Slowly increase the speed until it reaches 100rpm. Record the motor speed
into the lab sheet accordingly.
5) 5.2.5. Press RECORD on the monitoring page software. Let the system run and
stabilize for an about 10 seconds.

6) 5.2.6. Slowly increase the speed until it reaches 200rpm. Record the motor speed
into the lab sheet 1 accordingly.
7) 5.2.7. Let the system run stabilize for about 10 seconds.
8) 5.2.8. Follow the step 5.1.6 to 5.1.7 for the speed adjustment of 300rpm, 400rpm,
500rpm, 600rpm, and 700rpm.
9) 5.2.9. Turn OFF the potentiometer slowly.
10) 5.2.10. Record all values into your lab sheet.

OBSERVATIONS :
TABLE 2 : 4 Stage Gear with Same Size Gear Gear Set
Gear 0
( Motor )
No of teeth (t)
Pitch Diameter (D) mm
Gear Ratio (Calculation)
Speed (rpm)

Gear Ratio (From Data)

Gear Efficiency

18
36
100
200
300
400
500
600
700
-

Gear 1

Gear 2

Gear 3

78
156
0.23
23
46
70
92
115
138
162
0.23
0.87

78
156
0.23
5
11
16
22
27
32
38
0.05
0.84

78
156
0.23
2
2
4
5
6
8
8
0.01
0.87

TABLE 3 : 4 Stage Gear with Same Size Gear Gear Set 2

Gear 0
( Motor )
No of teeth (t)
Pitch Diameter (D) mm
Gear Ratio (Calculation)
Speed (rpm)

Gear Ratio (From Data)

Gear Efficiency

18
36
100
200
300
400
500
600
700
-

Gear 1

Gear 2

Gear 3

38
76
0.47
48
95
143
189
237
285
332
0.23
0.87

78
156
0.23
12
23
34
42
55
66
78
0.05
0.87

118
232
0.15
2
4
5
6
7
11
14
0.01
0.87

Gear with different size make motor speed (Rpm) increase.

The value is not accurate and very sensitive to define.

Speed motor with same size or different size with Gear 0 to 3, the value of speed
motor from result will decrease until the lowest value in the data from Gear 0 to Gear
3

DISCUSSIONS :
i.

From table 1 and 2, calculate the gear ratio theoretically and experimentally and
compare the result.

ii.

From the data, the value from table 1 and 2 shows that the gear ratio of
calculation and the gear ratio of theory are different.
It show that data with experimentally, that motor speed is higher than data
With theory.it because depending with the size and teeth that we use to
Experiment

Gear Ratio (Calculation)

0.23

0.23

0.23

Gear Ratio (From Data)

0.23

0.05

0.01

Gear Ratio (Calculation)

0.47

0.23

0.15

Gear Ratio (From Data)

0.23

0.05

0.01

SET 1

SET 2

From the experiments, plot the graph Speed (rpm) versus Time (seconds) of the Gear
set 1 and 2. Review the results.

iii.

What are the input torque and the output torque of the gear system. Given that the
input power Pin equal to 20kW and the efficiency, equal to 0.7.

The value taken from data Table 1

Calculation For () Gear 0

Formula : 2N/60
2 x x 100 =10.47 rad/s

60
Calculation Torque (T) ,Given data input power =20kW
T=P/
T= 20kW/10.47
= 1910.2 Nm (input Torque)

The value taken from data Table 1

Calculation For () Gear 1
Formula : 2N/60
2 x x 23 = 2.408 rad/s
60
Calculation Tork (T) ,Given data input power =20kW
T=P/
T= 20kW/2.408
= 8305.6Nm (Output Torque)

The value take from data Table 1

Calculation For () Gear 2
Formula : 2N/60
2 x x 5 = 0.524 rad/s
60
Calculation Torque (T) ,Given data input power =20kW
T=P/
T= 20kW/0.524
= 38167.9 Nm (Output Tork)

The value take from data Table 1

Calculation For () Gear 3
Formula : 2N/60
2 x x 2 = 0.209 rad/s
60
Calculation Torque (T) ,Given data input power =20kW
T=P/
T= 20kW/0.209
= 95693.7 Nm (Output Torque)
Gear 0

Gear 1

Gear 2

Gear 3

(rpm)
100
200
300
400
500
600
700

Rad/s
10.47
20.94
31.42
41.89
52.36
62.83
73.30

Rad/s
5.026
9.948
14.97
19.79
24.82
29.85
34.76

(Nm)
3979.3
2010.5
1336.0
1010.6
805.8
670.0
575.37

(rpm)
12
23
34
42
55
66
78

Rad/s
1.256
2.408
3.560
4.398
5.760
6.911
8.168

(Nm)
15915.5
8305.6
5617.9
4547.5
3472.2
2893.9
2448.5

(rpm)
2
4
5
6
7
11
14

Rad/s
0.209
0.418
0.523
0.628
0.733
1.152
1.466

(Nm)
95693.7
47746.5
38197.1
31847.1
27285.1
17362.3
13641.8

(Nm) (rpm)
1910.2
48
955.10
95
6365.3 143
476.42 189
381.97 237
318.32 285
272.85 332

Table 2: 4 stage Gear with Different size Gear - Gear Set 2

The value take from data Table 2
Calculation For () Gear 0

Formula : 2N/60
2 x x 100 =10.47 rad/s

60
Calculation Torque (T) ,Given data input power =20kW
T=P/
T= 20kW/10.47
= 1910.2 Nm (input Torque)

The value take from data Table 1

Calculation For () Gear 1

Formula : 2N/60
2 x x 48 = 5.026 rad/s

60
Calculation Torque (T) ,Given data input power =20kW
T=P/
T= 20kW/2.408
= 3979.3 Nm (Output Torque)

The value take from data Table 1

Calculation For () Gear 2

Formula : 2N/60
2 x x 12 = 1.256 rad/s

60
Calculation Torque (T) ,Given data input power =20kW

T=P/
T= 20kW/0.524
= 15915.5 Nm (Output Torque)

The value take from data Table 1

Calculation For () Gear 3

Formula : 2N/60
2 x x 2 = 0.209 rad/s

iv.

60
Calculation Torque (T) ,Given data input power =20kW
T= P/
T= 20kW/0.209
= 95693.7 Nm (Output Torque)

Calculate the efficiency of the gear system (gear set 1 and 2) of the following
combination gear :a. Gear 1 to gear 0
b. Gear 2 to gear 0
c. Gear 3 to gear 0

Set 1
Gear 0 Gear 1

Gear 0 Gear 2
=efficenc
Gear Ratio
y
0.05
1.0
0.06
1.0
0.05
0.1
0.06
1.0
0.05
0.8
0.05
1.0
0.05
1.0

N (rpm)

Gear Ratio

=efficency

100
200
300
400
500
600
700
Average

0.23
0.23
0.23
0.23
0.23
0.23
0.23

1.0
1.0
0.1
1.0
1.0
1.0
1.0

0.23

0.05

0.87

Gear ratio
Average
Effeciency

Gear 0 Gear 3
Gear Ratio

=efficency

0.02
0.02
0.01
0.01
0.01
0.01
0.01

1.0
1.0
0.1
1.0
1.0
1.0
1.0

0.01

0.84

0.87

Set 2
Gear 0 Gear 1

Gear 0 Gear 2
=efficenc
Gear Ratio
y
0.05
1.0
0.06
1.0
0.05
0.1
0.06
1.0
0.05
1.0
0.05
1.0
0.05
1.0

N (rpm)

Gear Ratio

=efficency

100
200
300
400
500
600
700
Average

0.23
0.23
0.23
0.23
0.23
0.23
0.23

1.0
1.0
0.1
1.0
1.0
1.0
1.0

0.23

0.05

0.87

Gear ratio
Average
Effeciency

Gear 0 Gear 3
Gear Ratio

=efficency

0.02
0.02
0.01
0.01
0.01
0.01
0.01

1.0
1.0
0.1
1.0
1.0
1.0
1.0

0.01

0.87

0.87

CONCLUSION :
From the experiment, the objectives have been achieved which are describing the different
types of gear system, calculating the ratios, angular velocity, input and output speed and
efficiency. From what I have learn to this experiment, this experiment similarly like system
gearbox in car is to transmit rotational motional from a driving prime mover to a driven
machine.
troubleshooting the software and the speed sensor so the value given are accurate and precise.
REFERENCES :
http://en.wikipedia.org/wiki/Gear
McGraw Hill Encyclopedia of Science and Technology, "Gear"
Gear Dive Systems: Design and Application, by Peter Lynwander
http://www.codecogs.com/reference/engineering/materials/shear_force_and_bending_momen
t.php