DESIGN OF GEARBOX (SPEED REDUCERS) Motor Machine Tools & Engine Road wheels

To get different speeds Gear Box

What is moving inside the transmission when move the shifter?

What would happen if accidentally shift into reverse gear? Would the entire transmission explode?

When hearing that horrible grinding sound, what is actually grinding?

Components of Speed Reducers Shafts for mounting gears Bearings to support shafts and gears Gearbox housing to support bearings, to hold lubricants and to protect from dirt and dust Provisions to prevent axial movement of the shafts relative to bearings

and to prevent axial movement of bearing

Space for oil reservoir Oil level indicator, drain plug and inspection hole

Cooling fins
Provision for easy assembly and disassembly

Single Reduction

Double Reduction

Since, Centre distance of the shafts A and B is fixed, it is essential that the

sum of the teeth of engaging pairs should be equal for same module

Z1 + Z2 = Z 3 + Z 4 = Z 5 + Z6

Multi Speed changing

Neutral condition

First Gear engaged

5 speed Gearbox

Reverse Gear operation

PROGRESSION RATIO []

The ratio of adjacent speeds will be a constant called

progression ratio. The spindle speeds (output speeds) are

arranged in geometric progression.

If Nmax is the maximum speed, Nmin is the minimum speed, then

Consider a five speed gear box, where N5 is the maximum speed, N1 is the min speed and r is the number of speeds. Progression ratio = = = =

5-1 r -1 =

/()

6 Speed Gearbox (23) or (32)

9 Speed Gearbox (33)

12 Speed Gearbox (322) or (232) or (322)

STRUCTURAL RAY DIAGRAM

Follow for all stages,

If it is not possible,

Structural formula: Z = P1 (X1). P2 (X2). P3 (X3)

Where P1, P2, P3 are speeds available in each stage X1 = 1, X2 = P1, X3 = P1.P2

Principles to be followed to obtain optimum design: Number of gears on the last shaft (spindle) should be

minimum.
Number of gears on the shafts should not be more than 3. It is preferable to have nmax ninput > nmin in all the stages

except in the first stage.

The velocity ratio between the spindle and the shaft preceding it should be the max possible.