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Overview
A machine consists of a power source and a power transmission system, which provides controlled application of the power. Transmission is an assembly of parts including the speedchanging gears and the propeller shaft by which the power is transmitted from an engine to a live axle. Often transmission refers simply to the gearbox that uses gears and gear trains to provide speed and torque conversions from a rotating power source to another device.
Objective
To build a gearbox for a electric run motor car:
Minimize travel time required for a run on a straight route Minimize the cost of the gearbox Minimize the weight of the gearbox Maximize the performance and durability Maintain aesthetic design
Design Steps
Geometry of gears
Type of gear, module, no. of teeth, etc. Using C++ code and ANSYS
Design of Casing
As per final gear design and ANSYS
CAD
Dimensions of gears:
First Pinion = 20* mm and Module = 2 First Gear = 18 mm and Module = 2 Second Pinion = 24* mm and Module 2.5 Second Gear = 22 mm and Module 2.5
Dimensions of Shafts:
(for relaxed condition of only max torque=60Nm) OD 25mm shafts (for a conservative design: FOS=3 and max torque=60Nm) OD 36mm shafts
CAD
Dimensions of bearings:
ID=35 OD=62 T=18 wt=224 gm ID=25 OD=52 T=19.25 wt=187 gm ID=35 OD=62 T=21 wt=263 gm
Outer Shaft
Intermedia te Shaft
Input shaft
CAD
CAD
CAD
CAD
CAD
CAD
CAD
Code
For design of gears, Shigleys Mechanical Engineering Design was referred to Design analysis was carried out for both spur gears and helical gears
Reliability Factor
For a reliability of 95%, the following equation was used:
Other Factors
Temperature factor = 1 for temperatures less than 120o C Factor of safety is taken to be 1
Output
Shaft Design
3 types of shaft
Connected to motor on which pinion is attached Intermediate Connected to wheel drive
Steps:
Calculated radial, axial and tangential forces from helical gear design provided for both interfaces of gear and pinion. Used maximum torque of 60Nm that motor can provide for calculation (though in steady state the torque will be less) Accordingly calculated axial and radial forces on shaft
Design of Bearings
To account for axial forces, used Tapper Roller Bearing Because, they can take large axial forces (i.e., they are good thrust bearings) as well as being able to sustain large radial forces. Commonly used for moderate speed, heavy duty applications where durability is required. We can also use Deep Groove Ball Bearings(calculations for this are provided, if we want to use ball bearings), But Its life is limited and does not fulfill our requirement .
References
http://www.skf.com/skf/productcatalogue/jsp/calculation/calc ulationIndex.jsp http://www.irusa.com.br/catalogos/timken/usa_chap_1.pdf
ANSYS
Purpose:
ANSYS was used to
confirm the output of C++ code Ansys Analysis decrease the weight of gears design casing decrease weight of casing confirm shaft calculations
Gear 1 (FOS)
Gear 2 (FOS)
Casing
Initially used MS casing
but too heavy (from solidworks CAD model) used Al for casing
References
Motor Specification: http://agnimotors.com/95_Series_Performance_Graphs.pdf