Drive Systems exercise pack 4

Exercise 4.1
For the gearset shown below, where gear 1 is the driving gear and gear 2 is the driven
gear, please determine:
a) Amount of teeth of both gear.
b) If the modulus of the gears is M=2mm, what are the pitch diameters of the gears?
c) Transmission ratio
d) If gear 1 is rotating with a rotational speed of n1= 1500min-1, what is the angular
velocity of gear 2?

Exercise 4.2

The gearbox shown is used to connect an AC motor to drive some conveyor system in a
factory. Given information: Teeth gear A: za=18; Teeth gear B: zb=46; Teeth gear C: zc=15
Teeth gear D: zd=32
a) Calculate the ratio of both gear sets separately.
b) Calculate the train value of the gearbox.
In steady state operation, the input shaft is turning with a rotational speed of n 1=1500
min-1, and loaded with a Torque of T1=300N. The efficiency of the gearbox is tot=95%.
c) Calculate the rotational speed n2 of shaft 2
d) Calculate the output rotational speed n3
e) Calculate the Torque T3 at the output shaft
f) Calculate input power P1; output power P3; and lost power PL.
When starting the system, shaft 2 broke and you need to investigate why. You have
found out that during the start the output shaft of the gearbox was loaded with a
Torque T2= 2000Nm.
In the documentation of the gearbox you found that shaft 2 was rated for a maximum
Torque of T2=800Nm for a limited amount of load cycles. (For example during start).
f) For how much torque should shaft 2 have been designed? Was it overloaded?
Reference: Mott; Machine Elements in mechanical design.

Exercise 4.4
Your car has 5 gears. You want to determine the conversion ratio of the total conversion
in each of the four gears. The tyres have a diameter of 600mm.
To do this, you drove with the engine running at 3000rpm in all gears, while measuring
the velocity, and entered that data in a table:
Gear

Velocity in [km/h] Angular velocity of total conversion

the tyres t,g [s-1]
at 3000rpm
TV

24

60

96

120

140

Conversion
gearbox i

a) Calculate the angular velocities t,g of the tyres at the measured velocities, and enter
those in the table.
b) Calculate the total conversion, i.e. the train value TV, in each of the gears and enter
that into the table.
If the transmission consists of the shift-able gearbox and a differential at the rear axle:
c) make a sketch of the layout of the drivetrain
d) Knowing the differential has a ratio of 2.5, calculate the conversion ratios of the
gearbox for each of the gears.
e) At the relatively quite A57 between Goch and Rheinberg you decide to test the top
speed of your car, but you are afraid that you speedometer is not accurate. In fifth gear
at top speed the engine rotates at 4800rpm. Assuming the speeds in the table were
accurately measured, what is the top speed of your car?
f) If the lowest rotational speed the engine can drive at without stalling is 1000rpm,
what is, without slipping the clutch, the slowest speed you can steadily drive?

Exercise 4.4
Below a simplified schematic sketch of the drive train layout of a rear wheel drive car is
given.

gearbox

Diff.

Tyre size: 225/50 R 17 W, that means a diameter: D tyre=656.8mm

Gearbox ratios:
1st gear: ig1=4.110
2nd gear: ig2=2.248
3rd gear: ig3=1.403
th
th
4 gear: ig4=1
5 gear: ig5=0.802
6th gear: ig6=0.659
The differential has a ratio of idiff=3.462
a) Calculate the total Train value for all gears (TV1, TV2, , TV6)
b) If the top speed of the car is stated to be 242km/h, how fast does the engine rotate at
top speed? Give your answer in revolutions per minute.
c) Calculate the revolutions per minute of the input of the differential, while driving
130km/h
d) Calculate the revolutions per minute of the input of the gearbox while driving
130km/h in 6th gear.
e) Compare the results between c and d, what do you notice? Why is this done?
The tyres weigh 11kg each, the rims weigh 9kg each
f) Estimate the mass moment of inertia of the wheels. Assume the tyre is a thin walled
cylinder. Assume the rim is a combination of a thin walled cylinder of 5kg with a radius of
17 inch and a solid cylinder of 4kg with a radius of 17 inch.
Note: This is just one way to approximate a mass inertia, it is NOT an exact calculation.
With some passengers on a certain day the car weighs in total 1800kg
g) Calculate the total mass moment of inertia acting on the output shaft of the engine
in 6th gear. Assume the mass moment of inertia of the differential and gearbox
components to be small enough to neglect.
The engine of the car delivers a torque of 450NM from 1500rpm all the way until
2700rpm. And reaches a maximum power output of 165kW at 4400rpm.
h) While driving in sixth gear with 1800rpm, the speed limit is lifted and you put your
foot down. How much torque will be delivered to each rear wheel?
i)* A little bit of dynamics is already needed: What is the acceleration you achieve in
question h, considering the drag is Fd=380N and the rolling resistance is Fw=360N
Reference: http://www.automobile-catalog.com/car/2015/1818185/bmw_325d.html