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Gear Efficiency
Introduction
Important Note:
The equations used are mainly derived from the technical information provided in the SDP/SI technical library see links below.
I recommend that for serious work the linked information is more suitable.
The output power is the (input power - the power losses). Power losses in gear systems are associated primarily with tooth friction and lubrication
churning losses. Churning losses are relatively independent of the nature of the gears and the gear ratios - they are primarily realated to the
peripheral speed of the gears passing through the fluid. Churning losses are difficult to calculate and estimates based on experience are often
used in initial gear design. The frictional losses are related to the gear design,the reduction ratio,the pressure angle, gear size, and the coefficient
of friction.
The notes below relate primarily to estimating /calculating the the part of the efficiency of gear trains which is associated with the tooth friction.
A simple table is provided below showing the efficiencies of various gear types. These efficiencies related to tooth friction losses only for single
tooth meshes. For drive trains the efficiencies or each mesh in the line is multiplied together ( 2 gears pairs of 90% efficiency result in a gear train
efficiency of 81%.
Symbols
R g = Gear ratio
α n = normal pressure angle
Ro = Outside Diameter of gear (m) vs = gear surface sliding velocity (m/s)
ro = Outside Diameter of pinion(m) α = pressure angle
Rp = Pitch Diameter of gear (m) β = helix angle (deg)
rp = Pitch Diameter of pinion(m) γ = worm lead angle (deg)
E = efficiency of gear pair (%) γ = worm lead angle (deg)
P = Power loss of gear pair as a percentage of input power (%)
µ = coefficient of friction
Considering a spur gear a good first approximation for average operating conditions is that the power loss at each mesh can be approximated as
P% of the potential power transmitted through the mesh. The efficiency is therefore..
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Gears- Gear Efficiency http://www.roymech.co.uk/Useful_Tables/Drive/Gear_Efficiency.html
cos φn / cos 2 β
Single Helical tan φn = tan α.cos β (Rg+1)
β = helix angle
Worm Gears
The theoretical efficiency of a worm gear is provided on page worm gears and is shown again below as.
The graph below shows a worm gear efficiencies plotted against the lead angle for different coefficient of friction
Notes:
This chart agrees with the equation for worm gears having a normal pressure angle of 20 degrees...
An approximation for the friction coefficient for worm gears (Bronze -steel) is
µ = 0,04 vs-0,25
vs = sliding velocity (m/s)
Epicyclic Gears
Consider the two meshing gears below which are part of an epicyclic gear train. This is provided as and example of a typical component in an
epicyclic gear. The two gears and the arms are rotating as shown .
Now it the arm was stationary the contact point P would have a instantaneous velocity = -ω2 R2. (velocities to the right are positive ). Now if the
whole system was rotating as a rigid assembly with the velocity of the arm the instantaneous velocity -ω3 R2. Combining these two motions
together, the linear velocity of the tooth engagement (gear 2 -> gear 1)is therefore
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Gears- Gear Efficiency http://www.roymech.co.uk/Useful_Tables/Drive/Gear_Efficiency.html
Now the magnitude of the transmitted tangential force F12 x the tooth engagement velocity v12 is called the potential power and the power loss
due to tooth friction is proportional to this power. Generally for spur gears ( and helical gears) it is sufficient to estimate the power loss as 1% of the
potential power. For more accurate estimations the equations above can be used.
P = 0,01 F12v12
The potential power is not the actual power but is the but is the power transmitted by the same gears operating on fixed centres at angular
velocities of ( ω2 - ω3 ) for gear 2 and ( ω1 - ω3 ) for gear 2.
The actual pitch line velocity of the gear mesh is -(ω2) and therefore the ration of the potential power to the actual power is
Now in cases where the arm is rotating faster than the gear the potential power can be greater than the actual power and the losses proportionally
greater.
Consider the epicyclic gear chain shown below. The input speed = 250 RPM (ACW) and the input torque = 2.5 Nm
For the gear mesh between gear 3 and the fixed sun 2 the velocity of tooth engagement is calculated by the product of the angular velocity of the
arm 2 at pitch radius of R2. = ω2R1 = 26,18.0,075 = 1,96m/s
For the gear engagement between the gears 4 and 5 the angular velocity of gear five =
The velocity of tooth engagement between gear (4) and gear (5) =
R5 (ω5 - ω2) = 0,068(-5,95- 26,18)=-2.18 m/s
The power input to the epicyclic gear = 65 W therefore the Gear efficiency = 100(1 - (3,64 + 0,39) /65 ) = 94%
1. SDP/SI Technical Library...Lots of useful download documents with information of gear efficiency
2. Gear Efficiency comparison .. Short comparison -
3. A second look at GearBox efficiencies .. A short informative download paper on spur gears /motors -
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Gears- Gear Efficiency http://www.roymech.co.uk/Useful_Tables/Drive/Gear_Efficiency.html
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