Example 1(Taken from Roslan, Che’ Abas, Yunus (2001), UTM)

A motor is accelerating a 250 kg load with acceleration of 1.2 m/s2 through a gear system as
shown below. The rope that carries the load are encircled on a hoist with diameter 1.2m.Gear for
the hoist’s shaft has 200 teeth, gear for motor shaft has 20 teeth. Gear efficiency is 90%. Mass
and radius of gyration of each shaft is as below;

Mass (kg) Radius of gyration (mm)

Motor shaft 250 100
Hoist shaft 1100 500

Calculate the torque of the motor needed to bring up the load with acceleration 1.2 m/s 2. Neglect
friction effect.

Dia = 1.2 m

Hoist

Figure 13: Gear system attached to hoist

Solution

Total torque at motor to bring up load

Ttotal  TM 1  TM 2

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).

TM 2 =Torque to accelerate the load through gear system

a) Consider for TM 1 I n2
I equiv  I M  G
From G

Thus I M = Motor shaft inertia

I M  mk 2  2500.1  2.5 kgm2
2

IG
= Hoist shaft inertia
I G  11000.5  275
2
kgm2
 N1 20
n   0.1
Gear ratio, N 2 200
 2750.12 
I equiv  2.5     5.55
Put into  0.9 
kgm2
aG   G rG
Acceleration of hoist,
1.2
G  2
Thus 0.6 rad/s2
G 2
m    20
From the gear ratio, angular acceleration of motor, n 0.1 rad/s2
T  I equiv m
Now torque due to equivalent inertia, M 1
TM 1  5.55(20)  111.1 Nm.

b) Consider for TM 2

F  250
From Newton g
2nd 250a F  ma
Law,
F  250g  a   2509.81  1.2
F  2752.5 N

Then, torque at hoist

TG  Fr  2752.50.6  1651.5
Nm
But due to gear efficiency (since the hoist shaft is connected to the gear system), torque to

1651.50.1
accelerate the load,
T n
TM 2  G 1 / 2   183.5
 G ,1 / 2 0.9
Nm TG
Hoist
r

Then total torque referred to motor side is;

Ttotal  TM 1  TM 2 a F
Ttotal  111.1  183.5

Ttotal  294.6 250 kg

Nm

250g

Figure 14: Free body diagram of hoist and load

Example 2(Taken from Roslan, Che’ Abas, Yunus, (2001), UTM)

Figure 12 below shows a motor used to accelerate a hoist through two sets of gear reducing
system. Moment of inertia for the motor shaft is 5 kgm2, middle shaft is 40 kgm2 and hoist shaft
is 500 kgm2. Gear ratio for gear set 1 and 2 is 1/3.5 while for gear set 3 and 4 is 1/ 4.5. Gear
efficiency for both gear set is 90%. By neglecting the friction effect, find the total torque
required by the motor to accelerate the load of 6 tones at acceleration of 0.4 m/s2.

Hoist

Diameter = 1.2 m
m

Figure 15: Loading system on gear

Solution
n1 / 2  1 n 1
Given that I M =5 kgm2, I T  40 kgm2, G =500 kgm2,
I 3.5 , 3 / 4 4.5 ,  G  0.9
Neglect friction effect.

Total torque required for the motor is

Ttotal  TM 1  TM 2

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).

TM 2 =Torque to accelerate the load through gear system

a) Consider for TM 1
T  I 2 m
Recall that MI1 (n equiv ) I, but
(n for) 2two(n3 / set 2 of gear system with friction effect is neglected,
4)
I equiv  I m  T 1 / 2  G 1 / 2
 G ,1 / 2 ( G ,1 / 2 )( G ,3 / 4 )
40( 1 ) 2 500( 1 ) 2 ( 1 ) 2
I equiv  5 3.5  3.5 4.5  11.116 Nm
0.9 (0.9)(0.9)
 aG  0.4
From question,
a 0.4 given that, m/s2, thus;
G  G 
rG 0.6

 G  0.6667 rad/s2
 G  G T 1 1 1
    
From gear ratio,  m  T  m 4.5 3.5 15.75

Thus,
 m  15.75 G
 m  15.750.6667  10.5 rad/s2
Tm1  I equiv m  11.11610.5
Thus,
TM 1  116.72 Nm.

b) Consider for TM 2 in Figure 13;

From Newton 2nd Law, 

F  ma
Hoist
4500 g  F1  4500a
a
F1  4500g  a   45009.41  42345 N
a F1 F2
F2  6000 g  6000a
F2  6000a  g   61260 N
6000 kg
4500 kg
Resultant torque at hoist
FR  F2  F1  18.915 kN
6000g
4500g Thus torque at hoist
TG  FR rG  18.9150.6  11.349
Figure 16: Loading FBD kN

T
It is known thatTG nG1 /referred
2 n3 / 4
to motor side will be denoted as TM 2 and is related by
TM 2 
 G ,1 / 2 G ,3 / 4

TM 2 
11.349 1   
1
3.5 4.5  889.6
0.90.9 Nm

Thus total torque at motor required is

Ttotal  TM 1  TM 2
Ttotal  116.72  889.6
Ttotal  1006.32
Nm.
Example 3(Taken from Roslan, Che’ Abas, Yunus, (2001), UTM)

Hoist
Dia = 0.9 m

Figure 17: Gear with inclined loading

Figure 14 above shows a motor accelerating a hoist with diameter 0.9m, through two sets
of gear reducing system. Gear ratio for gear 1 and 2 is 1/3.5 while for gear 3 and 4 is 1/ 4.5.
Moment of inertia for the motor shaft is 5 kgm2, middle shaft is 20 kgm2 and hoist shaft is 100
kgm2. The rope that is encircled on the hoist must be capable to lift up a load of 5 tones that is
sliding on a 1 in 50 slope. Friction on the slope is 1000N and the total torque at motor required to
raise the load is 1500N. Use gear efficiency of 90% for both gear set. If there is friction torque
T  800
effect on the middle shaft, TX  150 Nm and at hoist shaft is y Nm. Calculate the
acceleration of the load at the above condition.

Solution

For the overall gear ratio,1 1 1

n0  n1 / 2 n3 / 4   
3.5 4.5 15.75

Total torque required by motor to raise load

Ttotal  TM 1  TM 2  TM 3

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).

TM 2 =Torque to accelerate the load through gear system
TM 3 
Total torque to overcome friction effect.

a) Consider for TM 1
T  I equiv m
Previously, M 1
For double set of gear (n ) 2 system,
I reducing I ( n ) 2 ( n3 / 4 ) 2
I equiv  I m  T 1 / 2  G 1 / 2
 G ,1 / 2 ( G ,1 / 2 )( G ,3 / 4 )
20( 1 ) 2 100( 1 ) 2 ( 1 ) 2
I equiv  5 3.5  3.5 4.5  7.312
0.9 (0.9)(0.9) kgm2
 a a
G  
a   G rG rG 0.45
From , thus,
G 1  a 
  m  15.75 G  15.75   35a
Also from gear ratio,  m 15.75 , thus,  0.45 

Thus TM 1  7.31235a   255.92a Nm

b) Consider for TM 2 as in Figure 15;

From  F  ma,
F1 F1  FR  mg sin   ma
F1  5000a  1000  50009.81 1  50
FR Mg sinθ F1  5000a  1981 N
5000g Thus, torque to accelerate hoist
θ
TG  F1r  5000a  19810.45

TG  2250a  891.45
Nm
F1
TG
Use gear efficiency to relate with TM 2
T n n
TM 2  G 1 / 2 3 / 4
r  G ,1 / 2 G ,3 / 4
hoist
TM 2  176.4a  69.876 Nm
Figure 18: inclined loading

TM 3
c) Consider for

TM 3
Friction effect Tcan
n be grouped
T n ntogether to form where;
TM 3  X 1 / 2  Y 1 / 2 3 / 4
 G ,1 / 2  G ,1 / 2 G ,3 / 4
 1   1  1 
150  800  
TM 3   3.5 
  3.5  4.5 
 110.33
0.9 0.9 2 Nm

Ttotal  TM 1  TM 2  TM 3
From
1500  255.92a   176.4a  69.876  110.33
Thus a  3.1 m/s2
 Tutorial 1-GEAR SYSTEM

1. The axes of two parallel shafts are to be 600mm apart approximately, and have to be
connected by spur gear, having a circular pitch of 30 mm. If gear A rotate at 200 rpm and
gear B rotate at 600 rpm, find the number of teeth on each gear.

600 mm

2. Figure below showed a motor used to accelerate a hoist through a set of gear system.
Gear for the hoist’s shaft has 200 teeth and gear for motor shaft has 20 teeth. Gear
efficiency is 90 %. Moment of inertia for the motor shaft is 2.5 kgm² and hoist shaft is
275 kgm². The rope that carries a 250 kg load are encircle on hoist with diameter 1.2 m.
By neglecting the friction, find
a) gear ratio,
b) equivalent moment inertia for a gear system,
c) the total torque required by the motor to accelerate the load at acceleration of 1.0
m/s².

Set of gear
Motor

Hoist

Rope

Load
3 The diagram above shows a gear train composed of three gears. Gear A revolves at 60
revs/min in a clockwise direction.

GEAR GEAR GEAR

A B C
20 60 10
TEETH TEETH TEETH
a) What is the output in revolutions per minute at Gear C?
b) In what direction does Gear C revolve ?
[ 120 rpm, clockwise ]

4 Spur gears are arranged as shown below. Driver gear is rotating at 200 rpm in clockwise
direction. Calculate;
(i) Rotational speed, N of gear D and
( ii ) Gear ratio, n of the gear train system

(…..)
5 FIGURE Q1(b) shows a motor used to accelerate a hoist through a set of gear system.
Gear for the hoist’s shaft has 100 teeth and gear for motor shaft has 10 teeth. Gear
efficiency is 90 %. Moment of inertia for the motor shaft is 2 kgm² and hoist shaft is 200
kgm². Motor shaft attached by a support bearing with friction, Tx is 9 Nm. The rope that
carries a 147 kg load are encircled on hoist with radius 0.5 m. By neglecting the gear
friction, find
(i) Gear ratio n,
( ii ) Equivalent moment inertia, Iequi for a gear system and
( iii ) The total torque, Ttotal required by the motor to accelerate the load at acceleration

Set of gear
Motor

Tx Hoist

Rope

Load