CHAPTER 1 POWER TRANSMISSION SYSTEM - GEAR SYSTEM

1.1 Introduction to Gear System 1

1.2 Types oI Gear system 1
1.3 Relationship between pitch diameter and pitch circle 7
1.4 Gear Ratio 9
1.5 Gear Train 11
1.6 Gear EIIiciency 12
1.7 Power Transmission in a Gear Train System 12
1.8 Equivalent Moment oI Inertia 14
1.9 Gear Train Applications 15
1.10 Vehicle Dynamics 22







CHAPTER 1

POWER TRANSMISSION SYSTEM: GEAR SYSTEM



1.1 Gear System

Gears are used Ior two basic purposes; increase or decrease oI rotation speed and increase
or decrease oI power or torque. Torque is a measure oI a Iorce to produce torsion and rotation
about an axis. To increase speed and reduce torque a large drive gear is coupled to a smaller
driven gear. To reduce speed and increase torque a small Lego gear turning a larger gear is used.
They are also used Ior enhancement Ior positioning systems.
In gear system, gear that Iunctions as mover mentioned as driver gear, while gear moved
name as driven gear.


1.2 Types of Gear System

Gears are categorized into several types. They are used in a wide era oI industries
including automotive, milling, paper industry etc. According to diIIerent applications in
industries and diIIerent materials used they are categorized separately. DiIIerent types oI gears
are also custom design and are Iabricated by gear manuIacturing services as par the
speciIications.
Gears Types
- Angular Bevel Gears
- Bevel Gears
- rown Wheel
- rown Wheel and Pinion
- DiIIerential Gears
- ine Pitch Gears
- Girth Gears
- ardened and Ground Gears
- elical Bevel Gears
- elical Gears
- erringbone Gears
- Master Gear
- Mill eaders
- Miter Gears
- on-Involute Gears
- Pinion Gears
- Rack Gears
- Ring Gear and Pinion
- Spiral Bevel Gears
- Spur Gears
- Straight Bevel Gears
- Support Rollers
- Tacho Drives
- Thrust Rollers
- Idler Gear
- Gear Trains
- Planetary Gear
- Ground Gear
- ace Gear
- Internal Gears
- ycloidal Gears
- External Gear
- Winch Gears
- Sprockets
- Worm Gears
- Involute Gears
1able 1


Gear can also be classiIied according to the relative position oI the axes oI mating gears.

Parallel Axes
Intersecting
Axes
Non-Intersecting
(Non-parallel) Axes
Rotary to
Translation
Spur Gears Bevel gears ypoid gears Rack and Pinion
elical Gears Straight bevel rossed helical gears -
erring bone or
double helical
gears
Zerol bevel Worm gears -
- Spiral bevel - -

1able 2


a) !arallel Axes Shaft

The shaIt axes between driver and driven gear is parallel to each other. Example oI this
type oI gear is Spur Gear.

:re 1: Sp:r Cear


Spur gears connect parallel shaIts, have involute teeth that are parallel to the shaIt and
can have internal or external teeth. They cause no external thrust between gears. They are
inexpensive to manuIacture. They give lower but satisIactory perIormance. They are used when
shaIt rotates in the same plane.

The main Ieatures oI spur gears are dedendum, addendum, Ilank, and Iillet. Dedendum
cylinder is a root Irom where teeth extend, it extends to the tip called the addendum circle. lank
or the Iace contacts the meshing gear, the most useIul Ieature iI the spur gears. The Iillet in the
root region is kinetically irrelevant.

The speed and change oI the Iorce depends on the gear ratio, the ratio oI number oI teeth
on the gears that are to be meshed. One gear among the two is on the input axle; the axle oI the
motor and the other gear oI the pair is on the output axle, the axle oI the wheel.

They have higher contact ratio that makes them smooth and quiet in operation. They are
available Ior corrosion resistant operation. They are among the most cost-eIIective type oI
gearing. They are also used to create large gear reductions.

They are available in plastic, non-metallic, brass, steel and cast iron and are manuIactured
in a variety oI styles. They are made with many diIIerent properties. actors like design liIe,
power transmission requirements, noise and heat generation, and presence oI corrosive elements
contribute to the optimization oI the gear material.

Generally used in simple machines like washing machines, clothes dryer or power
winches. They are not used in automobiles because they produce sound when the teeth oI both
the gears collide with each other. It also increases stress on the gear teeth. They are also used in
construction equipment, machine tools, indexing equipment, multi spindle drives, roller Ieeds,
and conveyors.


b) 3tersect3 Axes Shaft

The shaIt axes between driver and driven gear is perpendicular to each other. Example oI
gear is bevel gears.







:re 2: bevel ear



:re 2: Bevel Cear


They connect intersecting axes and come in several types. The pitch surIace oI bevel
gears is a cone. They are useIul when the direction oI a shaIt's rotation needs to be changed.
Using gears oI diIIering numbers oI teeth can change the speed oI rotation. They are usually
mounted on shaIts that are 90 degrees apart, but can be designed to work at other angles as well.

These gears permit minor adjustment during assembly and allow Ior some displacement
due to deIlection under operating loads without concentrating the load on the end oI the tooth.
or reliable perIormance, Gears must be pinned to shaIt with a dowel or taper pin. Bevel gear
sets consist oI two gears oI diIIerent pitch diameter that yield ratios greater than 1:1.



The teeth on bevel gears can be straight, spiral or bevel. In straight bevel gears teeth have
no helix angles. They either have equal size gears with 90 degrees shaIt angle or a shaIt angle
other than 90 degrees. Straight bevel angle can also be with one gear Ilat with a pitch angle oI 90
degrees. In straight when each tooth engages it impacts the corresponding tooth and simply
curving the gear teeth can solve the problem. Spiral bevel gears have spiral angles, which gives
perIormance improvements. The contact between the teeth starts at one end oI the gear and then
spreads across the whole tooth. In both the bevel types oI gears the shaIt must be perpendicular
to each other and must be in the same plane. The hypoid bevel gears can engage with the axes in
diIIerent planes. This is used in many car diIIerentials. The ring gear oI the diIIerential and the
input pinion gear are both hypoid. This allows input pinion to be mounted lower than the axis oI
the ring gear. ypoid gears are stronger, operate more quietly and can be used Ior higher
reduction ratios. They also have sliding action along the teeth, potentially reducing eIIiciency.

A good example oI bevel gears is seen as the main mechanism Ior a hand drill. As the
handle oI the drill is turned in a vertical direction, the bevel gears change the rotation oI the
chuck to a horizontal rotation. The bevel gears in a hand drill have the added advantage oI
increasing the speed oI rotation oI the chuck and this makes it possible to drill a range oI
materials.

The bevel gears Iind its application in locomotives, marine applications, automobiles,
printing presses, cooling towers, power plants, steel plants, deIenses and also in railway track
inspection machine. They are important components on all current rotorcraIt drive system.

Spiral bevel gears are important components on all current rotorcraIt drive systems.
These components are required to operate at high speeds, high loads, and Ior an extremely large
number oI load cycles. In this application, spiral bevel gears are used to redirect the shaIt Irom
the horizontal gas turbine engine to the vertical rotor.


c) 433tersect3 (43parallel) Axes Shaft

The shaIt axes between the driver and driven gears are not intersecting but not parallel at
the same time. A very good example oI a non-intersecting-non-parallel gear system is a worm
gear as in igure 3.










:re 3: W4rm Cear

A worm gear is an inclined plane wrapped around a central axle. It is a gear with one or
more teeth in the Iorm oI screwed threads. Worm gears are made oI two parts: the pinion and the
worm gear. The pinion has small number oI teeth and they wrap around the pitch cylinder. The
worm gear has concave Iaces to Iit the curvature oI the worm in order to provide line oI contact
instead oI point oI contact. They are cut helically Ior better mating Worm gears can provide a
high angular velocity between non-intersecting shaIts at right angles.

They are capable oI transmitting high tooth loads, the only disadvantage is the high
sliding velocities across the teeth. They provide ultimate power ratio. The eIIiciency oI worm
gear depends on the lead angle, sliding speed, and lubricant, surIace quality and installation
conditions. They oIIer smoothest, quietest Iorm oI gearing. They provide high-ratio speed
reduction in minimal spaces.

Worm gears are used when large gear reductions are required. Worm gear has a unique
property oI easily turning the gear. The gear cannot turn the worm because the angle on the
worm is shallow and when the gear tries to spin the worm, the Iriction between the two holds the
worm in place.

Worm gears work under diIIicult conditions, presenting unique lubrication demands. The
types oI oils most commonly used to lubricate worm gears are compounded mineral oils, EP
mineral gear oils and synthetics. Worm gear is always used as the input gear. or the operation
oI worm gear, torque is applied to the input end oI the worm shaIt by a driven sprocket or
electric motor. The worm and the worm shaIt are supported by anti-Iriction roller bearings.
Because oI high Iriction worm gears are very ineIIicient. There is lot oI Iriction between a worm
gear and the gear being driven by the worm gear. When used in high torque applications, the
Iriction causes the wear on the gear teeth and erosion oI restraining surIace.

There are three types oI worm gears. on throated- a helical gear with a straight worm.
Tooth contact is a single moving point on the worm drive. Single throated- has concave helical
teeth wrap around the worm. This leads to line contact. Double throated- called a cone or
hourglass. It has concave teeth both on the worm and helical gear. Worm gears are widely used
in packaging machinery, material handling, machine tools, indexing and Iood processing. They
are used widely in conveyor systems. They are also used in torsen diIIerential, used on some
high-perIormance cars and trucks. They serve as speed reducers in many diIIerent industries.












/) !erpe3/c:lar Axes Shaft / R4tary t4 1ra3slat43

The shaIt axes between driver and driven gear are perpendicular to each other and do not
intersect to each other. Example oI gear is Rack and Pinion Gear.
:re 4: Rack a3/ !343 Cear

Rack and pinion gears are used to convert rotation into linear motion. The speed with
which the rack moves as the pinion turns is determined by the diameter oI the gear. The Ilat,
toothed part is the rack and the gear is the pinion. A piston coaxial to the rack provides hydraulic
assistance Iorce, and an open centered rotary valve controls the assist level. A rack and pinion
gears system is composed oI two gears. The normal round gear is the pinion gear and the straight
or Ilat gear is the rack. The rack has teeth cut into it and they mesh with the teeth oI the pinion
gear. Rack and pinion gears provide a less mechanical advantage than other mechanisms, but
greater Ieedback and steering sensation.

Rack and pinion gears are available in three variations: straight teeth metric pitch, straight
teeth modular pitch, and helical teeth modular pitch. Rack and pinion gears variations are
available in diIIerent qualities: 9/10 milled teeth or milled and hardened quality, 7/8 precision cut
or precision cut and hardened quality, and 5/6 teeth hardened and ground quality. A rack and
pinion gear gives a positive motion especially compared to the Iriction drive oI a wheel in
tarmac. In a rack and pinion railway, a central rack between the two rails engages with a pinion
on the engine allowing a train to be pulled up very steep slopes. A ring and pinion gear is the
diIIerential's critical point oI power transIer. A ring and pinion gear set is one oI the simplest
perIormance modiIications that can be perIormed on a vehicle. The most common reason to
change ring and pinion ratios Irom the original equipment is to retain power when bigger tires
are put on a vehicle. The torque can be increased by a ratio change when there is enhanced
pulling or higher take oII power Irom a dead start. A well designed mechanism such as the rack
and pinion gears save eIIort and time.

Rack and pinions gears are commonly used in the steering system oI cars to convert the
rotary motion oI the steering wheel to the side to side motion in the wheels. The steering wheel
rotates a gear which engages the rack. As the gear turns, it slides the rack either to the right or
leIt, depending on which way the wheel is turned. Rack and pinion gears are also used in some
scales to turn the dial that displays a weight.

1.3 Relationship between Pitch Diameter and Pitch Circle




:re 5: Cear term34l4y

Some oI the terminology oI gear system includes;
- Pitch surface : The surIace oI the imaginary rolling cylinder (cone, etc.) that the toothed
gear may be considered to replace.
- Pitch circle: A right section oI the pitch surIace.
- Addendum circle: A circle bounding the ends oI the teeth, in a right section oI the gear.
- Root (or dedendum) circle: The circle bounding the spaces between the teeth, in a right
section oI the gear.
- Addendum: The radial distance between the pitch circle and the addendum circle.
- Dedendum: The radial distance between the pitch circle and the root circle.
- Clearance: The diIIerence between the dedendum oI one gear and the addendum oI the
mating gear.
- lank of a tooth: The part oI the tooth surIace lying inside the pitch surIace.
- Circular thickness (also called the tooth thickness): The thickness oI the tooth
measured on the pitch circle. It is the length oI an arc and not the length oI a straight line.
- Tooth space: The distance between adjacent teeth measured on the pitch circle.
- acklash: The diIIerence between the circle thickness oI one gear and the tooth space oI
the mating gear.
- Circular pitch p: The width oI a tooth and a space, measured on the pitch circle.
- Diametral pitch P: The number oI teeth oI a gear per inch oI its pitch diameter. A
toothed gear must have an integral number oI teeth. The circular pitch, thereIore, equals
the pitch circumIerence divided by the number oI teeth. The diametral pitch is, by
deIinition, the number oI teeth divided by the pitch diameter. That is,
N
D
p
x
= and
D
N
P = ence x = pP
Where;
p circular pitch N number oI teeth
P diametral pitch D pitch diameter
That is, the product oI the diametral pitch and the circular pitch equals .
- Module m: Pitch diameter divided by number oI teeth. The pitch diameter is usually
speciIied in inches or millimeters; in the Iormer case the module is the inverse oI
diametral pitch.
- Pinion: The smaller oI any pair oI mating gears. The larger oI the pair is called simply
the gear.
- 'elocity ratio: The ratio oI the number oI revolutions oI the driving (or input) gear to the
number oI revolutions oI the driven (or output) gear, in a unit oI time.
- Pitch point: The point oI tangency oI the pitch circles oI a pair oI mating gears.
- Pressure angle : The angle between the common normal at the point oI tooth contact
and the common tangent to the pitch circles. It is also the angle between the line oI action
and the common tangent.
1.4 Gear Ratio

Gear ratio 3 is deIined as ratio oI speed oI driven gear with the speed oI driver gear.

onsider a gear set below;

:re : Cear set

When two gear mate eIIiciently at point A, the vel4cty, ; 4f b4th ear are the same.

Thus;
2 1
; ; ; = =
with
2
D
; =

Then Irom
2 2
2 2 1 1
D D
= will produce
1
2
2
1
D
D

=
Where
1
speed oI driver gear

2
speed oI driven gear
D
1
pitch diameter oI driver gear

D
2
pitch diameter oI driven gear

ence, gear ratio, n;

1
2
2
1
2
1
1
2

= = = =
N
N
D
D

3

Where N
1
number teeth oI driver gear
N
2
number teeth oI driven gear
1
angular acceleration oI driver gear

2
angular acceleration oI driven gear



Driver gear
Driven gear
1.5 Gear Train

Gear trains consist oI two or more gears Ior the purpose oI transmitting motion Irom one
axis to another.

Simple Gear Train is the most common oI the gear train is the gear pair connecting
parallel shaIts. The teeth oI this type can be spur, helical or herringbone. The angular velocity is
simply the reverse oI the tooth ratio. The main limitation oI a simple gear train is that the
maximum speed change ratio is 10:1. or larger ratio, large sizes oI gear trains are required; this
may result in an imbalance oI strength and wear capacities oI the end gears.

The sprockets and chain in the bicycle is an example oI simple gear train. When the
paddle is pushed, the Iront gear is turned and that meshes with the links in the chain. The chain
moves and meshes with the links in the rear gear that is attached to the rear wheel. This enables
the bicycle to move.

Compound Gear Train is used Ior large velocities, compound arrangement is preIerred.
Two keys are keyed to a single shaIt. A double reduction train can be arranged to have its input
and output shaIts in a line, by choosing equal center distance Ior gears and pinions.

Gear trains are used in representing the phases oI moon on a watch or clock dial. It is also
used Ior driving a conventional two-disk lunar phase display oII the day-oI-the-week shaIt oI the
calendar.



:re 7 (a) Smple ear tra3 (b) C4mp4:3/ ear tra3

When a gear train is complex (consist oI many gear sets), it is important Ior the designer
to identiIy the rotation oI the driver and the Iinal driven gear respectively. owever, there is a
simple Iormula to determine the rotation oI each successive gear in a gear train.



:re 8: etw4rk ear sh4rt

A ear trai3 may have several drivers and several driven gears. When gear A turns once
clockwise, gear B turns 4 times counter-clockwise and gear turns once clockwise. ence gear
B does not change the speed oI Irom what it would have been iI geared directly to gear A, but
it changes its direction Irom counterclockwise to clockwise.









:re 9: O// 3:mber 4f mat3 ear

'or an ODD number oI mating gears, the rotation oI Driven gear is the SAME as Driver Gear.








:re 1: Eve3 3:mber 4f mat3 ear

'or an EJE number oI mating gears, the rotation oI Driven gear is REJERSE oI Driver
Gear.

Another classiIication oI gear train is called Reverted Gear Train and Epicyclic Gear Train.



1.6 Gear Efficiency

Gear eIIiciency is deIined as the ratio oI Output Power Irom Driven Gear to the Input
Power Irom Driver Gear. Gear eIIiciency measures how eIIicient a gear system is to transmit
power. igh value oI gear eIIiciency reIlects a more eIIicient gear system. Power loss in a gear
system may come Irom sources like Iriction, slip, backlash and so on.
rom Power, % P = , then

Gear EIIiciency, 3
%
%
%
%
P
P
G
1
2
1 1
2 2
1
2
2 1 ,
= = =

g

Where
1
P Input power Irom driver gear

2
P Output power Irom driven gear
3 Gear ratio

II the 0 . 1 =
G
g , thus the torque at driver gear
1
% is;
2 1
3% % =
II the 0 . 1 =
G
g , thus the torque at driver gear
1
% is;
2 1 ,
2
1

=
G
3%
%
g





1.7 Power Transmission in a Gear Train System

In a gear train system, power loss normally happen in the bearing and gear due to Iriction
and loading imposed on it and also power loss in overcoming shaIt inertia. onsider a gear train
consists oI two sets oI gear reducing arrangement. A motor is attached to the system with
m
I is
the moment oI inertia oI motor shaIt,
%
I is moment oI inertia oI middle shaIt and
G
I is the
moment oI inertia oI hoist which acts as the load oI the system. Gear ratio and gear eIIiciency oI
gear set 1-2 is
2 / 1
3 and
2 / 1 G
g , between gear set 3-4 is
4 / 3
3 and
4 / 3 G
g respectively. Let;

m
% Torque oI motor
G
% Torque oI hoist

% riction torque at bearing X

Draw the Iree body diagram and using ewton Second Law,

= I %


:re 11: ree b4/y /aram

Assume clockwise direction as positive value.

4r (A)

m m m
I % % =
1
........................ (1)

4r (B)

% %
I % % =
3 2
......................... (2)

Since there is gear mating between gear 1 and 2, thus, must include in the analysis its own gear
ratio and gear eIIiciency, and relate it to the inertia oI middle shaIt,
%
I .
Previously,
2 / 1
1
2
2 / 1
3
%
%
G
= g , thus it Iollows that

2 / 1
1 2 / 1
2
3
%
%
G
g
= ............................... (3)

4r (C)

G G G
I % % % =
4
............................. (4)
also
4 / 3
4 / 3 3
4
3
%
%
G
g
= ..............................(5)



Hoist
Using power, , % P = power transIer to each gear component is;

a) !4wer tra3sfer by the m4t4r
m m m
% P =
b) !4wer at ear 1

m m m m m
I % % P = =
1 1

c) !4wer at ear 2
2 / 1 1 2 G
P P g =
/) !4wer at ear 3

% % % %
I % % P = =
2 3 3

e) !4wer at ear 4
4 / 3 3 4 G
P P g =
f) !4wer at h4st

G G G G G G
I % % % P = =
4

) Overall p4wer tra3sfer effce3cy,

g

m
G

P
P
= g
Thus iI Iriction torque,

% eIIect is neglected,
This concludes that
4 / 3 2 / 1 G G
%
G
m
%
m
G

P
P
P
P
P
P
g g g - =

'
+

'

'
+

'

= =
Also;
4 / 3 2 / 1
3 3
%
%
m
G

= g


1.8 Equivalent Moment of Inertia,
equi;
I

onsider a simple gear system as igure below. In order Ior the driver gear A to start
rotate, it must have enough torque to overcome its own inertia,

I Iirst, and then another

additional torque to start accelerate the driver gear B. owever, to relate torque with the gear
parameter, inertia term will be taken into account. or a simple gear system, the solution is
straightIorward, but when it comes to complex gear train design, it is useIul to simpliIy / group
together all inertia term in the system into a single compact inertia expression. The inertia term
oI each moving gear parts will be reIerred to a single part in the system, normally at motor side.

:re 12: Eq:vale3t m4me3t 4f 3erta

1. Torque at B to overcome

I


I % =
ReIer

to gear A side. Use gear ratio,

= =
Thus,

3 I % =

2. Gear eIIiciency is related to power and thus torque oI the mating gears, thus

G
%
3 %
P
P
= = g

3. ThereIore, torque at A, to accelerate

I


G

G

G

G

3 I 3 3 I
3
I 3 %
%
g

g
2
= = = =

4. ThereIore total torque at A to accelerate

I and

I is

%%
% I % =

%%
3 I
I %
g

|

=
2
, Or in general Iorm,
equi; %%
I % = (reIerred to motor side)
Thus

'
+

'

=
G

equi;
3 I
I I
g
2


The derivation oI
equi;
I oI this simple gear system can be extended to a double set oI gear
reducing problem as in section 1.7. By neglecting the Iriction torque eIIect,

% , thus,

) )( (
) ( ) ( ) (
4 / 3 , 2 / 1 ,
2
4 / 3
2
2 / 1
2 / 1 ,
2
2 / 1
G G
G
G
%
m equi;
3 3 I 3 I
I I
g g g
=



Driven gear Driver gear

A
1.9 Gear Train Applications (Solved Problem)

Example 1(1ake3 fr4m R4sla3, Che' Abas, Y:3:s (21), U1M)

A motor is accelerating a 250 kg load with acceleration oI 1.2 m/s
2
through a gear system as
shown below. The rope that carries the load are encircled on a hoist with diameter 1.2m.Gear Ior
the hoist`s shaIt has 200 teeth, gear Ior motor shaIt has 20 teeth. Gear eIIiciency is 90. Mass
and radius oI gyration oI each shaIt is as below;

Mass (kg) Radius oI gyration (mm)
Motor shaIt 250 100
oist shaIt 1100 500

alculate the torque oI the motor needed to bring up the load with acceleration 1.2 m/s
2
. eglect
Iriction eIIect.

:re 13: Cear system attache/ t4 h4st

S4l:t43

Total torque at motor to bring up load

2 1 total
% % % =
Where
1
% Torque to overcome equivalent inertia (reIer to motor side).

2
% Torque to accelerate the load through gear system

a) C43s/er f4r
1
%
rom
G
G
equi;
3 I
I I
g
2
=
Thus

I Motor shaIt inertia

5 . 2 1 . 0 250
2 2
= = = mr I

kgm
2


G
I oist shaIt inertia
275 5 . 0 1100
2
= =
G
I kgm
2

Dia 1.2 m
Hoist
Gear ratio, 1 . 0
200
20
2
1
= = =
N
N
3
Put into

55 . 5
9 . 0
1 . 0 275
5 . 2
2
=

=
equi;
I kgm
2

Acceleration oI hoist,
G G G
r a =
Thus 2
6 . 0
2 . 1
= =
G
rad/s
rom the gear ratio, angular acceleration oI motor, 20
1 . 0
2
= = =
3
G
m

rad/s
ow torque due to equivalent inertia,
m equi;
I % =
1

1 . 111 ) 20 ( 55 . 5
1
= =

% m.

b) C43s/er f4r
2
%

rom ewton 2
nd
Law,

= ma F

N F
a F
a F
5 . 2752
2 . 1 81 . 9 250 250
250 250
=
= =
=


Then, torque at hoist
5 . 1651 6 . 0 5 . 2752 = = = Fr %
G
m
But due to gear eIIiciency (since the hoist shaIt is connected to the gear system), torque to
accelerate the load,


5 . 183
9 . 0
1 . 0 5 . 1651
2 / 1 ,
2 / 1
2
= = =
G
G

3 %
%
g
m


Then total torque reIerred to motor side is;

5 . 183 1 . 111
2 1
=
=
total
total
%
% % %

6 . 294 =
total
% Nm




:re 14: ree b4/y /aram 4f h4st a3/ l4a/


250g
a
T
G
250 kg
r
oist
Example 2(1ake3 fr4m R4sla3, Che' Abas, Y:3:s, (21), U1M)

igure 12 below shows a motor used to accelerate a hoist through two sets oI gear reducing
system. Moment oI inertia Ior the motor shaIt is 5 kgm
2
, middle shaIt is 40 kgm
2
and hoist shaIt
is 500 kgm
2.
Gear ratio Ior gear set 1 and 2 is 1/3.5 while Ior gear set 3 and 4 is 1/ 4.5. Gear
eIIiciency Ior both gear set is 90. By neglecting the Iriction eIIect, Iind the total torque
required by the motor to accelerate the load oI 6 tones at acceleration oI 0.4 m/s
2
.


:re 15: L4a/3 system 43 ear


S4l:t43
Given that

I 5 kgm
2
, 40 =
%
I kgm
2
,
G
I 500 kgm
2
,
5 . 3
1
2 / 1
= 3 ,
5 . 4
1
4 / 3
= 3 , 9 . 0 =
G
g
eglect Iriction eIIect.

Total torque required Ior the motor is

2 1 total
% % % =
Where
1
% Torque to overcome equivalent inertia (reIer to motor side).

2
% Torque to accelerate the load through gear system

a) C43s/er f4r
1
%
Recall that
m equi;
I % =
1
, but Ior two set oI gear system with Iriction eIIect is neglected,

) )( (
) ( ) ( ) (
4 / 3 , 2 / 1 ,
2
4 / 3
2
2 / 1
2 / 1 ,
2
2 / 1
G G
G
G
%
m equi;
3 3 I 3 I
I I
g g g
=
Nm I
equi;
116 . 11
) 9 . 0 )( 9 . 0 (
)
5 . 4
1
( )
5 . 3
1
( 500
9 . 0
)
5 . 3
1
( 40
5
2 2 2
= =


Diameter 1.2 m
Hoist
rom question, given that, 4 . 0 =
G
a m/s
2
, thus;

6 . 0
4 . 0
= =
G
G
G
r
a

6667 . 0 =
G
rad/s
2
rom gear ratio,
75 . 15
1
5 . 3
1
5 . 4
1
= - = - =
m
%
%
G
m
G

Thus,
G m
75 . 15 =
5 . 10 6667 . 0 75 . 15 = =
m
rad/s
2

Thus, 5 . 10 116 . 11
1
= =
m equi; m
I %
72 . 116
1
=

% m.



It is known that
G
% reIerred to motor side will be denoted as
2
% and is related by

4 / 3 , 2 / 1 ,
4 / 3 2 / 1
2
G G
G

3 3 %
%
g g
=



6 . 889
9 . 0 9 . 0
5 . 4
1
5 . 3
1
349 . 11
2
= =

% m
Thus total torque at motor required is

2 1 total
% % % =
6 . 889 72 . 116 =
total
%
32 . 1006 =
total
% Nm.


4500g

1
a
4500 kg
oist
6000g
6000 kg

2
a
:re 1: L4a/3 BD
b) C43s/er f4r
2
% 3 :re 13;
rom ewton 2
nd
Law, ma F =

a F 4500 4500
1
=
42345 41 . 9 4500 4500
1
= = = a F
a F 6000 6000
2
=
61260 6000
2
= = a F
Resultant torque at hoist
915 . 18
1 2
= = F F F
R
k
Thus torque at hoist
349 . 11 6 . 0 915 . 18 = = =
G R G
r F % k

Example 3(1ake3 fr4m R4sla3, Che' Abas, Y:3:s, (21), U1M)

:re 17: Cear wth 3cl3e/ l4a/3


igure 14 above shows a motor accelerating a hoist with diameter 0.9m, through two sets
oI gear reducing system. Gear ratio Ior gear 1 and 2 is 1/3.5 while Ior gear 3 and 4 is 1/ 4.5.
Moment oI inertia Ior the motor shaIt is 5 kgm
2
, middle shaIt is 20 kgm
2
and hoist shaIt is 100
kgm
2
. The rope that is encircled on the hoist must be capable to liIt up a load oI 5 tones that is
sliding on a 1 in 50 slope. riction on the slope is 1000 and the total torque at motor required to
raise the load is 1500. Use gear eIIiciency oI 90 Ior both gear set. II there is Iriction torque
eIIect on the middle shaIt, 150 =

% m and at hoist shaIt is 800 =

% m. alculate the
acceleration oI the load at the above condition.


S4l:t43

or the overall gear ratio,

75 . 15
1
5 . 4
1
5 . 3
1
4 / 3 2 / 1 0
= - = = 3 3 3
Total torque required by motor to raise load

3 2 1 total
% % % % =
Where
1
% Torque to overcome equivalent inertia (reIer to motor side).

2
% Torque to accelerate the load through gear system
=
3
% Total torque to overcome Iriction eIIect.


a) C43s/er f4r
1
%
Previously,
m equi;
I % =
1

or double set oI gear reducing system,

) )( (
) ( ) ( ) (
4 / 3 , 2 / 1 ,
2
4 / 3
2
2 / 1
2 / 1 ,
2
2 / 1
G G
G
G
%
m equi;
3 3 I 3 I
I I
g g g
=
312 . 7
) 9 . 0 )( 9 . 0 (
)
5 . 4
1
( )
5 . 3
1
( 100
9 . 0
)
5 . 3
1
( 20
5
2 2 2
= =
equi;
I kgm
2

Dia 0.9 m
Hoist
rom r a = , thus,
45 . 0
a
r
a
G
G
= =
Also Irom gear ratio,
75 . 15
1
=
m
G

, thus, a
a
G m
35
45 . 0
75 . 15 75 . 15 =
'
+

'

= =
Thus a %

35 312 . 7
1
= a 92 . 255 = m

b) C43s/er f4r
2
% as 3 :re 15;



c) C43s/er f4r
3
%

riction eIIect can be grouped together to Iorm
3
% where;

4 / 3 , 2 / 1 ,
4 / 3 2 / 1
2 / 1 ,
2 / 1
3
G G
Y
G

3 3 % 3 %
%
g g g
=
33 . 110
9 . 0
5 . 4
1
5 . 3
1
800
9 . 0
5 . 3
1
150
2
3
=

'
+

'

'
+

'

'
+

'

% m


rom
3 2 1 total
% % % % =
33 . 110 876 . 69 4 . 176 92 . 255 1500 = a a
Thus 1 . 3 = a m/s
2



R
F
5000g
1
F
0
Mg sin0
r

1
hoist
:re 18: 3cl3e/ l4a/3
rom

= , ma F
ma m F F
R
= sin
1


50
1
81 . 9 5000 1000 5000
1
= a F
81 . 9 5000
1
= a F
Thus, torque to accelerate hoist
45 . 0 81 . 9 5000
1
= = a r F %
G

45 . 891 2250 = a %
G
m
Use gear eIIiciency to relate
G
% with
2
%

4 / 3 , 2 / 1 ,
4 / 3 2 / 1
2
G G
G

3 3 %
%
g g
=
876 . 69 4 . 176
2
= a %

m
1.10 'ehicle Dynamics

:re 19: Jehcle /y3amcs

or a moving vehicle as in igure 16, some oI the Iorces acting on it are;
- riction due to the vehicle`s body (aerodynamic Iriction), R
- orces due to Iriction Irom the engine to the wheel such as Iriction in bearing, shaIt,
clutch and gears,
IN%
R .
- orces due the acceleration oI the vehicle, which is called tractive Iorce,
%
F considering
no slip between the wheel and the road surIace.
We can estimate the speed oI the moving vehicle by considering the speed oI the wheel itselI.

Vehicle speed,
'
+

'

=
2
D
;
r



Example 1 (S4lve/ !r4blem)

Total mass Ior a two wheeled motorcycle including passenger is 190 kg. The engine produce
torque oI 25 m at speed oI 1800 RPM. Moment oI inertia Ior each wheel is 1.4 kgm
2
while Ior
other rotating parts in the engine is considered as 0.15 kgm
2
. The wheel`s eIIective diameter is
610 mm. II the motorcycle is moving on a road with a speed 23 km/hr at second gear, Iind
(i) Gear ratio Ior the second gear
(ii) Acceleration at speed 23 km/hr
Assume wind Iriction is 200 and gear eIIiciency is 90.

S4l:t43

Given that;

m190 kg,
total
% 25 m at N 1800 PM,
R
I 1.4 kgm
2
,
int
I 0.15 kgm
2
, D610 mm,

II ; 23 km/hr at 2
nd
gear, with R 200 ,
G
g 90.


D/2

r
F
%
R
;
Wheel
S:rface
1
st
Step - Draw ree B4/y Daram


:re 2: ree b4/y /aram

2
3/
Step
Total torque at engine,
total
%

2 1 total
% % % =
Where
1
% Torque due to equivalent inertia oI rotating parts in the engine.(reIerred to engine
side).

2
% Torque to accelerate the wheel.

3
r/
Step
onvert all measurement to SI standard.

Engine speed,

5 . 188
60
1800 2
60
2
int
= = =
x xN
rad/s
Wheel speed,

3889 . 6
3600
1000 23
/ 23 = = = hr km ; m/s

4
th
Step- Determ3e
1
%
In order to Iind gear ratio Ior second gear,


9
1
5 . 188
305 . 0
3889 . 6
int
= = =

3
R
(Where
2 D
;

R
= )

1h:s ear rat4 f4r sec43/ ear s
9
1
= 3

Equivalent moment oI inertia is

G
R
equi;
3 I
I I
g
2
int
=


1884 . 0
9 . 0
9
1
4 . 1 2
15 . 0
2
=
-
=
equi;
I kgm
2

In order to Iind
int
, use
R
and gear ratio
Engine
Gear system
Wheel

I
int
I
R

2 D
a
R
=



a
a
3
R
508 . 29
9
1
305 . 0
int
= = =

rad/s
2

Thus, a I %
equi;
508 . 29 1884 . 0
int 1
= =
a %

559 . 5
1
= m.


5
th
Step - Determ3e
2
% as 3 :re 18;


:re 21: /y3amc f4rce 43 the m4t4rcycle

rom

= , ma F
ma R F
%
=
a F
%
190 200 =


Total torque at wheel,
305 . 0 190 200 a r F %
% R
= =
a %
R
95 . 57 61 =

ReIer
R
% to motor side using gear eIIiciency


9 . 0
9
1
95 . 57 61
2
a
3 %
%
G
R

= =
g

) 154 . 7 35 . 7 (
2
a %

= m

Thus, total torque at engine
a a %
total
154 . 7 35 . 7 559 . 5 =

The acceleration at that speed is;
By solving the equation Ior the total torque above, thus

374 . 1 = a m/s
2

m190 kg

T
R
a
PROEMS-GEAR SYSTEM


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








2. igure below showed a motor used to accelerate a hoist through a set oI gear system.
Gear Ior the hoist`s shaIt has 200 teeth and gear Ior motor shaIt has 20 teeth. Gear
eIIiciency is 90 . Moment oI inertia Ior the motor shaIt is 2.5 kgm and hoist shaIt is
275 kgm. The rope that carries a 250 kg load are encircle on hoist with diameter 1.2 m.
By neglecting the Iriction, Iind
a) gear ratio,
b) equivalent moment inertia Ior a gear system,
c) the total torque required by the motor to accelerate the load at acceleration oI 1.0
m/s.

Motor
Rope
Set oI gear
Load
oist
22
3 The diagram above shows a gear train composed oI three gears. Gear A revolves at 60
revs/min in a clockwise direction.



GEAR A GEAR B GEAR
20 TEET 60 TEET 10 TEET
a) What is the output in revolutions per minute at Gear
b) In what direction does Gear revolve
| 120 rpm, clockwise |