Gears & Drives

MEC1010 Design and Manufacturing 1 Dr. Simon Smith

Gears & Drives

Massive subject, for your wind turbines consider: How to transmit the turbine power to the generator Gearing (speed / torque changes) to match the speed of the turbine to the speed required at the generator Friction losing power between the turbine and the generator

Gears & Drives

Transmission of power from source to load

Gears & Drives

Power source should match load
Engine size to weight of vehicle / performance required Turbine size to generator Consider power losses (friction)

Drive system should be sized appropriately

Clutches, drive shafts, belts Power / torque / speed

DRIVE SHAFTS

PROP SHAFT

UNIVERSAL JOINTS GEARBOX

GEARBOX

DRIVE SHAFT DRIVE SHAFT

Transmissions
In British English the term transmission refers to the whole drive train
Gearbox, clutch, prop shaft, differential, drive shafts, universal joints, belts, chains, etc

In American English the term transmission refers only to the gearbox

Commercial Wind Turbine

Spur Gears
Simplest of gears Teeth parallel to shaft Rotate on two parallel shafts

Direction of Rotation Changes

Gearing
Ratio of teeth 10:28 speed reducing 28:10 speed increasing Fixed ratio

Gears
Can vary in:
Diameter Width No. of teeth Material Tooth form Gear form

Where have you seen spur gears?

Where have you seen spur gears?

Multiple designs this year will probably use small spur gears

Bevel Gears
Allows angle of drive to be changed Gearing ratio can be changed, although this is 1:1

Where have you seen bevel gears?

Where have you seen bevel gears?

And some designs this year will probably use bevel gears

Linear (Rack & Pinion) Gears

Rack can move relative to shaft
Steering on a car

Shaft can move along rack

Positional changes Some swing bridges

Pinion Rack

Internal / External Gears

Relative position changes Gearing Rotation
Example might be a food mixer

Worm Gears
Screw

Worm wheel

Large gear ratio

Often non-reversible & self-locking

Helical Gears
Teeth set at an angle to axis of rotation Advantages
Smoother Quieter High speed Large power transmission Direction change possible

Disadvantages
Expense More sliding friction Axial thrust

Belt Drives
Simple Quiet Smooth Can tolerate load changes No lubrication required

Belt Drives
Cheap Can cope with misalignment Can be very efficient 95% Can be very inefficient too! Can provide gearing

Belt must be tensioned correctly

Belt must be tensioned correctly

Minimize misalignment

Widely varying applications

Can be used as a clutch

Belt Types

Timing Belt / Cambelt

Toothed belt High speed Reliable Cheap Accurate timing

Some designs this year will probably use belt drives

Chain Drive
Strong Less prone to slipping Flexible Usually narrower than a belt for same power transmission Many applications, but often used in transport & vehicles

Chain Drive
Can be cheap Can provide gearing Can cope with some misalignment As with belt drives Tension correctly Align correctly

Chain Drive

Chain drive in biscuit manufacture

This year we will probably see chain drives

Flexible Drives
Power can be transmitted through large angles Minimal assembly Can be low friction Can accommodate load changes

Flexible Couplings
Allow power transmission Allow for misalignment Absorb shock loads Can protect against overloads Can be torque limiting in some cases

Flexible Couplings

Your Design WILL have at least 1

FLEXIBLE COUPLING

Examples of drive systems

Petrol engine
Shaft drive Bevel gear Cutting head

Many Ways to Transmit Power

Straight shaft drive

Bent shaft drive

Wind Turbines

Straight shaft connection Gearing is 1:1 Should be low friction Wind shadow?

Wind Turbines

Parallel shaft connection Gearing could now be altered Probably more friction

Wind Turbines
Perpendicular shafts Gearing could be altered Friction likely to increase Alignment an issue

Commercial Wind Turbine

Commercial Wind Turbines

What WILL Your Design Have?

Blades Drive system Bearings Flexible coupling Generator

What Might Your Design Have?

Rigid coupling(s) More bearings Another flexible coupling Gearing
Belt, Chain, Spur, Bevel, etc.