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Structure
10.1 Introduction
Objectives
Gear Trains
10.2 Types of Gear Trains 10.3 Simple Gear Train 10.4 Compound Gear Train 10.5 Epicyclic Gear Train
10.5.1 10.5.2 10.5.3 10.5.4 Algebraic Method Tabular Method Torque on Gears in Epicyclic Gear Train Special Purpose Epicyclic Gear Trains
10.1 INTRODUCTION
In this unit, the analysis of gears was presented to you. Involute profile is universally used for gears but they have problem of interference which can be avoided by using any one of the several methods proposed in the last unit. Here, you will be explained gear trains. A gear train is a combination of gears that is used for transmitting motion from one shaft to another shaft. It may include various types of gears depending on the location of input and output shafts. There are various types of gear trains which are used in practice. A gear train can be designed to provide smaller gear ratio to larger gear ratios depending on the requirement.
Objectives
After studying this unit, you should be able to understand various types of gear trains, determine gear ratio for different type of gear trains, determine torque in epicyclic gear trains, and describe and explain working of epicyclic gear box, cyclometer and differential gear.
Let N1, N2 be speed in rpm for gears 1 and 2. Referring Figure 10.1 and as it has been explained in Unit 9. The two meshing gears in external meshing rotate in opposite sense whereas in internal meshing they rotate in same sense. In simple gear train, there can be more than two gears also as shown in Figure 10.2.
1 2 3 4
Let N1, N2, N3, . . . be speed in rpm of gears 1, 2, 3, . . . etc., and t1, t2, t3, . . . be number of teeth of respective gears 1, 2, 3, . . . , etc. In this gear train, gear 1 is input gear, gear 4 is output gear and gears 2, 3 are intermediate gears. The gear ratio of the gear train is give by Gear Ratio =
N N1 N N = 1 2 3 N 4 N 2 N3 N 4
N N1 t2 N 2 t3 t = ; = and 3 = 4 N 2 t1 N3 t2 N 4 t3 N1 t2 t3 t4 t4 = = N 4 t1 t2 t3 t1
Therefore,
This expression indicates that the intermediate gears have no effect on gear ratio. These intermediate gears fill the space between input and output gears. 64
SAQ 1
(a) (b) There are six gears meshing externally and input gear is rotating in clockwise sense. Determine sense of rotation of the output gear. Determine sense of rotation of output gear in relation to input gear if a simple gear train has four gears in which gears 2 and 3 mesh internally whereas other gears have external meshing.
Gear Trains
Let N1, N2, N3, . . . be speed in rpm of gears 1, 2, 3, . . . , etc. and t1, t2, t3, . . . , etc. be number of teeth of respective gears 1, 2, 3, . . . , etc. Gear Ratio =
N N1 N N N = 1 2 = 1 3 N4 N2 N4 N2 N4 t2 t4 t1 t3
Therefore, unlike simple gear train the gear ratio is contributed by all the gears.
Determine number of teeth on various gears. The minimum number of teeth on the pinion should not be less than 18. The gear box should have minimum size and variation in the ratios should be as small as possible. Solution The gears in the gear box are shown in Figure 10.4 below :
Engine Shaft Input Shaft Main Splined Shaft (Output Shaft)
Dog Clutch C A E
D B Lay Shaft
For providing first gear ratio, gear A meshes with gear B and gear H meshes with gear G.
t B tG t A tH t B tG t A tH
t B tG = = 4.0 = 2.0 t A tH
tA = 20 teeth
B
tH = 20 and tG = 20 2 = 40 teeth
tB = 2 20 = 40 teeth
. . . (10.1) . . . (10.2)
For second gear, gear A meshes with gear B and gear E meshes with gear F.
NA = 2.24 NG N A NF = 2.24 NB NE
or, 66
tB tE = 2.24 t A tF 2 tF = 2.24 tG
. . . (10.3)
Gear Trains
or,
or,
t E 2.24 = = 1.12 2 tF
or, or,
tF =
60 = 28.3 2.12
t E = 60 t F
t E = 60 28.3 = 31.7
Since number of teeth have to be in full number. Therefore, tF can be either 28 or 29 and tE can be either 31 or 32. If tF = 28 and tE = 32. Second gear ratio = If tF = 29 and tE = 31. Second gear ratio =
t A t E 40 32 = = 2.286 t B t F 20 28
40 31 = 2.138 20 29
From these two values of gear ratios, 2.286 is closer to 2.24 than 2.138. For third gear, gear A meshes with gear B and gear D meshes with gear C.
or,
or,
or,
or,
tC 1.38 = = 0.69 tD 2
tD =
60 = 35.503 1.69
67
tC = 60 t D = 60 35.503 = 24.497
or
tC = 25 and tD = 35
t B tC 40 25 = = 1.4286 t A t D 20 35
40 24 = 1.333 20 36
tD = 36
Since, 1.333 is closer to 1.38 then 1.4286, therefore, tC = 24 and The top gear requires direct connection between input shaft and output shaft. For reverse gear an idler gear shall be required to change the sense of rotation. A gear is provided on the main or output shaft and a pinion is provided on the lay or counter shaft. These two should have some clearance and should not mesh each other. An idler gear is brought from the side where it rests to mesh these two gears. This idler gear can have any number of teeth depending on space available because its number of teeth shall not affect the gear ratio. To provide sufficient clearance between pinion and gear of reverse gear, let number of teeth on pinion be 18 and number of teeth on gear be 38. Reverse gear ratio =
40 38 = 4.22 20 18
Gear
+ +
Idler Gear Pinion
Gear Trains
P
Since the operation of an epicyclic gear train is different from other gear trains, there are special methods to analyse this gear train. The methods are as follows : (a) (b) Algebraic Method, and Tabular Method.
. . . (10.5)
where, N s , N sa , and N a are speeds of respective members in rpm. From Eq. (10.5)
N sa = N s N a
. . . (10.6) . . . (10.7)
Similarly,
N pa = N a N p
N sa N pa
Since,
N s Na Na N p tp ts
;
. . . (10.8)
N sa N pa tp ts =
or,
Ns Na N p Na
. . . (10.9)
In Eq. (10.9), left hand side is the train value. By substituting known quantities, unknown quantity can be determined.
69
1.
Arm a is fixed and gear S is given one CCW rotation (+ 1) Arm a is fixed and gear S is given + x rotations (Multiply I row by x) Arm is given y rotations in sense of + x rotations of gear S. (Add y to II row)
+1
t s tp t s x tp
2.
+x
3.
x+y
t y s x tp
After completing this table, the given conditions are applied to determine x and y. Once x, and y are known, the revolutions of other elements can be determined as these are expressed in x and y in III row in the table. For 1 CCW rotation of arm and gear S fixed. y = +1 x + y = 0 x = 1
ts t x = 1 s ( 1) tp tp
80 =3 40
80 (1) = 3 40
The gear shall make 3 rotations on its axis in CW sense. Had it been a simple gear train gear P shall make 2 rotations for one rotation of gear S.
SAQ 2
(a) (b) How many rotations gear P shall make for epicyclic gear train shown in Figure 10.6 for I CW rotations of arm and one CCW rotation of gear S? How many rotations gear P shall make for epicyclic gear train shown in Figure 10.6 for I CW rotation of arm and I CW rotation of gear S?
Example 10.2
An epicyclic gear train known as Fergusons Paradox is shown in Figure 10.7. Gear A is fixed. Gears C and D are free to rotate on the shaft. Gears A, C and D have 100, 101 and 99 teeth respectively and they are cut from gear blanks of same diameter. The arm B is free to turn on the shaft and makes one CCW rotation. Determine the number of turns of the gears D and C.
20 T P
70
B D C A
Gear Trains
Figure 10.7
Solution
N A NB = train value C to A NC N B
Since, NA = 0 and NB = 1
B
or, or,
N A NB = train value D to A ND NB
and NB + 1
B
or, or,
1 99 1 CW. 99
Rev. of Arm B
Rev. of gear A
Rev. of gear C
Rev. of gear D
71
1.
Arm B is locked and gear A is given I CCW rotation Arm is fixed and gear A is given + x rotations Add y to II row
+1
100 101
100 99
2.
+x
100 x 101
y+
100 x 99
y+
3.
x+y
100 x 101
100 x 99
=1+
Rotations of gear D = y +
100 ( 1) 99
1 1 or CW 99 99
Same answer is obtained by both the methods. Therefore, the problem can be attempted by any one of these methods.
. . . (10.10)
. . . (10.11)
. . . (10.12)
From Eqs. (10.10) and (10.12) desired quantity can be determined. The speed of the output shaft No can be determined by tabular method or algebraic method. Therefore, from the given power and speed Ti and To can be determined. Thus, from known values of Ti, To, Ni and No value of torque on fixed gear Th can be determined.
Example 10.3
An epicyclic gear train is shown in Figure 10.8 in which gear E is fixed. Gears C and D are integrally cast and form compound gear. The teeth on each gear are mentioned in the figure. If arm A makes one revolution per second in CCW, determine the speed and direction of rotation of gears B and F.
C = 35 T B = 20 T E = 20 T F = 30 T
72
D = 15 T
Gear Trains
Figure 10.8
Solution
1.
+1
20 15
35 20 9 22 15
7 = 3
= =
140 90 14 9
2.
+x
4 3
7 x 3
14 x 9
3.
x+y
4 3
y+
7
3
14 x 9
y+
7 x+0 3 7 x=0 3
y = +1 1+ x= 3 7
3 4 + 1 = rev./second 7 7
14 14 3 x =1 9 9 7
=1+
An epicyclic gear train is shown in Figure 10.9. Gear A has 40 external teeth. Gear B has 80 internal teeth. Gears C and D have 20 and 50 external teeth, respectively and they form compound gear. Gears E and F have 20 and 40 external teeth, respectively and they also form compound gear. Gear G has 90 external teeth. Gear wheel C gears with A and B, D gears with E and F gears with G. Gear A is fixed and arm makes 100 rpm in CW direction. Determine speed and torque exerted on gear G if input torque on arm is 1000 Nm.
G B D A E F
73
Figure 10.9
Solution
Rev. of Gear G
40 5 9
Arm is locked and gear A is given + 1 rotation Multiply I row by x Add y to II row
+1
40
20
=2
0 +x
1 2
=5
20 9
2.
2x y2x
1 x 2
5x
y+5x
20 x 9
3.
x+y
1 x 2
20 x 9
Since arm rotates at 100 rpm in CW. y = 100 Since gear A is fixed, or, x+y=0 x = y = ( 100) x = 100
Speed of gear G = y
20 20 x = 100 (100) 9 9
Ti i = To o
2 N i 2 N o Ti = To 60 60
Ti N i = To N o
2900 rpm 9 1000 100 9 9000 Nm = Nm To = Therefore, 2900 29 It is the resistance torque on gear G.
Example 10.5
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A gear train is shown in Figure 10.10. The driving shaft A rotates at 270 rpm in CCW (viewed from left). The casing acts as an internal gear (annular wheel) and it
is fixed. Gears E and H are keyed to the vertical shaft on which gear F can rotate freely. Gears K and L form compound gear and they are rigidly connected to the pin carried by gear F. Determine speed of the output shaft B.
Gear Trains
D, 40T G, 80T B
E, 30T
F, 50T K, 20T
L, 30T
Teeth on C
Figure 10.10
Solution
or,
tC = 40 + 20 + 30 = 90
Table 10.3
Sl. No. Operation Rev. of Arm (Gear F) Rev. of Compound Gears E H +1 Rev. of Compound Gears K L Rev. of Gear C
1.
40 =2 20
2x
y 2x
( 2)
2 30 = 3 90 2 x 3 2 x 3
2.
+x
3.
x+y
2 x=0 3
75
Since, rotations of gear D is 270 rpm Therefore, rotations of gear E = or, x + y = 360
x+
x = 216 y =
The Humpages gear train is shown in Figure 10.11. The input shaft is keyed to the gear A and output shaft is keyed to the gear E. The arm B rotates freely on the output shaft and it carries compound gear C D. Gear F is fixed. If input shaft rotates at 500 rpm in the clockwise (CW) sense looking from right. Determine speed of the output shaft.
Arm B C D A Input Shaft 56 T
Output Shaft E 35 T
24 T
20 T
76 T F
Figure 10.11
1.
Arm is locked and gear A is given + 1 rotation Multiply 1 row by x Add y to 2 row
+1
20 56
20 56
20 56 56 76
20 76
20 24 76 35
2.
+x
20 56
20 x 76
20 24 x 76 35 20 24 x 76 35
3.
x+y
y+
20 56
20 76
y
Since,
20 x=0 76
Gear Trains
x + y = 500 or y = 500 x
( 500 x)
or, or, or,
20 x=0 76
20 1 + x = 500 76
x=
500 76 96
x = 395.83
20 24 x 76 35
20 24 ( 395.83) 76 35
= 32.74 or 32.74 rpm (CW) The output shaft rotates at 32.74 rpm in CW sense.
Example 10.7
A bend gear epicyclic gear train is shown in Figure 10.12. The gear A is keyed to the driving shaft and gear F is keyed to the driven shaft. Gear E is fixed. The arm G which support the inclined shaft is free to rotate about the common axis of input and output shafts. Gears B, C and D are keyed to the inclined shaft. Gears A and B have equal number of teeth. Gears A, C, D, E, and F have teeth equal to 25, 19, 18, 75 and 75, respectively. Determine gear ratio of gear train.
B D C A G
Figure 10.12
Solution
77
Sl. No. 1.
Operation
Rev. of Arm G
Rev. of Gear A 1
Rev. of Gear B 1
Rev. of Gear C
Rev. of Gear E
19 75
2. 3.
0 y
x x+y
x x+y
x x+y
19 x 75 19 x 75
Gear E is fixed,
19 x=0 75
x = (1 y )
Let driving shaft rotates by 1 turn, i.e. speed of gear A is equal to 1 or, or, or, or, x + y = 1 or
19 (1 y ) = 0 75
19 19 1 + y= 75 75
y=
19 75 19 = rotations 75 94 94
Rev. of Gear C
75 19
Rev. of Gear E
+ 75 18 19 75
18 19
2. 3.
0 y
x x+y
75 x 19
75 x 19
18 x 19
y+
75 x 19
y+
75 x 19
y+
18 x 19
Now, y =
19 19 and x + y = 0 or x = y = 94 94
18 x 19
=
Gear ratio =
1 = 94 . 1 94
19 18 19 1 + = 94 19 94 94
78
The gear train is shown in Figure 10.13. C is a star wheel which is connected to the driving shaft. It is operated by a striker fixed to the wheel of the bike and makes 1 th of a revolution for one revolution of the wheel. There are two co-axial 5 internal gears R and S of which R is fixed. The gear Q meshes with S and P meshes with R. The internal gear S makes one revolution for 1 km travelled by the bike.
R P S
Gear Trains
O2 A P Q R S C O1 B
Vehicle Differential
The gear train is shown in Figure 10.14. The purpose of the rear-axle differential is to permit the two side wheels to rotate at different speeds when automobile takes a turn. This could be possible because of two degrees of freedom of the epicyclic gear train. Gears A and B constitute final drive and provide fixed gear ratio in the vehicle. Gears E and D have equal number of teeth and they are keyed to two parts of rear axle. These two parts of axle are connected to the two side wheels. When automobile moves along a straight road, there is no relative motion between pinion C and gears D and E. The planetory pinions act as keys to transmit motion from ring gear B to the gears D and E and thereby wheels rotate at same speed. When vehicle takes a turn, the planet gear C starts rotating about their axis and two side gears D and E rotate at different speeds with one input speed. However, the average of speeds of D and E remains equal to input speed.
79
The epicyclic gear box is shown in Figure 10.15. It provides four forward speeds and one reverse speed. The two sun wheels S1 and S2 are keyed to the input shaft from the engine. There are four internal gears I1, I2, I3 and Ir. P1, P2, P3 and Pr are planet gears. B1, B2, B3 and Br are brake bands which are used to lock various internal gears. G and F provide cone clutch arrangement. For applying I gear, the brake band B1 is applied to lock annulus I1. The power is transmitted through simple epicyclic gear train consisting S1, P1 and I1.
B B B B B
For II gear, only the brake band B2 is applied so that annulus I2 is locked. The power is transmitted through the compound epicyclic gear train S2, P2, I2 and S1, P1, I1.
B
For III gear, only the brake band B3 is applied so that sun gear S3 is locked. The power is transmitted through three epicyclic gear trains S3, P3, I3; S2, P2, I2 and S1, P1, I1.
B
For top gear, cone clutch is engaged to prevent any relative motion and it will make output shaft D to rotate at same speed equal to that of input shaft E. For reverse gear, only the brake band Br is applied to lock annulus Ir.
B
I2 I3 F G
I1
Ir A P3 P2 P1 Pr
S3 S2 S1
D To Propellor Shaft
B3
B2
B1
Br
10.6 SUMMARY
A gear train is a means of power transmission from one shaft to another shaft with a positive drive. It requires less space. The gear ratio of the gear train is the ratio of speed of input shaft to speed of output shaft. There are three types of gear trains which are simple gear train, compound gear train and epicyclic gear train. Simple gear train and compound gear train have single degree of feedom whereas epicyclic gear train has two degrees of freedom. Simple gear train and compound gear train have fixed gear ratios but gear ratio for epicyclic gear train depends of constraints imposed on this gear train. An epicyclic train can by analysed by algebraic method or by tabular method. The speed of the output shaft or gear ratio can be determined by any of these methods. However, sense of rotation of the gears can be determined easily in simple gear train and compound gear train. But sense of rotation is provided by the method in epicyclic gear train in terms of negative or positive sense. The convention of sign has to be assumed while feeding the known data. This convention shall be applicable along particular axis or parallel axes only. If axes of the gears rotate as in bevel gear train, the sign convention is not applicable for inclined axes to input and output axes. For example, three externally
80
meshing gears in simple gear train result in same sense of input and output gears (Figure 10.16(a)) whereas the same number of gears provide opposite sense in bevel gear train (Figure 10.16(b)). The tangential velocity direction can be used for bevel gear train for this purpose as shown in the Figure 10.16.
Gear Trains
(b)
Algebraic Method
Tabular Method
(a) (b)
SAQ 2
80 ( 2) = 5 40
80 (0) = 1 40
81