HYBRID GEAR BOX

Table of Contents
CHAPTER 1 .............................................................................................................................................. 3
INTRODUCTION ....................................................................................................................................... 3
AIM .......................................................................................................................................................... 4
OBJECTIVE ............................................................................................................................................... 4
CHAPTER 2 .............................................................................................................................................. 5
Literature review..................................................................................................................................... 5
Introduction ............................................................................................................................................ 5
TYPES OF TRANSMISSION SYSTEM.......................................................................................................... 6
ADVANTAGES OF HYBRID DRIVETRAINS ................................................................................................. 9
DRAWBACKS OF HYBRID DRIVETRAINS .................................................................................................. 9
CHAPTER 3 ............................................................................................................................................ 10
DESCRIPTION AND SPECIFICATION COMPONENTS USED ..................................................................... 10
GEAR SPECIFICATIONS .......................................................................................................................... 15
CHAPTER 4 ............................................................................................................................................ 16
WORKING PROCEDURE: - ...................................................................................................................... 16
ELECTRONICS ........................................................................................................................................ 17
CALCULATION........................................................................................................................................ 20
TORQUE CALCULATIONS ....................................................................................................................... 23
ISOMETRIC VIEWS OF COMPONENTS DESIGNED IN THE SOFTWARE CATIA V5................................... 26
MANUFACTURING PROCESS DETAILS ................................................................................................... 27
3D PRINTING TECHNOLOGY .................................................................................................................. 27
MATERIAL PROPERTIES OF PLA ............................................................................................................. 29
CHAPTER 5 ............................................................................................................................................ 30
CONCLUSION......................................................................................................................................... 30
SCOPE FOR FUTURE IMPROVEMENTS .................................................................................................. 30
ADVANTAGES ........................................................................................................................................ 30
DISADVANTAGES................................................................................................................................... 30
REFRANCES............................................................................................................................................ 31

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List of figures
1. Manual transmission- Fig. 2.1
2. Traditional transmission- Fig. 2.2
3. Automated-manual transmission- Fig. 2.3
4. Continuously variable transmission- Fig. 2.4
5. Dual clutch transmission- Fig. 2.5
6. Tiptronic transmission- Fig. 2.6
7. Hybrid transmission- Fig. 2.7
8. Electric motor- Fig. 3.1
9. Rechargeable battery- Fig. 3.2
10. Dog clutch- Fig. 3.3
11. Screw and nut- Fig. 3.4
12. Bearing- Fig.3.5
13. Clutch stops- Fig 3.6
14. Sleeve- Fig. 3.7
15. Clutch actuators- Fig. 3.8
16. Transmission shafts- Fig. 3.9
17. Motor shaft- Fig. 3.10
18. Gears- Fig. 3.11
19. Gear arrangements- Fig. 4.1
20. Gear arrangements (2)- Fig. 4.2
21. Gear arrangements (3)- Fig. 4.3
22. Isometric views of components- Fig. 4.4
23. Creality 3D printer- Fig. 4.5
24. PLA Chemical structure- Fig. 4.6
25. Assembled view of the project- Fig. 5.1
26. 3D printing- Fig. 5.2

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HYBRID GEAR BOX

CHAPTER 1
INTRODUCTION

A lot of fuel gets wasted on road due to traffic and here comes the need for hybrid vehicles
which run on 2 different kinds of fuels. The advantages of 2 different fuels are combined to
get an eco-friendly result. This is a 3-shaft gear box having 2 input shafts and a single output
shaft, this gearbox is helpful in conservation of fuel in slow moving traffic, it uses a certain
type of gear arrangement to crank the engine when required to move at greater speeds.
The gear shifting mechanism is made seamless using a simple electro- mechanical solution,
the kinetic energy from one source is used in an efficient way to make this as eco-friendly as
possible. The biggest advantage of this gear box is that it is maintenance free and
incorporates some simple concepts of electronics to control the fuel-air mixture going to the
engine. We can integrate both the engine and the gear box using the 2 input shafts. The dog
clutch mechanism is modified to suit the needs of this gear box. This gear box is suitable for
a parallel hybrid. Since the input shafts are separate for 2 different prime movers. The basic
idea occurred because of the fuel which is being lost due to the traffic jams on a daily basis
across globe.

The basic requirements of this gear box are dual driver shafts, one from the engine and the
other from the electric motor. These 2 shafts are in constant mesh with a single driven shaft
having gears of different sizes. The locking mechanism of gears to the shaft is achieved by
the dog clutch mechanism.
The rpm (rotations per minute) of both the engine and the motor must be matched by gear
reduction to avoid mechanical losses and sudden jerks while shifting power from one prime
mover to the other. A prototype of the complete model has been built out of plastic gears
and is demonstrable by moving the dog clutch to mesh the gears on to the shaft.
The gear box’s dog clutch mechanism functions in a similar fashion to that of the gearbox of
a vehicle.
The 2 drive shafts have same sized gears on them to give a constant speed to the gears on
driven shaft, the driven shaft going out of the gear box has varying gear sizes to change the
RPM (rotations per minute). The gear box has an additional feature where the motor’s drive
shaft works between 2 different gear speeds hence giving more initial torque. The electric
cars in the market doesn’t have a gearbox because the electric motors have a high initial
torque unlike an internal combustion engine where power and torque vary with rpm of
engine.

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The gear transmission for the motor is limited to only 1 gear in the prototype, the intention
is to raise the speed of the car up to a decent level powered by a motor. The second gear
called the transition gear is meshed with both the inputs of the engine and the electric
motor. The gear specifications are the same for the gears on the drive shaft and an
intermediate transition gear and. The contact between 3 independent shafts which is
meshed by an intermediate gear produces enough energy for the engine to crank and start,
until this stage the engine will be at rest and hence saves a lot of fuel in slow speeds. After
gear 2 in the gearbox is reached the engine runs the car with the motor at rest condition.
When slowing down the speed (when downshifting the gear) a tachometer calculates the
RPM (rotations per minute) & if it falls below a particular predetermined value, now this
input is given to a micro controller which sends signals in terms of current and voltage to a
solenoid valve near the fuel tank which blocks the fuel to the engine cylinders ultimately
stopping the engine and letting the motor take the load.

AIM –
To reduce complexity in gear box of hybrid car
To produce an eco-friendly and a simple solution
This project allows us to explore power train alternatives in a hybrid car.
To try various methods of manufacturing mechanical components.

OBJECTIVE –
To fabricate a working model in order to understand the concepts behind the working of a
gearbox in a hybrid car
To learn and evolve our level of understanding by a life-sized model of a concept in our
mind.
Industry exposure and to try and implement 3D printing of mechanical components.
To contribute towards eco-friendly ways of living.

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CHAPTER 2

Literature review
Introduction:
A machine consists of a power source and a power transmission system, which provides
controlled application of the power. Often transmission refers simply to the gearbox that
uses gears and gear trains to provide speed and torque conversions in motor vehicles, the
transmission generally is connected to the engine crankshaft via a flywheel and/or clutch
and/or fluid coupling, partly because internal combustion engines cannot run below a
particular speed. The output of the transmission is transmitted via driveshaft to one or more
differentials, which in turn, drive the wheels. While a differential may also provide gear
reduction, its primary purpose is to permit the wheels at either end of an axle to rotate at
different speeds as it changes the direction of rotation from a rotating power source to
another device. Transmission is the mechanism which transmits power from engine to the
road wheels.it also provides suitable variation of the engine torque at the road wheels. This
may be a manual transmission or an automatic transmission or a hybrid transmission.

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TYPES OF TRANSMISSION SYSTEM:

1)Manual Transmission
The manual transmission transfers power from the engine to the propeller shaft. It converts
and multiplies rotational speed, allowing engine RPM to remain in its limited optimal power
range while providing a wide range of RPM to the propeller shaft; which, in turn, controls
vehicle speed.

Fig. 2.1
2)Traditional Automatic Transmission
More known as a torque converter automatic, this widely-used automatic transmission can
be found in almost every car. This transmission uses a hydraulic fluid coupling or a torque
converter to do the job of changing gears instead of a clutch. The ECU (engine control unit)
is directly connected to this mechanism to allow smooth and precise engine control of the
vehicle.

Fig. 2.2

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3)Automated-Manual Transmission
This type of automatic transmission uses a regular clutch and gear configuration, but makes
use of sensors, actuators, processors, and pneumatics to simulate manual gear use. These
types of vehicles are known for jerky engine performance at low speeds and hard
acceleration, but can get high fuel mileage over long distances.

Fig. 2.3
4)Continuously Variable Transmission
The continuously variable transmission (CVT) is a transmission in which the ratio of the
rotational speeds of two shafts, as the input shaft and output shaft of a vehicle or another
machine, can be varied continuously within a given range, providing an infinite number of
possible ratios. Using belts or pulleys instead of traditional steel gears, a continuously
variable transmission allows for seamless gear shifting with various ratios dependent on
engine speed or RPM. This allows for maximum efficiency and continuous acceleration,
which is good for fuel economy. However, engine noise can be loud.

.
Fig. 2.4
5)Dual-Clutch Transmission
A combination of an automatic and manual transmission, a dual-clutch transmission has no
torque converter. Instead, it uses two separate shafts with their own clutches for gear
changing, one for odd-numbered gears, and one for even numbered ones. Shifting to higher
and lower gears are seamless, but they can get noisy and can shift roughly after wear. The
DCT is a dry transmission that does not need the driver to change the gearbox fluid ever. It
leaves the clutches dry and wears out its frictional quality eventually.

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Fig. 2.5

6)Tiptronic Transmission
Usually used in performance or sport-oriented vehicles, and also known as “manumatic”,
the Tiptronic transmission was pioneered by Porsche in the ‘90s. It functions similarly to a
manual gearbox; however, it uses a torque converter in place of a clutch pedal. There is an
option for automatic shifting of gears and an option for the driver to override the automatic
mode for manual selection of gears. There is a built-in safety feature that prevents the
driver from damaging the gearbox through over-revving when downshifting.

Fig. 2.6

7) Parallel Hybrid System:

The parallel hybrid transmission system allows both internal combustion engine and electric
motor to deliver power to drive the wheels. Since both the internal combustion engine and
electric motor are coupled to the drive shaft of the wheels via two clutches, the propulsion
power may be supplied by internal combustion engine alone, by electric motor only or by
both internal combustion engine and electric motor. The electric motor can be used as a
generator to charge the battery by regenerative braking or absorbing power from the
internal combustion engine when its output is greater than that required to drive the
wheels.

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Fig. 2.7

ADVANTAGES OF HYBRID DRIVETRAINS:

 Both engine and electric motor directly supply torques to the driven wheels and no
energy form conversion occurs, hence energy loss is less.
 Compactness due to no need of the generator and smaller traction motor.

DRAWBACKS OF HYBRID DRIVETRAINS:

 mechanical coupling between the engines and the driven wheels, thus the engine
operating points cannot be fixed in a narrow speed region.
 The mechanical configuration and the control strategy are complex

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CHAPTER 3
DESCRIPTION AND SPECIFICATION COMPONENTS USED
1. Electric motor -
Specifications and Features: -
RPM: 300.
Operating Voltage: 12V DC
Gearbox: Attached Plastic (spur)Gearbox
Shaft diameter: 6mm with internal hole
Torque: 2 kg-cm
No-load current = 60 mA (Max)
Load current = 300 mA (Max).

Fig. 3.1

2.Rechargable lead acid battery-

Specification and features of battery: -
Voltage 12V
Battery Capacity 1.3Ah
External Height 53mm

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External Width 45mm

External Depth 96.5mm

Fig. 3.2

3.Dog clutch-
Description: -
A dog clutch is a type of clutch that couples two rotating shafts or other rotating
components not by friction but by interference. The two parts of the clutch are designed
such that one will push the other, causing both to rotate at the same speed and will never
slip.

Fig. 3.3
4.screw and nut-

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Description: -
Screw and nut are used to bind the input shaft and electric motor shaft.

Fig. 3.4

5.bearings-
Description: -
A bearing is a machine element that constrains relative motion to only the desired motion,
and reduces friction between moving parts.

Fig. 3.5
6.clutch stops-
Description: -

Fig. 3.6
7.sleeve ring bearing-
Description: -

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sleeve bearings (also referred to as bushings or journal bearings) are used to constrain,
guide or reduce friction in rotary or linear applications. They function via a sliding action
instead of the rolling action used by ball, roller, and needle bearings.

Fig. 3.7
8.Clutch actuators-
Description: -
The clutch actuator is part of the overall clutch system. The force exerted is transmitted by
several components and passed on to the actual clutch system. The process takes place in
reverse on releasing the pedal.

Fig.3.8
9.Transmission shafts-
Description: -
A shaft is a rotating machine element, usually circular in cross section, which is used to
transmit power from one part to another, or from a machine which produces power to a
machine which absorbs power. Transmission shafts are used to transmit power between the
source and the machine absorbing power.

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Fig, 3.9
10.Motor and Shaft connector
A hollow shaft is designed to connect the electric motor and shaft in such way that it does
not produce wobbling motion and transfers steady motion.

Fig. 3.10
11.Spur gears-
Description: -
Spur gears are used for speed reduction or increase, torque multiplication, resolution and
accuracy enhancement for positioning systems. The teeth run parallel to the gear axis and
can only transfer motion between parallel-axis gear sets.
Fig. 3.11

GEAR 1 GEAR 2 GEAR 3

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GEAR SPECIFICATIONS:
GEAR 1 –
Diameter: 80mm
Number of teeth: 56
Module: Diameter / number of teeth
=80/56
=1.42
GEAR 2 –
Diameter: 54mm
Number of teeth: 38
Module: Diameter / number of teeth
= 54/38
= 1.42
GEAR 3 –
Diameter: 34mm
Number of teeth: 25
Module: Diameter / number of teeth
= 34/25
= 1.36

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CHAPTER 4
WORKING PROCEDURE: -
Gear 1–all motor phase -
The motor is switched on in order to move the vehicle, where the dog clutch
1helpsthepower transfer between 1st drive and driven gear hence multiplying the torque at
the wheels, gear box for an electric car is used in a Formula E high performance car. This
allows the cars to have more torque. This torque is transmitted through the input shaft to
the next gear.

Fig. 4.1
Gear 2 – the transition gear
The usually crowded slow moving traffic conditions in cities doesn’t allow us to go beyond
gear 2. By sliding the dog clutch from the 1st gear to 2nd gear on the motor’s input shaft we
allow the transfer of power from motor to the driven shaft. Here is the part of the gear box
which allows the engine to start by means of the power generated from the motor.
This gear set consists of 4 gears 2 drive gears and one idle gear and a single driven gear on
the output shaft. If we need to crank the engine by the use of a motor then we need to lock
the 2 drive gears and the single driven gear by the use of dog clutch. The dog clutch must be
present on both the drive shafts, one from the engine and the other from the motor, so that
we can switch to the engine whenever we want to travel at a higher speed. When we need
to switch on the engine in order to move at a greater speed then the 2 dog clutches engage
to gear 2 to drive the engine by the use of the electric motor. The method by which the
engine switches off when downshifting gears is discussed in the later section.

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Fig. 4.2

Gear3 – all engine phase-

The need for higher speeds is satisfied by the power from the engine which works at the
economy band of a particular engine. Here as the engine works in the economy band the
efficiency is very good with minimal environmental effects. Now as soon as the engine starts
to power the vehicle the motor shall be temporarily switched off electronically by a
mechanism which will be discussed in the later section.

Fig.4.3

ELECTRONICS
A. Electronics to stop engine after a certain rpm (after gear 2)
The need to switch the engine off while stepping down is important because we can’t let the
engine to be kept at idling which adds to unwanted fuel consumption, to counter this
problem we can integrate some electronics into the process to cut off the fuel input to
engine only to switch off the engine by itself.
A tachometer is an instrument measuring the RPM (Rotations per minute) of a rotating
element. This device measures the RPM (rotations per minute) at the wheel and sends the
acquired data to a micro controller. This microcontroller is programmed to 2 conditions
(hypothetical values considered to give examples)

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1. If RPM<800
Micro controller sends voltage to solenoid valve circuit to complete the circuit for a small
period of time until the engine halts.
When the condition is fulfilled the circuit opens and hence allowing the solenoid valve to
close the inlet of fuel and hence stopping the engine ultimately.
2. RPM>800
The circuit is in closed condition to allow the inlet of fuel to the engine.
After a certain amount of time, similar to working of an electrical ringing bell the solenoid
allows the opening of valve for further higher speeds which can be attained by the engine.

Electronics to switch off the motor -

The motor after being used in the initial stage of the movement of the vehicle must be
turned off for the engine to produce work.
Tachometer sends signals to an onboard microprocessor which regulates voltage based on
the acquired input of the tachometer
For example: if we consider the rpm of the wheel is 800 at (2nd transition gear) and this is
the limit at which power from motor changes from motor to engine then,
1. If motor’s RPM is less than 800 the motor is switched on.
2. If the motor rpm is greater than or equal to 800 then the motor is switched off.
The most suitable micro controller would be ATMEGA IR ATTINY.

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 18

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STEPS TO FOLLOW –
1.First determine the gear design and size.
2.Choose the smallest gear to determine the distance between the input shaft and the
output shaft.
3.Place the 3 gears in vertical fashion to determine the minimum gap between the shafts.
4.Determine the axis points for supports.
5.Considering the gap, we determined earlier find out the point of contact of the 4 gears of
gear 2 (in the transition stage).
6.Determine the axis points of the idler gear.
7.Consider the gap between gears on shafts of model.
8.Find the axis points for idler gear mounting.

THINGS TO TAKE NOTE BEFORE FABRICATION

1.Planning: Plan the events of projects with a deadline its better if we follow a Gantt chart
2.Calculation - Calculate the approximate distances of centres of the gears
3.Design: Design supports for idler gears which is a tiresome and time-consuming part of the
entire project.
4.Market survey: Must do a thorough search for all small scale or medium scale industries
who could be of some help and do contact a couple of people who make the same kind of
industrial work so that if things aren’t happening at the right pace you can always contact
the other person for getting your job done
5.Trial run: Always trial run the project for a couple of times so that you can rectify any
occurrences of failure beforehand.
6.Budgeting: Always keep in mind the amount of money spent on the project, because cost
is a key factor which plays role in a successful completion of project.

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CALCULATION –
TO FIND THE DISTANCE BETWEEN 2 INPUT SHAFTS:
Consider the gear set at 2nd gear -
since we know the dimensions of the sides of triangle ABC
By cosine rule:
(AC)^2 = (BC)^2 + (AB)^2 –2*AB*BC*Cos (Angle B)
(68) ^2 = (54) ^2 + (44) ^2 – 2*(54) *(44) * Cos (Angle B)
Cos (Angle B) = (228)/ {54*44*2}
Angle B = in Cos (19/396)
= 87.2499 degree
By sine rule –
44/[sin C] = 54/[sin A] = 68/ [sin B]
To find the angle A:
68/ [sin 87.499] = 54/sin A
sin A = 0.7932
A = in sin [0.7932]
A = 52.48557degrees

Since the angle CAD = 90deg

Angle BAD + Angle BAC = 90deg
Angle BAD = 90 – Angle BAC
= 90 – 52.4855
= 37.5145deg

TO FIND X/2 –
Consider triangle BAE –
Cos (Angle BAE) = [X/2]/ [44]
Cos (37.5145) = [X/88]
X = 88* Cos (37.5145)

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X = 69.8015mm
So,
X (approx.) = 70mm
X is the distance between the 2 input shafts considering that the centres of the shafts lie on
the same line.
To find distance BE –
(AB)^2 = (AE)^2 + (BE)^2
(BE)^2 = (AB)^2 – (AE)^2
= (44) ^2 – (35) ^2
BE = 26.6645 mm
BE is the distance from input shaft’s centre to the centre of idle gear axis.

Considering gear 1 in the arrangement –

In triangle CAD
Since angle CAD = 90deg
By Pythagoras theorem,

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[CD]^2 = [AD]^2 + [AC]^2

= [70] ^2 + [68] ^2
CD = [{70} ^2 + {68} ^2] ^1/2
= 97.59mm

In the triangle ECD –

(CD)^2 = (CE)^2+(CD) ^2+2*(CE)*(CD)*Cos (CED)

((CD)^2-[(CE)^2+(CD) ^2])/(2*(CE)*(CD)) = Cos (CED)

Cos (CED)= - 0.01372

Angle CED = 90.7861=90deg (approx.)

In triangle CAD,

In tan (70/68) = Angle (ACD)

Angle (ACD) = 45.83deg.

In triangle,

57/ [sin ECD] = 97.59/ [Sin DEC]

Sin ECD = 0.584
Angle ECD = 35.7323 degree

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Angle ECF + Angle ECD + Angle DCA = 90

35.7323 + 45.83 + Angle ECF = 90
Angle ECF = 8.4377 degree

In triangle CFE,

Sin ECF = FE / 80
Sin 8.4377 = FE/80
FE = 11.7387mm

So, the point of support is at 11.7387mm above the axis of output shaft

TORQUE CALCULATIONS –
The motor produces 2kgcm of torque.

Torque,
2 Kg-cm = 0.196133 N-m= 196.133N-mm
&
T = F*Radius (in case of gears)
196.133 = Force (in the Input gear) *17mm
Force = 196.133/ 17
Force = 11.5372 N

When the first gear is engaged –

A force of 11.5372 N is transmitted to the first gear which has an approx. pitch circle
diameter of 80mm
Hence going by the formula of torque

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T = force * radius
T = 11.5372 * 40
= 461.488 N-mm

So, this the highest amount of torque required to move the body in inertia

When the second gear is engaged –

A force of 11.5372 N is transmitted to the second gear which has an approx. pitch circle
diameter of 54mm

Hence going by the formula of torque

T = force * radius
T = 11.5372 * 54/2
= 311.5044 N-mm

This is where the motor cranks the engine by motion of dog clutch on the input shaft

When the third gear is engaged –

A force of 11.5372 N is transmitted to the second gear which has an approx. pitch circle
diameter of 34mm

Hence going by the formula of torque

T = force * radius
T = 11.5372 * 34/2
= 311.5044 N-mm
This is where the engines operate to produce work at high speeds.

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 24

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ASSEMBLED VIEW OF THE PROJECT:

Fig. 5.1
3D PRINTING:

Fig. 5.2

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 25

HYBRID GEAR BOX

ISOMETRIC VIEWS OF COMPONENTS DESIGNED IN THE SOFTWARE

CATIA V5: -

Fig. 4.4

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MANUFACTURING PROCESS DETAILS: -

3D PRINTING TECHNOLOGY
OVERVIEW OF 3D PRINTING TECHNOLOGY: -
3D printing or additive manufacturing is a process of making three dimensional solid objects
from a digital file. The creation of a 3D printed object is achieved using additive processes.
In an additive process an object is created by laying down successive layers of material until
the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-
section of the eventual object.3D printing is the opposite of subtractive manufacturing
which is cutting out / hollowing out a piece of metal or plastic with for instance a milling
machine.3D printing enables you to produce complex (functional) shapes using less material
than traditional manufacturing methods.
STEPS IN 3D PRINTING: -
• Deciding the most suitable material which full fills our needs.
• Filament procurement based on our needs.
• Design in 3d
• From CAD model to STP file.
• Virtual slicing.
• Creates objects through a sequential layering process.
APPLICATIONS OF 3D PRINTING: -
1.Rapid Prototyping: Manufacturers have long used 3D printers in their design process to
create prototypes. Using 3D printers for these purposes is called rapid prototyping.
2.Rapid Manufacturing: Rapid manufacturing is a new method of manufacturing where
companies are using 3D printers for short run.
3.Automotive: Automotive industry utilize it to produce not just parts, but tools, jigs and
fixtures. It has also enabled on-demand manufacturing, leading to lower stock levels for
spare parts.
4.Aviation: The aviation industry currently uses 3D printing in many different forms. Boeing
have been exploring the potential of printed parts and airplanes for a long time.
5.Aerospace: space travel requires an ultra-durable exterior. Multiple organizations, such as
NASA, have been perfecting the shielding on shuttles using 3D printers.
6.Architecture: Architects were one of the early adopters of 3D printing technology. When
architects need to present their work as a physical scale model, 3D printing will always be a
quick and efficient way to do it.
7.Consumer products: Furniture, Accessories and jewellery.

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 27

HYBRID GEAR BOX

Creality 3D Printer CR-10S with Dual Z Axis: -

Characteristic: Desktop 3d Printer.
Print resolution: +/-0.1mm.
Fast Self-assembly: It just needs to Install the Z-plane kit on the XY plane about 20 minutes,
Portable/ Simple and convenient.
Product forming size: 300*300*400mm. (X Y Z Axis)
Nozzle Diameter: 0.2/0.3/0.4mm (default=0.4mm)
Nozzle Temperature: PLA: 180-220 degrees Celsius
Printing Software: Cura
Supporting software: PROE, Solid-works, UG, 3d Max, Rhino 3D design software
File Types: STL/OBJ/G-Code/JPG/STP
Working Conditionate :10-30 degrees Celsius
Printer weight: 14Kg

Fig. 4.5

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 28

HYBRID GEAR BOX

MATERIAL PROPERTIES OF PLA (polylactic acid)

• Ultimate strength = 35 MPa
• Tensile strength =36 to 55 MPa
• Modulus of rigidity (G) = 2.4Gap
• Density = 1.25
• Maximum shear stress = yield stress/2*factor of safety
• Yield stress = 48.2 MPa
• Break stress =48.2 MPa
• Z axis
1. Tensile stress = 28.8 to 4.2 MPa
2. Break stress = 28.6 to 4.1 MPa
• XY plane
1. Tensile stress = 38.1 to 0.9
2. Break stress = 36.3 to 1.2

By maximum principle stress theory,

Factor of safety = yield stress/applied stress

PLA Chemical structure: -

Fig. 4.6

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 29

HYBRID GEAR BOX

CHAPTER 5
CONCLUSION
In this paper an attempt to design and analyse a gearbox which can transmit power from
two power sources was done. We can conclude that the gearbox designed will be effective
in conserving fuel, it will assist in longer driving duration with a lesser capacity and smaller
size battery, which, at present is possible only with higher capacity batteries which are
larger in size, increasing the weight of the vehicle. The ball lock mechanism is useful in this
gearbox as it requires very less space compared to other conventional gearboxes. Vibrations
are caused due to improper alignment of shafts, gears, bearings etc. which should be taken
care while manufacturing and assembling and moreover the vibrations in the gearbox can
be reduced by using dampers while installing the gearbox in the vehicle.

SCOPE FOR FUTURE IMPROVEMENTS –

Instead of relying on idler gears we can use chain to drive a sprocket on the driven and
driver shaft. Substantial study has to go into making one gearbox without gears but which
contains sprockets. We have to keep in mind that the transmission setup may become bulky
due to the presence of sprockets and chain. The disadvantage of the chain and sprocket
drive is that it can be noisy and more expensive than a belt and pulley drive system. On the
brighter side a chain & sprocket set can have very high efficiency (up to 96%) they do not
slip, they are easier to install & they can withstand abrasive conditions.

ADVANTAGES –
1. It’s an easy solution to reduce emission of greenhouse gasses.
2. It is simple in operation.
3. The arrangement of gears is robust and fail-proof.
4. Integrates 2 driver shafts to transmit power through a single driven shaft.

DISADVANTAGES –
1. Its heavier because of idler gear arrangement.
2. May fail due to sudden jerks while cranking up the engine through motor.
3. Could be used for small and medium vehicles.
4. Needs further improvement for it to be incorporated in real life.

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 30

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REFRANCES-

DEPT. OF MECHANICAL ENGINEERING, DR. AMBEDKAR INSTITUTE OF TECHNOLOGY pg. 31