Professional Documents
Culture Documents
INTRODUCTION
1.1 INTRODUCTION
Whereas while riding the hill or curve roads the vehicle requires more
power and the speed required is less. Conventional transmissions allow for
the selection of gear ratios but not continuously, thus limiting the engine to
providing maximum power according to need. Because the engine is forced to
adjust its speed to provide continuously variable output from the transmission
to the load, it operates much of the time in low power and low efficiency
regimes.
Page
1
source of power loss because some slipping is possible. This slipping is also
a major contributor to wear, which occurs in these devices. To overcome the
limitations occurring in the current continuous variable transmission employing
frictional positive engagement Engineer’s has been proposed for investigation
at Brigham Young University
Page
2
for the selection of discrete gear ratios, thus limiting the engine to providing
maximum power or efficiency for limited ranges of transmission output speed.
A continuously variable transmission, however, is a type of transmission that
allows an infinitely variable ratio change within a finite range, thereby allowing
the engine to continuously operate in its most efficient or highest performance
range. Beachley and Frank, 1979, present a sub-classification of the
continuously variable transmission called the infinitely variable transmission
(IVT). While the two terms are often used interchangeably, there is a distinct
difference between them. While a CVT allows an infinitely variable ratio
change within a finite range, an IVT must be capable of producing an output
speed of zero for any input speed, thus giving an infinite speed ratio.
1.3 CLASSIFICATIONS
There are several classifications of CVTs. The following five are most
relevant to the current research: hydrostatic, friction, traction, variable
geometry, and electric.
1.3.1 TRACTION
Page
3
(1986), however, and Singh and Nair (1992), categorize them separately. For
the purposes of this work, we will consider the definition of a traction drive
presented by Hewko (1986). A generic traction drive is “a power transmission
device which utilizes hardened, metallic, rolling bodies for transmittal of power
through an elastohydrodynamic fluid film.” This definition distinguishes traction
drives from variable-sheave drives because sheave contact is static, while
traction drives employ rolling contact. This means that sheave contact does
not exhibit significant elastohydrodynamic fluid film phenomena. In properly
designed traction drives, power is transferred from the driving roller to the
driven roller through the shearing of the fluid film between them, not through
body-to-body contact. This happens because the contact between the rolling
bodies, which generally happens over a finite area in the shape of an ellipse,
traps the fluid and subjects it to extreme compressive stress, usually on the
order of 100,000 to 500,000 psi. This extreme stress increases the
instantaneous viscosity of the fluid by several orders of magnitude, thereby
increasing its shear strength. It is the shear strength of the fluid at this
increased viscosity that determines the amount of torque that can be
transmitted.
Page
4
Chapter 2
NEED OF PROJECT
A. Disengage clutch
B. Change gear
Page
5
C. Gradually engage clutch
Thus three operations are to be performed while moving from one gear
to another, hence in all 15 operations are performed to move to the top gear,
So also, In 1st gear speed cannot exceed 20 km.ph, where as in 5th gear
vehicle cannot be tracked from stand still condition (e.g. At traffic signal).
Page
6
To solve above problem the MULTI-BALL DISK VARIABLE SPEED DRIVE is
designed which offers the following advantages,
Page
7
Chapter 3
The Multi-Ball disk Variable speed drive consists of the following parts
1. Motor
2. Belt
Belt is an FZ section rubber V-belt, which connects the input reduction pulley
and motor pulley in the open belt drive used as the input transmission drive.
4. Input shaft
Input shaft is an high grade steel (EN24) component housed in ball bearings
6004zz and 6003zz in input bearing housing at the left hand end, and bearing
6201 at the right hand end . The input shaft is integral with the left hand input
disk where as the right hand input disk is keyed to the input shaft. Right hand
input disk is moveable towards the left hand to maintain the contact pressure
thereby the torque is adjusted. To ensure the contact pressure an helical
compression spring is installed and an locknut is carried on the threaded end
of input shaft (M16 x 2 pitch) which ensures the contact pressure.
Page
8
5. Input bearing housing
Input bearing housing houses ball bearings 6004zz and 6003zz which hold
the input shaft at the left hand end. Input bearing housing is held in and
vertical structural member i.e. the left hand casing.
6. Driver disks:
The left hand driver disk is integral with the input shaft and the right hand
driver disk is keyed to the input shaft. The driver disks together drive the top
and bottom set of balls.
7. Balls (4 no’s)
Balls of the multi ball disk drive are high grade steel elements (EN24) , due
ground and lapped with hardness up to 63 HRC. These balls are held in ball
holders. Balls transmit the power from the driver disk to the intermediate
planet disks
Balls holders are structural steel (EN9) members that receive the balls at one
end and are mounted on the tilt shafts on the other end. The ball holders are
means of speed variation as they change the radii of contact between the
driver disks and the planet driven disks.
Planet disks are integral with the shafts and are mounted in ball bearings
6201zz on left hand side, and bearing 6004zz on the right hand side. These
bearings are supported in the intermediate bearing housings. Planet driven
disk shafts carry the driver planet gears which are keyed to the right hand end
of the shafts.
Page
9
10. Planet Driver gears (2 no’s)
Planet driver gears are high grade steel (EN24) gears of 2 module and 22
teeth. These planet gears are keyed to the right hand end of the planet driven
disk shafts which together drive the central sun driven gear.
Central Sun driven gear is high grade steel (EN24) gear of 2 module and 58
teeth. The planet gears keyed to the right hand end of the planet driven disk
shafts together drive the central sun driven gear. The central sun driven gear
is mounted on the output hub.
The output hub is the driven output member that carries the central sun driven
gear. It houses the ball bearing 6007zz held in position by means of an
internal circlip on the output bearing housing.
Output shaft is the output member integral with the output shaft, provisions of
central drill are made on the output shaft for output speed measurement.
Intermediate bearing housings on left hand side are structural steel parts that
house ball bearing 6201zz and that on the right hand side house bearings
6004zz. These bearings together hold the planed driven disk shafts.
Intermediate bearing housings are mounted in the left and right hand side
casing plates.
Gear sectors are elements that connect the tilt shafts on which the ball
holders are mounted. Gear sectors are partial gears with 2 module and 40
Page
10
teeth arrangement. The gears facilitate simultaneous motion of the two tilt
shafts in opposite direction and thereby changing the radii of contact equally
on both sides of the mean. Gear sectors are mounted on the right hand end of
the tilt shafts.
Tilt shafts are plain carbon steel (EN9) elements held in tilt shaft bushes
mounted on the casing plates, these shafts carry the ball holders, handle and
gear sectors. These shafts effect the speed change of the device.
17. Handle
Handle is of plain carbon steel (EN9) mounted on the tilt shaft, rotating the
handle in either clockwise or counter-clockwise direction will effect the speed
change. Handle is made of three pats that is the boss mounted on tilt shaft,
M8 stud and the 25 mm round knob.
Clamp nut is carried on the threaded end of input shaft (M16 x 2pitch) it
ensures the contact pressure between the driver disks, balls and the planet
driven disks.
19. Casing
Casing is in the form of the left hand and right hand mild steel casing plates,
two support plates and the base legs. Casing plates house the input and
output bearing housings, intermediate bearing housings and the tilt shaft
bushes.
Page
11
Page
12
Chapter 4
4.1 Assembling
• Welding of the left-hand driver disk on input shaft and mounting shaft in
central bearing of right-hand casing.
• Fixing of the left-hand ball holders along with balls on gear sector shaft.
• Mounting lock-nut along with spring to adjust the force acting on the
balls and the disks.
Page
13
4.2 Working
The balls and disks are brought into engagement by the helical
compression spring arrangement, whose tension is adjusted by the Clamp
nut. Motor drives the input pulley mounted on the input shaft. Also, the Driver
disk mounted on the input shaft rotates at the same speed. Driver disks drive
the four balls placed in the ball holders .Thus, this balls causes the rotation of
the driven disk mounted on the output shaft. The shaft transmits the torque to
the respective planet gears which are in mesh with the sun gear. The planet
gears mounted on the driven disk shafts drive the central gear mounted on
the driven hub thus power is transmitted to the output shaft.
Various speeds (35 gear ratios) are achieved by operating the handle
connected to the ball holders, which are interlinked by two gear sectors. The
movement of the ball holders gives the range of speeds as explained above,
and the speed changes are achieved without de-clutching action.
Page
14
Chapter 5
DESIGN
SYSTEM DESIGN
MECHANICAL DESIGN
SYSTEM DESIGN
Page
15
MECHANICAL DESIGN
• Design parts
• Parts to be purchased.
Page
16
APPROACH TO MECHANICAL DESIGN
Our present model is a demonstrative set up in order to show the motion and
power transmission capabilities of the proposed ‘TWIN WORM SYSTEM’
2xΠ xNxT
P = ----------------
60
60 x Π x 50
T = ---------------
2 Π x 4000
T = 0.119 N-m
Page
17
Power is transmitted from the motor shaft to the input shaft of drive by means
of an open belt drive,
Reduction ratio = 2
Page
18
Motor pulley diameter (d) = 38 mm
Reduction ratio = 2
α = sin-1 (D-d/2C)
α = sin-1 (76-38)/2x200
α = 10.950
θ = 2.95c
V = Π DN/(60 x 1000)
Tc = m V2
Tc = 14.56 N
T1
---- = eθµ
T2
185
------ = e(0.23 X 2.95)
T2
Page
19
T2 = 94.06 N
T2 = 19.756 N
Tension in tight side of belt (T1) = 185.4N
P = ( T1 - T2) v
P= 0.913 kw
RESULT TABLE
As the pulley is overhang let us check for the safe diameter of the input shaft
Page
20
72 44 15 56
98.5 50.5 48
Ra + Rb = 277.007+19.62 = 296.627 N
ΣMa = 0
( 19.62 x 98.5 ) + ( -Rb x 149 ) + ( 277.007 x 197 ) = 0
Therefore, Rb = 379.21 N
Ra = -102.203 N.
Maximum Bending Moment,
M = 18202.08 Nmm
Equivalent Torsional Moment,
Te = √ (Kt x T)2 + (Km x M)2
Te = √ 190.962 + 18202.08 2
Te = 18203.08 Nmm
Π x s x d3
Te= -----------------
16
Page
21
Π x 50 x d3 =18203.08
Te= ------------
16
d = 12.28 mm
SELECTION OF BELT
Page
22
MATERIAL SELECTION: -
EN 24 800 680
(40Ni2Cr1Mo28)
smax = 0.18 ut
= 0.18 x 800
= 144 N/mm2
OR
smax = 0.3 yt
=0.3 x 680
=204 N/mm2
Page
23
smax = 108 N/mm2
This is the allowable value of shear stress that can be induced in the
shaft material for safe operation.
T = 0.238 N-m
T design =2xT
= 2 x 0.238 x 103
= 0.476 x 103 N.mm.
d = 18 mm
Td = Π /16 x s act x d3
16 x Td
sact = --------------------
Π xd3
16 x 0.476 x 10 3
= --------------------
Π x (18) 3
sact = 0.415 N/mm2
Page
24
I/P shaft is safe under torsional load
MATERIAL SELECTION: -
EN 24 800 680
= 0.18 x 800
= 144 N/mm2
OR
smax = 0.3 yt
=0.3 x 680
=204 N/mm2
Page
25
Considering minimum of the above values ;
Shaft is provided with key way; this will reduce its strength. Hence
reducing above value of allowable stress by 25%
This is the allowable valve of shear stress that can be induced in the
shaft material for safe operation.
T = 0.238 N-m
T design = 2 x T
= 2 x 0.238 x 103
= 0.476 x 103 N-mm.
Now when mechanism runs at maximum torque condition i.e. the speed ratio
is maximum, which is given as 80/22 =3.636 (refer construction figure)
Torque at the planet driven disk shaft is
Page
26
Assuming minimum section diameter on input shaft = 16mm
d = 16 mm
Td = Π /16 x sact x d3
16 x Td
sact = -------------
Π xd3
= 16 x 1.73 x 10 3
---------------------
Π x (16) 3
Selecting parallel key from standard data book for given application.
Height 6
Page
27
selecting parallel key; =
6 x 6 x 20
T = L x d/2 x w x sact
20 x 5 x 20 x sact
3
1.73 x 10 = --------------------------------
2
Page
28
Number of active coils (n) =6
= 28/3 = 9.33
Π x d3 x s
W = -----------------
8 x D xKs
Π x 33 x680
W = -------------------
8 x 28 x 1.053
W = 244.53 N
Π x d3 x s
W = ------------
8xCxK
Π x 33 x680
W = ------------------ = 223.99 N
8 x 9.33 x 1.15
Page
29
δ 8 x W x D3 8 x 223.99 x 283
-- = -------------- = ---------------------- = 5.71mm
n G x d4 84 x 103 x 34
5.7 SPECIFICATIONS OF GEARS
T2 58
Gear Ratio = ---- = --- = 6.67
T1 22
Page
30
6 CounterBoring --”-- --”-- Boring 10 12 22
Ø 38through tool
length15mm
7 CounterBoring
PART --”--
NO : MBDVSD-3 --”--
MATERIALBoring
SPECIFICATION: EN 910 12 22
Ø 42through tool
RAWMATERIAL SIZE: Ø 70 X 40
PART NAME : IP_BRG_HSG
length12mm
QUANTITY :- 01NO’S.
Sr. Description Tools Time in minutes
8 Turning step Ø --”-- --”-- Straight Vernier 10 45 55
of
No 50mm to turning
Operation
20Length tool
Page
31
6.2 OUTPUT BEARING HOUSING
Page
32
PART NO : MBDVSD-17 MATERIAL SPECIFICATION: EN24
MATERIAL SPECIFICATION: EN 9
PART
PARTNAME : PLANET
NO : MBDVSD GEAR
– 00 RAW MATERIAL SIZE: ∅ 60 X 20
RAWMATERIAL SIZE: Ø 50 X 50
PART NAME : OP_BRG_HSG
QUANTITY :- 01NO’S.
Sr. Description of Tools Time in minutes
Sr. Description Tools Time in minutes
Operation
No of Operation
No
Jigs & M/c Cutting Measuri Settin M/c Tot
Jigs & M/c Cutting Measurin Setti M/c Total
Fixture ng g al
Fixture Tools Tools g Instrume ng Tim
Tools Tools Time Tim
e Time
Tim
nt
Instrume
Time e e
nt
1. Clamp stock Three Lathe - - 20 - 20
1 Clamping 3-jaw
jaw Lathe - - 10 - 10
. stock chuck
chuck
2. Turning OD Ø Turnin 5 10 15
2 48mm
Facingthrough
b/s to --”-- --”-- g tool Vernier
Turning 1 1
. length
17mm thick & facing caliper
3. Drilling Ø Three Lathe toolsTwist Vernier 5 12 17
3 15mm
Drillingthrough
Ø jaw
--”-- Lathe Twistdrill
drill 10 4 14
out length chuck
. 20through
4. Boring
length Ø Boring 10 15 25
17through out tool
4 Boring Ø --”-- --”-- Boring 10 12 22
length
. 25through tool
5. Facing
length
Both Three Lathe Facing Vernier - 5 5
side to total jaw
CounterBoring
5 length 10 mm --”--
chuck --”-- tool
Boring 10 12 22
. Ø 32through tool
length10mm
6. Gear Cutting Three Hobbin Hob Vernier 20 45 65
6 Turning step --”-- --”-- Straight Vernier 10 45 55
jaw g m/c
. Ø 34mm to chuck turning
5ength tool
Page
33
PART NO : MBDVSD-18 MATERIAL SPECIFICATION : EN24
2. Turning OD Ø Turning 5 10 15
120mm through tool
length
4. Boring Ø Boring 10 15 25
84through out tool
length
Page
34
Page
35
Chapter 7
BILL OF MATERIALS
Page
36
–12
Page
37
2 MBDVSD- BELT 01 STD
5. 25
Page
38
Chapter 8
COSTING
MS-MILD STEEL
The total raw material cost as per the individual materials and their
corresponding rates per kg is as follows,
Page
39
8.3 MACHINING COST
LATHE 80 20 1600
MILLING 90 10 900
DRILLING 60 4 240
HOBBING - - 1800
TOTAL 4540
OPERATION COST(Rs)
SAWING 120
TOTAL 420
Page
40
8.5 COST OF PURCHASED PARTS:-
1. MOTOR 01 2150
2. BELT 01 110
3. GRUB SCREW 09 36
4. BEARINGS 08 980
Chapter 9
Page
41
ADVANTAGES OF MULTI-BALL_DISK VARIABLE
SPEED DRIVE
Chapter 10
Page
42
APPLICATIONS OF MULTI-BALL_DISK
VARIABLE SPEED DRIVE
1. Automobiles
3. Agricultural equipment
6. Variable Speed drive in automatic transfer lines and pick and place
robotic device.
Page
43
Chapter 11
FUTURE SCOPE
The following are the future scope of the suggested developments that
could be done in the project for improving its Performance, Efficiency,
Durability, etc. in the future,
1. To ensure the entire project into a shell filled with the lubricating oil.
This would increase the heat dissipation capacity of the Machine,
which will increase the life of rollers and ten disk and would lubricate all
the parts of the Machine internally.
3. To obtain reverse motion, we have to use an gear pair after the output
shaft.
Page
44
Chapter 12
REFERENCES
Machine Design
- S D Ambatkar-TechMax Publication. Edition
2010, 2nd Reprint
Machine Design
– R S Khurmi.-S.Chand Publication-Edition 2005-27th
Reprint
Page
45