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2.72 Elements of Mechanical Design

Spring 2009

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 2.72

Elements of

Mechanical Design

Lecture 12:

Belt, friction, gear drives

Schedule and reading assignment

Quiz
‰ Bolted joint qualifying Thursday March 19th

Topics
‰ Belts

‰ Friction drives

‰ Gear kinematics

Reading assignment
• Read:
14.1 – 14.7

• Skim:
Rest of Ch. 14

© Martin Culpepper, All rights reserved 2

 Topic 1:

Belt Drives

© Martin Culpepper, All rights reserved 3

Belt Drives
Why Belts?
‰ Torque/speed conversion

‰ Cheap, easy to design

‰ Easy maintenance

‰ Elasticity can provide damping, shock absorption

Image by dtwright on Flickr.

Keep in mind
‰ Speeds generally 2500-6500 ft/min

‰ Performance decreases with age

Images removed due to copyright restrictions.

Please see:
Image by v6stang on Flickr.
http://www.tejasthumpcycles.com/Parts/primaryclutch/3.35-inch-harley-Street-Belt-Drive.jpg
http://www.al-jazirah.com.sa/cars/topics/serpentine_belt.jpg

© Martin Culpepper, All rights reserved 4

Belt Construction and Profiles
Many flavors
‰ Flat is cheapest, natural clutch
‰ Vee allows higher torques
‰ Synchronous for timing

Usually composite structure

‰ Rubber/synthetic surface for friction
‰ Steel cords for tensile strength

© Martin Culpepper, All rights reserved 5

Belt Drive Geometry

Driven

Pulley
Slack Side
d2
d1
ω1 ω2

Driving vbelt
Pulley Tight Side

© Martin Culpepper, All rights reserved 6

Belt Drive Geometry

θ2

θ1

dspan

dcenter

© Martin Culpepper, All rights reserved 7

Contact Angle Geometry

θ2
d2
θ1
ω1 d1 ω2

dspan

dcenter

⎛ d2 −d1 ⎞ ⎛ d2 −d1 ⎞
θ1 = π −2sin ⎜⎜ ⎟⎟ −1
θ2 = π +2sin ⎜⎜
−1
⎟⎟
⎝ 2dcenter ⎠ ⎝ 2dcenter ⎠
© Martin Culpepper, All rights reserved 8
Belt Geometry

θ2
d2
θ1
ω1 d1 ω2

dspan

dcenter

⎛ d2 −d1 ⎞
2

dspan = d −⎜ ⎟ Lbelt = 4d − (d2 −d1 ) + 1 (d1θ1 +d2θ2 )

2 2 2
center
⎝ 2 ⎠
center 2

© Martin Culpepper, All rights reserved 9

Drive Kinematics

θ2
d2
θ1
ω1 d1 ω2

dspan

dcenter

d1 d2 d1 ω2

vb = ω1 = ω2
=
2 2 d 2 ω1

© Martin Culpepper, All rights reserved 10

Elastomechanics
Elastomechanics → torque transmission
‰ Kinematics → speed transmission
Link belt preload to torque transmission
‰ Proceeding analysis is for flat/round belt

Driven
Pulley
Slack Side
d2
d1
ω1 ω2

Driving vbelt
Pulley Tight Side

© Martin Culpepper, All rights reserved 11

Free Body Diagram
y
x
dS

μdN
F+dF

dN d/2

•Tensile force (F)

•Normal force (N)
dθ
•Friction force (μN)
•Centrifugal force (S)

© Martin Culpepper, All rights reserved 12

Force Balance

y
dS x

Using small angle approx:

μdN
F+dF dθ dθ
ΣFy = 0 = −(F + dF ) − F + dN + dS
dN d/2 2 2
Fdθ = dN + dS

dθ ΣFx = 0 = −μdN − F + (F + dF )
μdN = dF

© Martin Culpepper, All rights reserved 13

Obtaining Differential Eq

y
dS x

Let m be belt mass/unit length

μdN
2
F+dF ⎛d ⎞ 2
dS = m⎜ ⎟ ω dθ
dN d/2 ⎝ 2⎠
Combining these red eqns:
2
⎛d ⎞
dF = μFdθ − μm⎜ ⎟ ω 2 dθ
dθ ⎝2⎠
2
dF ⎛d ⎞
− μF = − μm⎜ ⎟ ω 2
dθ ⎝2⎠

© Martin Culpepper, All rights reserved 14

Belt Tension to Torque
Let the difference in tension between the loose side (F2) and the
tight side (F1) be related to torque (T)
T
F1 − F2 = F1
d
2
Solve the previous integral over contact angle and apply F1 and T
F2 as b.c.’s and then do a page of algebra:

μθcontact
Te +1 F2

Ftension = μθcontact
de −1
2e μθcontact
2
⎛d ⎞ 2
F1 = m⎜ ⎟ ω + Ftension μθcontact
⎝2⎠ e +1 Used to find stresses
2 in belt!!!
⎛ d ⎞ 2 2
F2 = m ⎜ ⎟ ω + Ftension μθcontact
⎝2⎠ e +1
© Martin Culpepper, All rights reserved 15
Practical Design Issues
Pulley/Sheave profile
‰ Which is right?

Manufacturer → lifetime eqs

‰ Belt Creep (loss of load capacity)
‰ Lifetime in cycles A B C

Idler Pulley Design

‰ Catenary eqs → deflection to tension
‰ Large systems need more than 1
Idler

IDL
ALT
P/S
Water
pump
& fan

Idler

Crank

Images by v6stang on Flickr.

© Martin Culpepper, All rights reserved Figure by MIT OpenCourseWare. 16

Practice problem
Delta 15-231 Drill Press

‰ 1725 RPM Motor (3/4 hp)

Images removed due to copyright restrictions. Please see

‰ 450 to 4700 RPM operation
http://www.rockler.com/rso_images/Delta/15-231-01-500.jpg

‰ Assume 0.3 m shaft separation

‰ What is max torque at drill bit?

‰ What size belt?

‰ Roughly what tension?

© Martin Culpepper, All rights reserved 17

 Topic 2:

Friction Drives

© Martin Culpepper, All rights reserved 18

Friction Drives
Why Friction Drives?
‰ Linear ↔ Rotary Motion Images removed due to copyright restrictions. Please see

http://www.beachrobot.com/images/bata-football.jpg
‰ Low backlash/deadband
http://www.borbollametrology.com/PRODUCTOS1/Wenzel/
‰ Can be nm-resolution WENZELHorizontal-ArmCMMRSPlus-RSDPlus_files/rsplus.jpg

Keep in mind
‰ Preload → bearing selection
‰ Low stiffness and damping
‰ Needs to be clean
‰ Low drive force

© Martin Culpepper, All rights reserved 19

Friction Drive Anatomy
Motor and
Transmission/Coupling
Drive Roller

Drive Bar
Concerned with:
•Linear Resolution
•Output Force
Backup

•Max Roller Preload Rollers

•Axial Stiffness

© Martin Culpepper, All rights reserved 20

Drive Kinematics/Force Output
Kinematics found from no slip cylinder on flat

d wheel
Δδ bar = Δθ ⋅
dwheel

2
Δθ

d wheel Δδ

vbar = ωwheel

Force output found from static analysis

‰ Either motor or friction limited

2Twheel
Foutput = where Foutput ≤ μFpreload
d wheel

© Martin Culpepper, All rights reserved 21

Maximum Preload
−1
⎛ ⎞ For metals:
⎛ 1 −ν 1 −ν
2 2
⎞
−1
⎜ 1 1 ⎟ 3σ y
⎜
Ee = ⎜ + wheel bar
⎟⎟ Re = ⎜ + ⎟
d
⎜ wheel rcrown ⎟
τ max =
⎝ Ewheel Ebar ⎠ 2
⎝ 2 ⎠
1
⎛ 3Fpreload Re ⎞ 3
Variable Definitions acontact = ⎜⎜ ⎟⎟
⎝ 2Ee ⎠
Shear Stress Equation
acontactEe ⎛ 1 + 2ν wheel 2 ⎞
τ wheel = ⎜ + ⋅ (1 +ν wheel ) ⋅ 2(1 +ν wheel ) ⎟
2πRe ⎝ 2 9 ⎠

16π 3τ max
3
Re
2

Fpreload , max =
⎛ 1+ 2ν wheel 2
3

⎞
3E ⎜2
e + ⋅ (1+ ν wheel ) ⋅
2(1+ ν wheel ) ⎟
⎝ 2 9 ⎠

© Martin Culpepper, All rights reserved 22

Axial Stiffness
−1
⎛ ⎞
⎜ ⎟ 4ae Ee
⎜ 1 1 1 1 ⎟ ktangential =
kaxial = + + +
⎜ kshaft ktorsion ktangential kbar ⎟ (2 −ν )(1+ν )
⎜ 2 ⎟
⎝ d ⎠
3π Ed
wheel 4

k shaft =
shaft
3
4L
π Gd wheel
4
k torsion =
32 L

EA c , bar
k bar =
L
© Martin Culpepper, All rights reserved 23
Friction Drives
Proper Design leads to
‰ Pure radial bearing loads

‰ Axial drive bar motion only

Drive performance linked to motor/transmission

‰ Torque ripple

‰ Angular resolution

Images removed due to copyright restrictions. Please see

http://www.borbollametrology.com/PRODUCTOS1/Wenzel/WENZELHorizontal-ArmCMMRSPlus-RSDPlus_files/rsplus.jpg

© Martin Culpepper, All rights reserved 24

 Topic 3:
Gear Kinematics

© Martin Culpepper, All rights reserved 25

Gear Drives
Why Gears?
‰ Torque/speed conversion
‰ Can transfer large torques
‰ Can run at low speeds
‰ Large reductions in small package

Image from robbie1 on Flickr.

Keep in mind
‰ Requires careful design
‰ Attention to tooth loads, profile

Image from jbardinphoto on Flickr.

Images removed due to copyright restrictions. Please see

http://elecon.nlihost.com/img/gear-train-backlash-and-contact-pattern-checking.jpg
http://www.cydgears.com.cn/products/Planetarygeartrain/planetarygeartrain.jpg

© Martin Culpepper, All rights reserved 26

Gear Types and Purposes
Spur Gears
‰ Parallel shafts
‰ Simple shape → easy design, low $$$
‰ Tooth shape errors → noise
‰ No thrust loads from tooth engagement

Helical Gears
‰ Gradual tooth engagement → low noise
‰ Shafts may or may not be parallel
‰ Thrust loads from teeth reaction forces
‰ Tooth-tooth contact pushes gears apart

Images from Wikimedia Commons, http://commons.wikimedia.org

© Martin Culpepper, All rights reserved 27

Gear Types and Purposes
Bevel Gears
‰ Connect two intersecting shafts

‰ Straight or helical teeth

Worm Gears
‰ Low transmission ratios

‰ Pinion is typically input (Why?)

‰ Teeth sliding → high friction losses

Rack and Pinion

‰ Rotary ↔ Linear motion Images from Wikimedia Commons, http://commons.wikimedia.org

‰ Helical or straight rack teeth

Pinion, m2
F (t) a
+
b
k k
Figure by MIT OpenCourseWare. Rack, m1

© Martin Culpepper, All rights reserved Viscous damping, c Rack & Pinion
28
Tooth Profile Impacts Kinematics
Want constant speed output
‰ Conjugate action = constant angular velocity ratio
‰ Key to conjugate action is to use an involute tooth profile

Output speed of gear train

“Real” involute/gear

“Ideal” involute/gear

ωout, [rpm]

Non or poor involute

time [sec]

© Martin Culpepper, All rights reserved 29

Instantaneous Velocity and Pitch
Model as rolling cylinders (no slip condition):

v v v v v ω1 r2
v = ω1 × r1 = ω2 × r2 =
ω 2 r1

Model gears as two pitch circles

‰ Contact at pitch point

Pitch Circles Meet @ Pitch Pt.

ω2 ω2
r1 r2 r1 r2

ω1 ω1

© Martin Culpepper, All rights reserved 30

Instantaneous Velocity and Pitch
Meshing gears must have same pitch
-Ng = # of teeth, Dp = Pitch circle diameter
Ng
Diametral pitch, PD: PD =
Dp
πD p π
Circular pitch, PC: PC = =
Ng PD

© Martin Culpepper, All rights reserved 31

Drawing the Involute Profile
•Gear is specified by Pitch Point

diametral pitch and Φ

pressure angle, Φ Pitch Circle

Base Circle

Images from Wikimedia Commons, http://commons.wikimedia.org

DB/2
DP/2
Image removed due to copyright restrictions. Please see
http://upload.wikimedia.org/wikipedia/commons/c/c2/Involute_wheel.gif

DB = DP cos Φ
© Martin Culpepper, All rights reserved 32
Drawing the Involute Profile
Pitch Point
DB
Pitch Circle
L3 Ln = n Δθ
L2 2
3
2
1
L1
Base Circle

DB/2

© Martin Culpepper, All rights reserved 33

Transmission Ratio for Serial Gears

Power out: Tout y ωout

Power in: Tin y ωin Gear train

ωout

Transmission ratio for elements in series: TR = ( proper sign ) ⋅

ωin

N1 N 2 D1 N1 ω2
From pitch equation: P1 = = = P2 = = 11 2
D1 D 2 D 2 N 2 ω1

For Large Serial Drive Trains:

TR = ( proper sign) ⋅
Productof drivingteeth
Productof driven teeth
© Martin Culpepper, All rights reserved 34
Transmission Ratio for Serial Gears
TR = ( proper sign ) ⋅
Product of driving teeth
Serial trains: Product of driven teeth
Example 1:

TR = ?
in out
Example 2:
driven

drive

driven
drive

TR = ?
driven
drive

in out

© Martin Culpepper, All rights reserved 35

Transmission Ratio for Serial Gears
Example 3: Integral gears in serial gear trains
‰ What is TR? Gear 1 = input and 5 = output

TR = ( proper sign ) ⋅
Product of driving teeth
Product of driven teeth
5
Gear - 1

N1 = 9

Gear - 2

N2 = 38

Gear - 3

N3 = 9

Gear - 4

N4 = 67

Gear - 5

N5 = 33
3

© Martin Culpepper, All rights reserved 36

Planetary Gear Trains
Planetary gear trains are very common
‰ Very small/large TRs in a compact mechanism
Terminology:

Planet Planet
Ring Planet gear gear
gear Arm

Planet
ω Arm
2

Planet
Sun
gear
gear

© Martin Culpepper, All rights reserved 37

Planetary Gear Train Animation
How do we find the transmission Ring Arm
ratio? gear

Train 1
Image removed due to copyright restrictions. Please see
http://www.cydgears.com.cn/products/Planetarygeartrain/
planetarygeartrain.jpg Planet
gear
Sun

Ring Arm
gear

Train 2
Planet
gear
Sun

© Martin Culpepper, All rights reserved 38

Planetary Gear Train TR
If we make the arm
Sun Gear
stationary, than this is
Planet Gear
Ring Gear
a serial gear train:
ωra ωring − ωarm
= = TR

ωsa ωsun − ωarm

N sun N planet N sun
TR = − ⋅ = −

N planet N ring N ring

Arm
ω pa ω planet − ω arm
= = TR
ω sa ω sun − ω arm
N sun
TR = −
N planet

© Martin Culpepper, All rights reserved 39

Planetary Gear Train Example
If the sun gear is the
Sun Gear
input, and the ring
Planet Gear
Ring Gear
gear is held fixed:

ωra 0 − ωarm
= = TR
ωsa ωsun − ωarm
N sun N planet N sun
TR = − ⋅ =−
Arm N planet N ring N ring
TR
ωoutput = ωarm = ωsun
TR −1

© Martin Culpepper, All rights reserved 40

Case Study: Cordless Screwdriver
Given: Shaft TSH (ωSH) find motor TM (ωSH)
‰ Geometry dominates relative speed (Relationship due to TR)

2 Unknowns: TM and ωM with 2 Equations:

‰ Transmission ratio links input and output speeds
‰ Energy balance links speeds and torques

© Martin Culpepper, All rights reserved 41

Example: DC Motor shaft
⎛ ω ⎞
T(ω): T(ω ) = TS ⋅ ⎜⎜1− ⎟⎟ Motor torque-speed curve
⎝ ω NL ⎠ T(ω)
P(ω) obtained from P(ω) = T(ω) y ω
( 0 , TS )

Speed at maximum power output:

(ωNL , 0 )

⎛ 2 ⎞ ω
ω
P(ω ) = T(ω ) ⋅ ω = TS ⋅ ⎜ ω − ⎟
⎜ ω ⎟
⎝ NL ⎠ P(ω
) Motor power curve

ω NL
ω PMAX = PMAX

⎛ ω NL ⎞ (ωNL , 0 )
PMAX = TS ⋅ ⎜ ⎟

⎝ 4 ⎠
ωPMAX ω
© Martin Culpepper, All rights reserved 42
Example: Screw driver shaft
T(ω) A = Motor shaft torque-speed curve
What is the torque-speed curve for the screw driver?
B
Train ratio = 1/81

C ω
SCREW DRIVER SHAFT

MOTOR SHAFT TSH, ωSH

TM, ωM

Electric
GT-1 GT-2 Screw Driver Shaft
Motor

System boundary

GEAR train # 1 GEAR train # 2

© Martin Culpepper, All rights reserved 43
Example: Screw driver shaft
P(ω) C = Motor shaft power curve
D What is the power-speed curve for the screw driver?
Train ratio = 1/81
C

ω
SCREW DRIVER SHAFT

MOTOR SHAFT TSH, ωSH

TM, ωM

Electric
GT-1 GT-2 Screw Driver Shaft
Motor

System boundary

GEAR train # 1 GEAR train # 2

© Martin Culpepper, All rights reserved 44