P.

A HILTON LTD

INSTRUCTION MANUAL

HTM25 Gear Train Apparatus

INDEX

LABORATORY TECHNIQUE

Safety in the laboratory

Success in the laboratory

Design of experimental models

Sources of resistance

Repeatability of readings

GEAR TRAIN APPARATUS

INTRODUCTION

APPARATUS ASSEMBLY

APPARATUS DESCRIPTION

EXPERIMENT

OBJETIVE No.1

Procedure

OBJETIVE No.2

Procedure

RESULTS PROCESSING

OBSERVATIONS

EXAMPLE RESULTS FOR SIMPLE GEAR TRAINS

GEAR TRAINS

EPICYCLIC GEARS

Part 1

Part 2

Part 3

MAINTENANCE

Replacement and spares

Test Specimens

CONTACT DETAILS

Results tables for photocopying

Epicyclic gears

Part 1
Part 2

Part 3

LABORATORY TECHNIQUE

Safety in the laboratory

The principal hazards in using apparatus that demostrates the static and dinamyc
performance of associated theorems and the assumptions involved are where rotary or linear
motion occurs and where the handling of loose heavy ítems, for example weights, is part of the
procedure

Of the loose ítems the heavier weights must be regarded as the most dangerous objects,
Should one of these fall onto the feet of those around the apparatus the potential for damage
is present. Hence it is recommended that cast iron weights be handled carefully and when
moving and placing the heavier ones (say 10 N upward) on load hangers this should be
regarded as a two handed operation. It is surprisingly easy to spill a complete stack of weights
off a hanger when adding a futher one.

In addition to weights there are some heavy parts that have to be interchanged during some
experiments and a similar approach using two hands where required is suggested. It may also
be both sensible and necessary for two people to take part in changes to the apparatus.

Success in the laboratory

Work in the laboratory depends on understanding, observation and skill. In the first place a
good understanding of the performance, and limitations, of experimental models is needed. To
know about the theory involved is useful but not essential, In the second place keen
observation leads to better results and avoidance of mechanical mistakes. Lastly, the way in
which students handle the apparatus can influence the accuracy and speed of the work

To help students gain experience and improve their experimental technique a range of
information is offered in the following notes. Bear in mind that in the world of real engineering
it is often necessary to check the performance of new designs using the methods and
instruments of laboratory experiments.

Design of Experimental Models

The purpose of each experiment is to ilustrate an ítem of structural theory, or to show how
well simplifying assumptions in the applied mathematics correspond to actual behaviour. This
often requires the model to exaggerate the behaviour of a real structure.

In order to achieve specific objectives each experiment has a particular arrangement best
suited to the theoretical requirement. These arrangements of the apparatus are described in
the Construction Appendix, where included, of each experimental instruction Manual. Before
starting an experiment students should read through the instruction Manual and be prepared
to follow the recommended procedure.
Increased deflections are usually achieved by using very flexible models. The stiffness depends
on EI O EA so a change of material from Steel (E=205KN/MM2) to aluminium (E about 1/3 E for
Steel) or a plastic (E about 1/80 E for steel) is a solution The alternative is to use thin Steel
beams with a low l

One disadvantage experimentally is that friction in bearings may affect displacements and
force measurements. The other is that large changes in dimensión (geometry) of models must
be accommodated if posible.

Results can be improved by using stiffer models and larger loads. But this reduces visual effects
such as curvature of beams.

Sources of Resistance

A knife-edge can simulate a frictionless pin or bearing, but horizontal and rotational
movements demand ball bearings. These are packed with grease and fitted with shields to
keep out dust and grit. Hence ball bearings have some torsional restraint, which affects forces
in the order of magnitude 1N .This shows up as a difference in readings for loading and
unloading.

Pin joints in trusses are also subject to friction, which increases in proportion to the loading.

Repeatability of Readings

The ability to obtain accurate and repeatable experimental results is generally a matter of care
and technique. Of course it helps to know the sources of error and to recognise when the
apparatus contributes to the variability of readings.

Frictional variation can be minimised by using vibration. The extend of the friction can be
observed by first increasing and then decreasing an applied load by hand to get the difference
in readings. Tapping the frame on which the experiment is mounted will reduce the variation.

Cast iron weights for loading must always be applied gently. A load suddenly added will
instantaneously apply twice is static. Although weights are hand finished there is a
manufacturing tolerance of +- ½ %. This may affect linearity in experimental readings.
INTRODUCTION

There are two main purposes for using a train of gears. The most important is to establish a
speed ratio between two rotating shafts; the other is to transfer rotation from one axis to
another with or without a change in the direction of rotation( that is clockwise or
anticlockwise). If spur gears are used the axes may be parallel or coincident. The use of bevel
gears enables the axes to be at an angle to each other.

In the following experiments the speed ratio is the subject being studied. Nevertheless some
account will be taken of the direction of rotation as this can be changed independently of the
speed ratio. Only simple spur gears will be used, although an introduction to the principles of
epicyclic gear trains is included in an elementary form. Hence there are several aspects of the
application of gears and gear trains to be learned by doing this experiment.

APPARATUS ASSEMBLY

The unit comes fully assembled with the spares (spare pin for compound gears and spare
spacer) situated onto the unit itself. No further assembly work is required other than preparing
the unit for the first experiment

During the course of the testing and experiments the unit will need multiple configurations of
the parts to be derived. This is done through unscrewing the gear pins, changing over the gears
and re-positioning into the different holes in the pivot arm
A pivoted arm mounted on a horizontal base carries three movables gear pin on which four
interchangeable spur gears can be arranged. All gears can be pinned together in order to
asssemle a compound gear train using the small pins supplied. The pivoting arm can be locked
in position for gear train work using the locking device at the non rotating end of the arm.
Alternatively it can be rotated about its pivot to simulate the planet arm of an epicyclic gear
system. The spur gears have 40, 60, 80 and 100 teeth and a module of 1

The arm has a series of threaded holes into which each gear pin mounts. The series of holes
allows many ratios to be made up from the gear supplied. All gears and gear pins have been
checked for free running when fixed to the arm, but a light drop of oil from to time will ensure
continuous free running.

Three spacer blocks are provided to ensure all gears mesh at the correct height when running
in a compound gear train arrangement. A spare spacer and joining pin are supplied. Also on
the rear of the base is a locating pin with wing nut for securing any spare gears and spacers
when not being used.

EXPERIMENT

There are two separate experiments to be performed on this apparatus, one on gear trains and
the other an introduction to epicyclic gears

NOTE: Clockwise rotation of the gears is denoted by +ve notation. Anticlockwise rotation of
the gears is denoted by-ve notation.

OBJETIVE No.1

The object is to study the speed ratios and directions of rotation of simple and compound gear
trains.

Procedure

Part .1 Simple Gear Trains

Assemble a two Wheel gear train the 80 tooth Wheel as the driver on the fixed pivot as shown
in the image above. Ensure the arm is in its locked position Add the 40 tooth gear as the
‘driven follower’ so that it meses with the driver gear. A spacer will be required on top of both
gears as shown. Mark the teeth of both gears at the point where they mesh using a pencil or
felt tip pen. To find the turns ratio (velocity ratio) turn the driver through one revolution
clockwise (+ve) and note how many full revolutions and/or part of a revolution the driven
follower Wheel completes.

As an alternative keep the driver through enough complete revolutions for the two marks to
come together again, and note the corresponding number of complete turns of the driven
Wheel (40 tooth gear)

Also record the direction in which the driven follower Wheel rotates, positive for CW negative
for ACW
Repeat the above procedure using the 60 and 100 tooth gear wheels, in turn as the driven
followers.

Table 1

Step Description

Driver revolutions

No.of follower teeth

Follower revolutions

Next assemble a three Wheel gear train as in the image above with the 80 tooth as the driver,
the 60 tooth Wheel at the end of the train and the 40 tooth in the middle of the two (idler),
spacer will be required on top of all gears as shown above.

Note the initial positions of marks on the driver and final Wheel of the train, and then
determine the turn ratio by rotating the driver 1 revolution clocwise (+ve) and recording the
rotation and direction of the final Wheel, complete table 1b

It is good practice to remove all marks from gears to avoid confusión in later experiments
Part 2. Compound gear trains

Note: Clockwise rotation of the gears is denoted by +ve notation, Anticlockwise rotation of the
gears is denoted by –ve notation

Position the 100 tooth gear as the driver with a spacer on top of it. Join the 40 and 60 tooth
gear using a small pin suplied, to créate a compound gear (It is advised to do this prior to
asembling to the pivot arm) With the 40 tooth gear uppermost and the 60 tooth gear
lowermost and meshing with the 100 tooth driver

Add the 80 tooth gear so that it meshes with the 40 tooth gear. A spacer underneath the 80
tooth gear will be required.

Create a pencil mark at the meshing point between the 100 and 60 tooth gears Create another
pencil mark at the meshing point between the 40 and 80 tooth gears. With the arm in its
locked position, rotate the driver Wheel 1 revolution clockwise and record the corresponding
directions and number of turns of the compound gears and final gear, in the following table 2

Table 2

Compound gear train

No. Of driver teeth A

No. Of teeth on bottom Compund Gear B

No. Of teeth on top Compound gear c

No. Of follower teeth D

Driver revolutions

Compound gear revolutions Follower Revolutions

Theoretical Speed Ratio

Where

N=Speed of relevant gear(rpm)

T=teeth on relevant gear Wheel

A=Driver gear

B=Large compound gear

C=Small compound gear

D=Follower
OBJECT No.2

The purpose of this experiment is to study the first principles of an epicyclic gear system
particular reference to the speed ratio and direction of rotation

Note:Clockwise rotation of the gears is denoted by +ve notation, Anticlockwise rotation of the
gears is denoted by –ve notation.

PROCEDURE

An epicyclic gear train consist of a train of wheels in which there is relative motion between
two of the axes of the wheels constituting the train. A form of such a train is shown below in
an experimental versión

The effect of the train (e) is given by

Speed of last Wheel relative to the arm

Speed of first Wheel relative to the arm

The value of e, being the velocity ratio of the train with the arm fixed, is easily calculated, and
is positive or negative according to whether the last Wheel and the first Wheel ratate in the
same or in opposite directions

Let s,r and f be the number of revolutions made in a given time by the sun Wheel, the last
Wheel and the arm respectively, relative to the base. Note that the last Wheel in this
experiment can be either the planet B or the outer ring C.
Then

The velocity ratio of any epicyclic train can be calculated by means of this formula and the
value of e

Hence

To simplify the design for the purpose of the experiment the planet Wheel frame is a single
arm that revolves on the same axis as the sun Wheel (But independently) while the outer ring
is represented by a normal spur gear (with many less teeth)

Part 1. Planet Wheel

Set up the 80 tooth Wheel as the sun Wheel with the 40 tooth Wheel in mesh as a planet
Wheel. Place gear spacers above each gear as shown above. The arm carrying the planet
Wheel should start in this locked position

As the velocity ratio of an epicyclic gear train is not easily observed when one considers the
simultaneous movement of gear wheels and arm, it is usually better to study the relative
movement of the gear wheels with the arm stationary, then the revolution of the gear trains
without any relative motion of the wheels, then finally the
Combination of these two operations. This system of establishing the relative motions is
ilustrated as follows

1.Step X Lock the arm Ensure the marks on the sun and planet wheels are together at the star
position (see figure 4.2)

2.Step X. Rotate the sun Wheel 1 revolution anti-clockwise (-ve) recording this and the
direction sing in the table 3ª below

3.Step Y. Release the arm and rotate the arm clockwise (opposite direction to step x)The sun
should rotate with the armo n its axis. Record the turns and sings carefully, bearing in mind the
method of counting the revolutions of the planet Wheel (Figure 4.3)

4.Add together (i, e , sum) the results of steps X and Y. This gives the turn ratio of all the gears
and arm when they are moving simultaneously

5.Step Z. Finally rotate the arm clockwise while holding the sun Wheel stationary. Record the
number of revolutions of the planet Wheel relative to the base noting is direction

Tabla 3ª

Relative motions of 80 tooth sun & 40 tooth planet wheels

Step

Step Description

Arm

Sun

Planet Formulae for Planet B

Keep arm stationary, rotate sun(ACW)

Rotate arm and sun together (CW) for 1 revolution of arm

Add steps X and Y together taking care to use the correct sing

Sun stationary, rotate arm (CW)

Repeat the whole procedure using the 60 tooth Wheel as the sun Wheel using tables similar to
table 3ª but labelling them 3b instead

You will see that adding steps Xand Y together is the same results as completing step Z, This is
because step Z is the culmination of these two processes

Part 2. Simple epicyclic gear

Add a 60 tooth “Outer” ring to the 80 tooth sun and 40 tooth planet Wheel chain as shown in
the image above (Figure 5) The experiment is to determine the speed and direction of the 60
tooth outer when the sun turns one revolution clockwise while the planet arm makes one
anticlockwise turn
1.Step X. Fix the arm in its locked position. Mark the mesh points of all gears

Table 3ª

Step

Step Description

Arm

Sun A

Planet B

Formulas for Planet B

Keep arm stationary, rotate sun (ACW)

Rotate arm and sun together (CW) for 1 revolution of arm

Add steps X and Y together taking care to use the correct sing

Sun stationary, rotate arm (CW)

Repeat the whole procedure using the 60 tooth Wheel as the sun Wheel using tables similar to
table 3ª but labelling them 3b instead

You will see that adding steps Xand Y together is the same results as completing step Z, This is
because step Z is the culmination of these two processes

Part 2. Simple epicyclic gear

Add a 60 tooth “outer” ring Wheel to the 80 tooth sun and 40 tooth planet Wheel chain as
shown in the image above (figure 5). The experiment is to determine the speed and direction
of the 60 tooth outer when the sun turns one revolution clockwise while the planet arm makes
one anticlockiwise turn.

1 Step X. Fix the arm in its locked position. Mark the mesh points of all gears
2.Step X Rotate the sun Wheel through 1 revolution clockwise. Note the direction and
revolutions of the planet and outer gears in table 4ª

3. Reset the gears to their original start positions so that the marks are aligned with each other

4.Step Y. Keep the sun stationary and rotate the arm anti-clockwise one revolution

5.Reset the gears to their original start positions so that the marks are aligned with each other

6. Add together (i.e. sum) the results of steps X and Y. This gives the turn ratiuo of all the gears
and arm when they are moving simultaneously

7.Step Z. The final action is to simultaneously ratate the sun Wheel once clockwise while
turning the arm once anticlockwise, and to count the number of revolutions and relative
directions of the planet and outer Wheel IT MAY BE EASIER TO DO THE PLANET FIRST, RESET
AND THEN DO THE OUTER as it is difficult to monitor both gears at the same time

Table 4ª

Relative motions of 80 tooth sun, 40 tooth planet & 60 tooth outer

Step

Step Description

Arm

Sun

Planet

Outer

Keep Arm Stationary and rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Add steps X and Y together taking care to use the correct sing

Sun clockwise, rotate arm (ACW)

Use the theory in the results processing section in this manual to calculate the revolutions of
the outer Wheel

Repeat part 2 for a 100 tooth sun Wheel, 40 tooth planet and 80 tooth outer Wheel, Record
the results ina similar table to table 4 above but labelling the table 4b
PART.3 COMPOUND EPICYCLIC GEAR

Next assembly the 100 tooth Wheel as the sun. Place the sun Wheel directly onto the arm
place a gear spacer on top of this gear, Join the 40 and 60 tooth gears as a compound gear
using the small pin supplied. Fix the compound gear. Then fix the remaining 80 tooth gear to
the arm so that it meshes with the 60 tooth Wheel of the compound gear assembly . The 80
tooth gear becomes the outer gear and a gear spacer will need to be placed underneath this
80 tooth gear

For use in table 5, the sun Wheel will be labelled as `A`,40 tooth gear labelled as ‘B’60tooth
gear labelled as ‘C’ and the outer 80 tooth gear labelled as ‘d’

1.Step X. Fix the arm in its locked position. Mark the visible mesh points of all gear

2.StepX Rotate the sun Wheel one revolution in a clockwise direction. Observe and record the
direction and number of revolutions (And parts of revolutions) of the 40 tooth gear within the
compound gear, and the outer gear

8.Reset the gears to their original start positions so that the marks are aligned with each other

3.Step Y. Rotate the arm anti-clockwise whilst keeping the sun stationary

4.Reset the gear to their original start positions so that the marks are aligned with each other

5.Add together (i.e.sum) the results of steps X and Y. This gives the turn ratio of all the gears
and arm when they are moving simultaneously

6.Step Z The final action is to simultaneously rotate the sun Wheel once clockwise while
turning the arm once anticlockwise, and to count the number of revolutions and relative
directions of the planet and outer Wheel. IT MAYEASIER TO DO THE PLANET FIRST, RESET AND
THEN DO THE OUTER as it is difficult to monitor both gears at the same time.

Table 5.

Relative motions of 100 tooth sun, 40/60 tooth pinned planet & 80 tooth outer

Use the theory in the results processing section in this manual to calculate the revolutions of
the outer Wheel.

In the case a real epicyclic gear system the outer ring must inevitably have a large number of
teeth. Estimate how many teeth it would have been for the simple epicycic gear of part 2, and
hence determine the speed ratio.

RESULTS PROCESSING

Compare the experimental results with the theoretical predictions

Where:

N=Speed (revolutions/unit time)

T=teeth on gear Wheel

D stands for driver

F stands for follower

Note:Nf will be –ve if the number of gear spindles is even and +ve if the number of gear
spindles is odd

For the three Wheel train the formula becomes

Where

N=speed (revolutions/unit time)

T=teeth on gear Wheel

D stands for driver

F stands for follower

I stands for idler

The compound gear train is resolved in a similar manner. Let the first driver and follower be
designated A and B, and the second set C and D. Then

But NB=NC, hence

Observations

What are the differences between a simple two and three Wheel gear train ? Predict what
would happen if a four wheel train using two idlers was set up

What advantage is there in using a compound gear train?

What would be the result in direction change if two compound gears were used?
EXAMPLE RESULTS for Simple Gear train

The following results were obtained by an average studen using clockwise +ve

GEAR TRAIN

Table 1

Step Description

Driver revolutions

No.of follower revolutions

Table 1b

Simple gear Train

Step Description

Driver revolutions

Idler teeth

No.of follower teeth

Follower revolutions

Table 2 Compound gear train

No. Of driver teeth

No.of teeth on bottom compound Gear B

No.of teeth on top compound Gear C

No. Of follower teeth, D

Driver revoltions

Compound gear Revolutions

Follower Revolutions

Theoretical speed ratio

WHERE

N=speed of relevant gear (rpm)

T=teeth on relevant gear Wheel

A= driver gear

B= Large compound gear

C= Small compound gear

D=Follower

EPICYCLIC GEARS

Part 1.

Table 3ª Relative motions of 80 tooth sun & 40 tooth planet wheels

Step

Step Description

Arm

Sun A

Planet B

Formulae for planet B revs

Keep arm stationary, rotate sun (ACW)

Rotate arm and sun together (CW) for 1 revolution of arm

Add steps X and Y together taking care to use the correct sign

Sun stationary, rotate arm

Table 3b Relative motions of 60 tooth sun & 40 tooth planet wheels

Step

Step Descriptions of 60 tooth sun & 40 tooth planet wheels

Step

Step Description

Arm

Sun A

Planet B

Formulae for Planet B

Keep arm stationary, rotate sun (ACW)

Rotate arm and sun together (CW) for 1 revolution of arm

Add steps X and Y together taking care to use the correct sign

Sun stationary, rotate arm (CW)

PART.2 Table 4ª

Relative motions of 80 tooth sun, 40 tooth planet &60 tooth outer

Step No.
Step Description

Arm

Sun

Planet

Outer

Keep arm Stationary and rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

Add steps X and Y together taking care to use the correct sign

Sun clockwise, rotate arm (ACW)

Table 4B

Relative motions of 100 tooth sun, 40 tooth planet &80 tooth outer

Step No.

Step Description

Arm

Sun

Planet

Outer

Keep arm Stationary and rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

Add steps X and Y together taking care to use the correct sign

Sun clockwise, rotate arm (ACW)

Table 5

Relative motions of 100 tooth sun, 40/60 tooth pinned planet &80 tooth outer

Step

Step Description

Arm

Sun A

Compound Planet gear B/C

Outer D

Keep arm Stationary and rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

Add steps X and Y together taking care to use the correct sign

Sun clockwise, Arm anti-clockwise

MAINTENANCE

P.A Hilton Ltd equipment needs Little maintenance since so far as posible materials and
finishes are corrosión proof and long lasting

Replacement and Spares

These can be ordered using the experiment and part number plus a description

Test Specimens

Most of the experiments are within the linear elastic range of the test specimen and materials
used

CONTACT DETAILS

Table 1 Simple Gear Trains

Step Description

Driver revolutions

No. Of follower revolutions

Result

Table 1b Simple Gear Trains

Step Description

Driver revolutions

Idler teeth

Follower revolutions

Table 2 Compound gear train

No.of driver teeth, A

No. Of teeth on bottom compound gear, B

No. Of teeth on top compound gear, c

No. Of follower teeth

Driver revolutions

Compound Gear Revolutions

Follower revoltions

Theoretical speed ratio

WHERE
N=speed of relevant gear (rpm)

T=teeth on relevant gear Wheel

A= driver gear

B= Large compound gear

C= Small compound gear

D=Follower

EPICYCLIC GEARS

PART 1

TABLE3A

SE REPITE UNA HOJA ANTERIOR

TABLE 4B

Relative motions of 100 tooth sun, 40 tooth planet &80 tooth outer

Step No.

Step Description

Arm

Sun

Planet

Outer

Keep arm Stationary and rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

Add steps X and Y together taking care to use the correct sign

Sun clockwise, rotate arm (ACW)

Part 3

Table 5

Relative motions of 100 tooth sun, 40/60 tooth pinned planet &80 tooth outer

Step

Step Description

Arm

Sun A

Compound Planet gear B/C

Outer D

Keep arm Stationary and rotate sun (CW)

Rotate arm and sun together (ACW) for 1 revolution of arm

Sun stationary, rotate arm (ACW)

Sun clockwise, arm anti- clockwise

Table 5

Relative motions of 100 tooth sun, 40/60 tooth pinned planet &80 tooth outer

Step

Step Description

Arm

Sun A

Compound Planet gear B/C

Outer D

Keep arm Stationary, rotate sun (CW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Sun stationary, rotate arm (ACW)

RESET ALL GEARS SO MARKS ARE ALIGNED AS AT START OF TEST

Add steps X and Y together taking care to use the correct sign

Sun clockwise, arm anti- clockwise