EXPERIMENT NO – 1

AIM: Study of various types of gear boxes such as Industrial gear box, Synchromesh
gear box, Differential gear box etc.
THEORY:
1) INDUSTRIAL GEARBOX:
An industrial gearbox is an enclosed system that transmits mechanical energy to
an output device. Gearboxes can modify their speed, torque, and other attributes
to convert the energy into a useable format. Gearboxes are used in a variety of
devices, for a broad range of purposes. These machines can slow the rate of
rotation to increase torque and speed.
An industrial gearbox is defined as a machine for the majority of drives
requiring a reliable life and factor of safety, and with the pitch line velocity of
the gears limited to below 25 m/s, as opposed to mass produced gearboxes
designed for a specific duty and stressed to the limit, or used for very high speeds
etc., e.g. automobile, aerospace, marine gearboxes. To the competent engineer,
the design of a gear unit, like any other machine, may seem a fairly easy task.
However without experience in this field the designer cannot be expected to
cover all aspects of gearbox design.
Applications of industrial gearboxes –
Sugar, Elevator, Cement, Paper, Textile, Plastic
& leather, Rubber, Power plants, Mines and
minerals, Waste water treatment, Tobacco Sugar,
Solvent Extraction, Coal, Steel And Engineering
Industries, Food Processing And Dairy Plants,
Drugs & Pharmaceutical Plants and Printing
Machinery. Industrial Helical Gearbox are
usually used in applications involving high shock
loads. Industrial Helical Gearboxes may require a
larger initial investment, but maintain high
efficiency, so they are usually preferred in high
load applications.
Gearboxes are used in a very wide range of industrial fields. Thanks to the use
of gearboxes, a small rotation force (torque) can be used to produce a much
greater rotation force, and a slow rate of revolution can be speeded up. In many
industries, the gearbox, which is the equipment that transmits mechanical power,
is an essential piece of equipment. In the most basic sense, a gearbox functions
like any system of gears; it alters torque and speed between a driving device like
a motor and a load.
 2) SYNCHROMESH GEARBOX:
A synchromesh gearbox is a usually manually operated transmission in which a
change of gears takes place between gears that are already revolving at the same speed.
Two synchromesh gears can engage with one another [running at different speeds]
without any jerking. Whereas non-synchromesh gears will cause jerking unless their
mating speeds are equal. Working of a synchromesh gear box is almost similar to that
of a constant mesh gear box, but it has a certain improvement over it. It has the provision
of synchromesh device which avoids the necessity of double declutching. The parts
which ultimately are to be engaged are first brought into frictional contact which
equalizes their speed, after which these may be engaged smoothly. This reduces the
unnecessary grinding noise which would occur due to the clatter. In most cars however
synchronous devices are fitted only on the higher gears and on the low and reverse gear
only dog clutches are provided. This is done to reduce the cost.

In this type of gearbox, gears can rotate freely or it are locked on layout shaft.
Synchromesh is really an improvement on dog clutch. The synchronizer is the main part
of this gearbox that stabilizes the speed. A synchronizer is a kind of clutch which lets
components turning at different speeds. To synchronize the speeds cone friction is used.
This synchronizer consists two parts, Synchro cone and Baulk ring. In synchromesh
gearbox Layshaft is connected to the engine directly, but it rotates freely when the clutch
is disengaged. Because the gears have meshed all the time, the synchro brings the
layshaft to the right speed for the dog teeth to mesh to achieve desire speed of output
shaft.
Principle - In a gearbox, there is always a difficulty in engaging the stationary gear
with the gears already rotating at a high speed. The principle states that “Before
engaging the gears they are brought in frictional contact with each other and after
equalizing the speed the engagement is done.”
3) DIFFERENTIAL GEARBOX –
A differential is a gear train with three shafts that has the property that
the rotational speed of one shaft is the average of the speeds of the others, or a
fixed multiple of that average. Differential gear, in automotive
mechanics, gear arrangement that permits power from the engine to be
transmitted to a pair of driving wheels, dividing the force equally between them
but permitting them to follow paths of different lengths, as when turning a corner
or traversing an uneven road. On a straight road the wheels rotate at the same
speed; when turning a corner the outside wheel has farther to go and will turn
faster than the inner wheel if unrestrained.

A differential allows the outer drive

wheel to rotate faster than the inner
drive wheel during a turn. This is
necessary when a vehicle turns in order
to allow the wheel that is traveling
along the outside of the turning curve
to roll faster and to cover greater
distance than the wheel on the inside of
the turning curve. The average of the
rotational speed of the two driving
wheels is simply the input rotational
speed of the drive shaft. An increase in
the speed of one wheel is balanced by
a decrease in the speed of the other. A transient analysis is performed to
compute the motion of the spider gears in cases where a vehicle moves on a
straight or curved path. The velocity magnitude of the different components
and the angular velocity of inner and outer wheels are calculated for the two
cases. The benefit of open type differential is mostly limited to the basic function
of any differential as previously described, focusing primarily on enabling the
axle to corner more effectively by allowing the wheel on the outside of the turn
to move at a faster speed than the inside wheel as it covers more ground. It does
also benefit from its basic design being relatively cheap to produce.

CONCLUSION –
We have studied the gearboxes – industrial, synchromesh and differential.