3.1.

1: Product Design Specifications of Reverted Gear Drive

1. Performance
 Gear drive should be able to reduce motor speed of 1500rpm to 150 rpm in two
stages.
 The gear drive to should be capable of handling motor power input of 5.5kW
2. Life in service
 The gear drive should be able to cope with 20,000 hour service interval
3. Maintenance
 All parts should be accessible.
 The replacements of parts should be done easily.
4. Manufacturing facility
 It should be possible to manufacture the gear drive in local workshops, with
traditional machine tools and welding facilities.
 Standard parts should be purchased from local suppliers.
5. Size
 It is recommended that the height of drive should be the same as the height of the
motor shaft.
 The width should be not exceeding 1 m.
 The length of the gear drive should not exceed 1 m.
6. Weight
 The mass of product should not exceed 100kg.
7. Materials
 18CrNiMo case-carburized steel is selected as gear material
 45C8 carbon steel is selected as shaft material
 Gear drive casing should be made out strong, durable and hard material that has
good damping capabilities.
8. Product life span
 The life span of the product shall be 5 years.
9. Standards
 Tooth error is 50μm
 Standardized 20 degrees full depth tooth system
 Rolling contact bearings are to be used
10. Ergonomics
 It should be easy to mount gear drive with motor
 Provisions to enable handling of the gear drive for movement should be made.
 Should be able to be relatively easy to disassembled and assembled in order to do
maintenance
11.Shelf life
 The gear drive may be stored for at least ten months without breakage or rusting
of its parts.
12. Process
 Machining and fabrication processes shall be done using traditional machine
tools, welding machines and equipment.
13.Safety
 Rotating parts should be covered.
 The gear drive should be safe during operation.
 The finishing of the parts of the gear drive shall be such that there will not be
sharp edges.
 3.1.2: Gear Data

 Gear 1 – 1st Stage Pinion (input driving gear)

 Gear 2 – 1st Stage Wheel (driven by gear 1)
 Gear 3 – 2nd Stage Pinion (driving gear, speed equal to gear 2)
 Gear 4 – 2nd Stage Wheel (output driven by gear 3)
 n - Speed [RPM]
 Z - Number of teeth
 d - Pitch circle diameter [mm]
 Pc - Circular Pitch [mm]
 A - Addendum circle diameter [mm]
 D - Dedendum circle diameter [mm]
 b - Face Width [mm]
 α - Pressure Angle [degrees]
 e - Gear Train Number
 m - Module

α = 20o: From table 9-4 minimum number of teeth (Z) required for a pressure angle of 20
degrees is 18

Choosing m = 1

n4
n1 = 1500 RPM, n4 = 150 RPM [from e = ] e = 1/10
n1

Hence in order for the gear drive to reduce the speed in 2 stages the 1st stage should have a

‘e1 = 1/5’ and 2nd stage should have ‘e2 = 1/2’

Z1 1
For 1st stage [ = ] hence,
Z2 5

Z2 = 5Z1 …. (i)
 Z3 1
For 2nd stage [ = ] hence,
Z4 2

Z4 = 2Z3 …. (ii)

We know that for reverted gear drive

Z1 + Z2 = Z3 + Z4 = K …… (iii)

Combining equation (i) & (ii) into equation (iii)

6Z1 = K ; 3Z3 = K

Hence using minimum number of teeth, Z1 = 18, we find K = 108 therefore Z3 = 36

Replacing values of Z1 and Z3 into equations (i) and (ii), we get Z2 = 90 and Z4 = 72

Hence Z1 = 18, Z2 = 90, Z3 = 36, Z4 = 72

Hence the speeds of the gears can be obtained from

n1 Z2 n3 Z4
= = 5 and = =2
n2 Z1 n4 Z3

We get n1 = 1500 RPM, n2 = 300 RPM, n3 = n3 = 300RPM and n4 =150 RPM

d
As m = 1 [from m = ] therefore, d = Z, hence,
Z

d1 = 18 mm, d2 = 90 mm, d3 = 36 mm, d4 = 72 mm

Meaning

A1 = 2(1m) + d1 = 2(1)(1) + 18 = 20 mm

A2 = 2(1m) + d2 = 2(1)(1) + 90 = 92 mm

A3 = 2(1m) + d3 = 2(1)(1) + 36 = 38 mm

A4 = 2(1m) + d4 = 2(1)(1) + 72 = 74 mm

D1 = d1 - 2(1.25m) = 18 - (2)(1.25)(1) = 15.5 mm

D2 = d2 - 2(1.25m) = 90 - (2)(1.25)(1) = 87.5 mm

D3 = d3 - 2(1.25m) = 36 - (2)(1.25)(1) = 33.5 mm

D4 = d4 - 2(1.25m) = 72 - (2)(1.25)(1) = 69.5 mm

b = 10m = (10)(1) = 10 mm

𝜋𝑑
Pc1 = Pc2 = Pc3 = Pc4 = = π = 3.14 mm
𝑍