BB502 Xd07aen E1

MECHANICAL
LEARNING
DRIVES 1 ACTIVITY
PACKET
MULTIPLE SHAFT DRIVES
BB502-XD07AEN
LEARNING ACTIVITY PACKET 7
MULTIPLE SHAFT DRIVES
INTRODUCTION
In the last LAP, you learned about gear drives which only have two gears. In this
LAP, you will continue your study of gear drives by exploring the operation and
applications of gear drives which have more than two gears. Multiple pairs of gears can
be used to drive multiple output shafts, create higher gear ratios, and reverse the direction
of rotation of output shafts which are on the same axis as the input shaft. These setups are
quite common in gear reducers and other machinery.
Also, this LAP will continue your study of couplings by learning about solid
couplings. Solid couplings are used both for very small and very large motors. They
are also used to extend the length of a shaft by connecting it to another shaft. The major
disadvantage of solid couplings is that they can tolerate no misalignment.
ITEMS NEEDED
Amatrol Supplied
950-ME1 Mechanical Drives 1 Learning System
Amatrol or School Supplied

Assorted Hand Tools
FIRST EDITION, LAP 7, REV. B

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol,
Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 2012 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic,
optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and
retrieval system, without written permission of the copyright owner.
Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
BB502-XD07AEN MULTIPLE SHAFT DRIVES 2

Copyright © 2012 Amatrol, Inc.
TABLE OF CONTENTS
SEGMENT 1 MULTIPLE SHAFT GEAR ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe how to calculate the speed and torque output in a multiple shaft gear drive
SKILL 1 Calculate the shaft speed and torque of a multiple shaft gear drive system
OBJECTIVE 2 Describe the function of a compound gear drive system and give an application
OBJECTIVE 3 Describe how to calculate the torque and speed output of a compound gear drive system
SKILL 2 Calculate the torque and speed output of a compound gear drive system
SEGMENT 2 MULTIPLE SHAFT DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OBJECTIVE 4 Describe how to determine the direction of rotation of a gear drive
SKILL 3 Determine the direction of rotation of a gear given its position in a gear drive
OBJECTIVE 5 Describe how to install and align a multiple shaft drive system
SKILL 4 Install and align a multiple shaft drive system
SEGMENT 3 SLEEVE COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

OBJECTIVE 6 Describe the function of a solid coupling and list two types
OBJECTIVE 7 Describe the operation of a sleeve coupling and give an application
OBJECTIVE 8 Describe the alignment procedure of a sleeve coupling
SKILL 5 Install and align a sleeve coupling and shaft

SEGMENT 1
MULTIPLE SHAFT GEAR ANALYSIS
OBJECTIVE 1 DESCRIBE HOW TO CALCULATE THE SPEED AND TORQUE

OUTPUT IN A MULTIPLE SHAFT GEAR DRIVE
Gear drives can have more than two gears in the gear train. These additional
gears act either as idlers or to drive an additional output shaft. As mentioned in an
earlier LAP, idler gears are used mainly to change the direction of rotation or to
transfer the power to a shaft which is located further away from the driver shaft.
INPUT
GEAR
IDLER
GEARS OUTPUT
GEAR
10
TEETH
20
30 TEETH
TEETH
60
TEETH
Figure 1. Idler Gears

An example of a multiple output shaft gear drive is the lathe shown in figure 2.
For each shaft driven, a separate gear is needed.
Figure 2. Lathe Gear Drive

In either case, the method used to determine the speed and torque output of a
gear drive with more than two gears is basically the same. To understand how to
do this, it is first important to note that idler gears do not affect either the torque
or the speed of the driven shaft. To understand why, look at the example in figure
3. If you were to calculate the gear ratio by multiplying the ratios of each pair of
neighboring gears together, the effect of the idler gears is canceled out as follows:
Formulas now looks like:
A B C
R= × ×
B C D
60 10 20 60
R= × × =
10 20 30 30
Notice that the number of teeth of both idler gears are used twice in the formula.
Therefore, they cancel each other out as shown.
This calculation results in a gear ratio of 2:1. This is the same gear ratio you
would get if you calculated the gear ratio without accounting for the idler gears
(60 / 30 = 2). Since the idler gears do not affect the gear ratio, they do not affect
the speed or torque. The same formulas used in the previous LAP to calculate the
speed and torque of two gears can therefore be used to calculate the output of a
gear drive with multiple gears.
OUTPUT
A GEAR
IDLER
INPUT GEARS
GEAR
D C
B
10
TEETH
20
30 TEETH
TEETH
60
TEETH
Figure 3. Effect of Idler Gears

The speed of any driven gear is therefore determined by calculating the gear
ratio using the driven gear as the output gear along with the input gear and ignoring
all other gears in between. For example, the gear drive shown in figure 4 has three
output gears, each of which drive a separate shaft with a separate load. It also has
one true idler gear. The gear ratios of the three output gears are as follows:
R1=30/20=1.5
R2=10/20=0.5
R3=60/20=3.0
The speed of each output shaft can now be calculated separately using its own
gear ratio. The idler gear has no effect on the speed of any output shaft. Also, the
speed of one output shaft has no effect on the speed of the other output shafts
because they act like idlers with respect to the other shafts.
OUTPUT OUTPUT
OUTPUT
SHAFT 1 SHAFT 2
SHAFT 3
TORQUE TORQUE
TORQUE = 20 in-lbs
30 in-lbs 15 in-lbs
INPUT
GEAR
20 TEETH
OUTPUT OUTPUT OUTPUT

GEAR 1 GEAR 2 GEAR 3
30 TEETH 10 TEETH 60 TEETH
IDLER
MOTOR GEAR
15 TEETH
TOTAL INPUT
TORQUE
Figure 4. Gear Drive with Three Output Shafts
The total torque required from the input shaft is calculated by summing the
torques that would be required to drive each output shaft by itself. The torque
created at the driver shaft by each output shaft is found by dividing the output
torque by the gear ratio.
Output Torque
Input Torque =
Gear Ratio
For example, the torque created at the driver shaft by gear 3 is found by dividing
shaft 3’s output torque by its gear ratio as follows:
T3 = 20/3 = 6.7 in-lbs.

The same goes for the torque created by shafts 2 and 1:
T2 = 15/0.5 = 30 in-lbs.
T1 = 30/1.5 = 20 in-lbs
The total torque created on the driver shaft is then calculated by summing the
individual torques as follows:
T=T1+T2+T3
=20+30+6.7
Total Input Torque = 56.7 in-lbs
SKILL 1 CALCULATE THE SHAFT SPEED AND TORQUE OF

A MULTIPLE SHAFT GEAR DRIVE SYSTEM
Procedure Overview
In this procedure, you will use the formulas just described to determine
speed and torque of either the driver or the driven shaft of a gear drive which
has more than one output gear.
 1. Calculate the driven shaft speeds of the two output gears of the gear drive
system shown in figure 5.
Gear 1 Shaft Speed _______________________________________ (RPM)
Gear 2 Shaft Speed _______________________________________ (RPM)
INPUT GEAR 1 IDLER GEAR GEAR 2

GEAR 20 TEETH 10 TEETH 20 TEETH
10 TEETH 200 in-lbs 150 in-lbs
500 RPM
Figure 5. Gear Drive System
The solution is:
Gear 1=250 RPM

Gear 2=250 RPM

 2. Calculate the driver shaft torque created by gears 1 and 2 in the gear drive
shown in figure 5.
Driver Shaft Torque_______________________________________ (in-lbs)
The solution is 175 in-lbs.

 3. Calculate the driver shaft speed of the gear drive system shown in figure 6.
Driver Shaft Speed _______________________________________ (RPM)
INPUT IDLER
(DRIVER) 10 TEETH
15 TEETH
OUTPUT
(DRIVEN)
IDLER
10 TEETH
20 TEETH
1000 RPM
500 in-lbs
The solution is 667 RPM.

 4. Calculate the driver shaft torque of the gear drive shown in figure 6.

 5. Calculate the driven shaft speed of the gear drive system shown in figure 7.
Output Shaft 1 Speed _____________________________________ (RPM)
Output Shaft 2 Speed _____________________________________ (RPM)
INPUT
GEAR
10 TEETH
OUTPUT 1
30 TEETH
200 in-lbs
400RPM
20 TEETH
200 RPM
OUTPUT 2
15 TEETH
500 in-lbs
20 TEETH
The solution is Output 1 = 133 RPM.
Output 2 = 267 RPM.

 6. Calculate the total torque at the input gear.
Input Torque ____________________________________________ (in-lbs)

OBJECTIVE 2 DESCRIBE THE FUNCTION OF A COMPOUND GEAR DRIVE
SYSTEM AND GIVE AN APPLICATION
A compound gear drive is a type of gear train that has two or more gears
mounted on one shaft, as shown in figure 8. These gears can be mounted anywhere
on the shaft, either next to each other or on opposite sides of the shaft.
COMPOUND
GEAR 1
INPUT
OUTPUT
Figure 8. Compound Gear Drive

Compound gear drives are used in several types of applications. Two such
applications are driving two output shafts at different speeds and driving an output
shaft which is offset from the driver shaft, as shown in figure 9.
OUTPUT
SHAFT 1 OUTPUT
SHAFT 2
INPUT
GEAR
COMPOUND
SHAFT
MOTOR
Figure 9. Compound Gear Drive Applications
A third type of application for the compound gear drive is to create a gear
reduction between two shafts which are located on the same axis, as shown in
figure 10. This is called a reverted gear drive.
COMPOUND
SHAFT
INPUT
SHAFT
OUTPUT
SHAFT
MOTOR
Figure 10. Reverted Gear Drive

OBJECTIVE 3 DESCRIBE HOW TO CALCULATE THE TORQUE AND SPEED
OUTPUTS OF A COMPOUND GEAR DRIVE SYSTEM
The concepts which were used to calculate speed and torque of simple
multiple-gear gear drives can also be applied to compound gear drives with one
minor change. The gear ratio of any gears that are mounted on the same shaft must
be included in the calculation. In effect, these gear ratios must be combined as
shown in the following formula:
FORMULA: COMPOUND GEAR DRIVE SPEED
Driver Speed (RPM) ⎡ Pitch Dia. Driven ⎤ ⎡ Pitch Dia. Com Input ⎤
= ×
Driven Speed (RPM) ⎢⎣ Pitch Dia. Driver ⎥⎦ ⎢⎣ Pitch Dia. Com Output ⎥⎦
OR
Driver Speed (RPM) ⎡ No. Teeth Driven ⎤ ⎡ No. Teeth Com Input ⎤
= ×
Driven Speed (RPM) ⎢⎣ No. Teeth Driver ⎥⎦ ⎢⎣ No. Teeth Com Output ⎥⎦
Where: Com Output = Compound Output Gear

Com Input = Compound Input Gear
As you can see, the formulas for speed are the same as the simple gear drive
except that they are multiplied by the gear ratio of the compound gears. Like a
simple gear drive, idler gears have no effect of the output speed.

To give an example of how these formulas work, look at the compound gear
drive shown in figure 11. In this case, the gear ratio of the driven to driver gears is
3:1 and the gear ratio of the compound gears is 1:2. This means that the combined
or compound gear ratio is 3:2. The speed of the output gear is therefore 1200 RPM
given an input speed of 1800 RPM.
The drive in figure 11 is called a double reduction gear drive because it reduces
the speed using the combination of 2 gear ratios. A triple reduction would use 3
gear ratios and have 2 compound gear sets.
DRIVEN GEAR
COMPOUND 30 TEETH
OUTPUT GEAR
20 TEETH
DRIVER COMPOUND
GEAR INPUT GEAR
10 TEETH 10 TEETH
1800 RPM
MOTOR
Figure 11. Compound Gear Drive Application
In a similar way, the torque output is also determined by combining the two
gear ratios. These formulas are as follows:
FORMULA: COMPOUND GEAR DRIVE TORQUE
Driven Torque ⎡ Pitch Dia. Driven ⎤ ⎡ Pitch Dia. Com Input ⎤

= ×
Driver Torque ⎢⎣ Pitch Dia. Driver ⎥⎦ ⎢⎣ Pitch Dia. Com Output ⎥⎦
OR
Driven Torque ⎡ No. Teeth Driven ⎤ ⎡ No. Teeth Com Input ⎤

= ×
Driver Torque ⎢⎣ No. Teeth Driver ⎥⎦ ⎢⎣ No. Teeth Com Output ⎥⎦

SKILL 2 CALCULATE THE TORQUE AND SPEED OUTPUTS OF
A COMPOUND GEAR DRIVE SYSTEM
Procedure Overview
In this procedure, you will use the formulas just described to determine
speed and torque of either the driver or the driven shaft of a compound gear
drive.
 1. Calculate the driven shaft speed of the compound gear drive system shown in
figure 12.
Driven Shaft Speed _______________________________________ (RPM)
DRIVEN GEAR
COMPOUND 30 TEETH
OUTPUT GEAR
20 TEETH
DRIVER
GEAR COMPOUND
15 TEETH INPUT GEAR
1500 RPM 20 TEETH
750 in-lbs
MOTOR

 2. Calculate the driven shaft torque of the compound gear drive shown in figure
12.
Driven Shaft Torque ______________________________________ (in-lbs)

 3. Calculate the driver shaft speed of the compound gear drive system shown in
figure 13.
DRIVEN GEAR
COMPOUND
10 TEETH
OUTPUT GEAR 1850 RPM
20 TEETH 250 in-lbs
DRIVER COMPOUND
GEAR INPUT GEAR
25 TEETH 10 TEETH
MOTOR

 4. Calculate the driver shaft torque of the compound gear drive shown in figure
13.

 5. Calculate the driver shaft speed of the compound gear drive system shown in
figure 14.
2000
COMPOUND
GEAR 3
1000 20 TEETH
COMPOUND
OUTPUT GEAR 2
20 TEETH
COMPOUND
GEAR 1
10 TEETH COMPOUND
DRIVER GEAR 4
GEAR 10 TEETH
10 TEETH
DRIVEN
GEAR
20 TEETH
MOTOR
OUTPUT
SHAFT
2000 RPM TORQUE 400 in-lbs
SPEED 1000 RPM

 6. Calculate the driver shaft torque of the compound gear drive shown in figure
14.

SEGMENT 1
SELF REVIEW
1. ___________ gears only change the direction in which a driven gear

rotates. It has no affect on the speed and torque that is transferred from
driver to driven shafts.
2. To calculate the speed and torque of a multiple shaft drive, you only
need the gear ratio of the output gear and the driver gear. All other
gears are ___________.
3. A(n) ___________ shaft drive has a driver gear and several output
gears.
4. ___________ torque is found by summing all of the torque that would

be required to drive each output shaft by itself.
5. When calculating the speed and torque of a(n) ___________ drive, you
need to apply all gears that are mounted to the same shaft.
6. ___________ gear drives have more than one gear mounted on the
same shaft.

SEGMENT 2
MULTIPLE SHAFT DRIVE INSTALLATION
OBJECTIVE 4 DESCRIBE HOW TO DETERMINE THE DIRECTION OF

ROTATION OF A GEAR DRIVE
Each gear which is added to a gear train causes the driven gear’s rotation direc-
tion to change. When there are only two gears, the driven gear turns in the opposite
direction to the driver gear, as shown in figure 15. If one gear is added, either an
idler gear or another driven gear, the direction of rotation of the first driven gear
will be the same as the driver gear.
EVEN NUMBER OF GEARS
INPUT OUTPUT
CW CCW
ODD NUMBER OF GEARS

INPUT OUTPUT
CW CW
Figure 15. Effect of Multiple Gears on Rotation of Output Gear

To determine the direction of rotation of a gear drive, you can remember that
an even number of gears in the drive causes the driven gear to turn in the opposite
direction, and an odd number of gears causes the driven gear to turn in the same
direction.
The exception to the even/odd rule is for compound gear drives. In this case,
you should treat gears which are on the same shaft as one gear. For example, the
compound gear drive in figure 16 has four gears. Since two gears are on the same
shaft, the number of gears to use with the even/odd rule is three. Therefore, the
output turns in the same direction as the input In this case, it is clockwise.
TURN CCW
FROM THIS
SIDE
COMPOUND
OUTPUT GEAR
DRIVEN
GEAR
MOTOR CW
DRIVER INPUT
GEAR COMPOUND
GEAR
VIEW
DIRECTION
CW
Figure 16. Effect Compound Gears on Rotation of Output Gear
A final point to remember about the direction of rotation is that these rules are
based on looking at the rotation of the output shaft from the same side from which
you viewed the input shaft. If you are viewing the output shaft from the opposite
side, the direction of rotation is reversed. For example, the output shaft in figure 16
turns CW when you look at the shaft from the side indicated by the arrow. From
the opposite side the shaft turns CCW.

SKILL 3 DETERMINE THE DIRECTION OF ROTATION OF A GEAR
GIVEN ITS POSITION IN A GEAR DRIVE
Procedure Overview
In this procedure, you will use the even/odd rule to determine the direction
of rotation of various gear drives. This is a basic skill you will need in order
to understand the operation of gear-driven machinery. You will also apply this
skill when designing or modifying existing gear drives.
 1. Determine the direction of rotation of the output shaft of the gear drive
system shown in figure 17. Give your answer as either clockwise (CW) or
counterclockwise (CCW) while looking at the end of the shaft indicated by
the arrow shown in the figure.
Direction of Rotation _________________________________ (CW/CCW)
CW
MOTOR

 2. Determine the direction of rotation of the input shaft of the gear drive
OUTPUT
MOTOR CW
INPUT

OUTPUT
MOTOR
CW
INPUT

CW
OUTPUT
MOTOR

OUTPUT
MOTOR
CW
In each of the above cases, you should have found the resultant direction of
rotation to be counterclockwise (CCW).

OBJECTIVE 5 DESCRIBE HOW TO INSTALL AND ALIGN A MULTIPLE
SHAFT DRIVE SYSTEM
Each shaft in a multiple shaft drive system must be individually aligned. The
alignment procedures for each shaft are the same as those for a single shaft drive
system. Although each shaft in the system must be individually aligned, there is
a certain order in which to align the shafts. Normally, the order of alignment is to
start with the last output shaft in the drive and work backwards toward the driver
shaft.
For example, in figure 22, generator #2 and the motor should be aligned first
and generator #1 and the motor last. For the first alignment, the motor is the move-
able machine. For the second alignment it is the stationary machine while gener-
ator #1 acts as the moveable machine.
MOVEABLE
MOVEABLE MACHINE/ STATIONARY
MACHINE STATIONARY MACHINE
MACHINE
GENERATOR GENERATOR
MOTOR
#1 #2
Figure 22. Alignment of Multiple Shaft System
Before you start the installation and alignment procedure, determine the actual
height of each shaft. To allow for shims to be added to align the shaft during the
alignment procedure, the driven shaft of each component should be slightly higher
than the driver shaft. The amount of difference in height depends on how uneven
the surface is. A good height difference to start with is 0.010 to 0.015 inches. This
means that each shaft must be progressively lower than the one downstream.

The alignment example shown in figure 22 addresses in-line shafts. For in-line
shafts, the centerlines of the two shafts must be in line with each other.
For adjacent shaft power transmission, the centerlines of the two shafts only
have to be parallel with each other, as shown in figure 23. The shaft heights can be
different to a certain degree without affecting the operation.
SIDE VIEW
GEAR 2
GEAR 1
H2
H1
OVERHEAD VIEW
GEARS
BEARING
PARALLEL
AXES
Figure 23. Adjacent Shaft-to-Shaft Alignment

SKILL 4 INSTALL AND ALIGN A MULTIPLE SHAFT DRIVE SYSTEM
Procedure Overview
In this procedure, you will assemble and align a spur gear drive which uses
multiple gears. First, you will assemble a simple gear system which uses two
gears and an idler. Then you will assemble a compound drive. In addition to
learning how to align a multiple shaft system, this skill will allow you to verify
the speed and torque characteristics of multiple shaft drives.
 1. Perform the following safety checkout to prepare for working with power
transmission equipment. Make sure that you are able to answer yes to each
item before proceeding.
YES/NO SAFETY CHECKOUT

Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
 2. Perform a lockout/tagout on the Motor Control Unit’s safety switch.

 3. Place the following panels on the Mechanical Drives System’s overhead rack.
• Shaft Panel 1
• Shaft Panel 2
• Gear Panel 1
 4. Perform the following substeps to mount and level the Variable Speed Gear
Motor.
A. Locate the Variable Speed Gear Motor and place it on the work surface.
B. Select four Gear Motor Risers from Shaft Panel 2.
C. Make sure that the motor base, risers, and mounting area of the work
surface shown in figure 24 are free of dirt, rust, and burrs.
D. Position the Gear Motor over the set of holes on the 950-ME work surface,
as shown in figure 24.
The outlines of the other components to be mounted are also shown.
SHAFT 4 (8") GEAR 3

GEAR 1
SHAFT 3 (12")
SHAFT 2 (6")
GEAR 1
GEAR 2
SHAFT 1 (12")
Figure 24. Positioning of Motor on 950-ME Work Surface
E. Place one Gear Motor Riser under each of the motor feet.
F. Locate four bolts with the specifications 5/16-18UNC-2A x 2-1/2 Hex
Head, along with compatible flat washers, lock washers, and nuts.
G. Fasten the motor base and risers to the work surface by assembling bolts,
washers, and nuts.
Use a criss-cross pattern to tighten the bolts.

H. Check the shaft for run-out. Record below the amount of run-out.
Run-out: ____________________________________________ (in/mm)
The run-out should be less than 0.002 inches.
I. Check for motor shaft end float.
End Float ___________________________________________ (in/mm)
It should be less than 0.002 inches.
J. Check the level of the motor shaft. Shim the motor feet as needed.
Feeler Gauge Leaf Thickness____________________________ (in/mm)
Effective Level Length _________________________________ (in/mm)
Mounting Bolt Distance ________________________________ (in/mm)
Shim Ratio _________________________________________________
Shim Thickness ______________________________________ (in/mm)

 5. Perform the following substeps to mount Shaft No. 1 and its pillow block
bearings.
A. Select four Bearing Standoffs from Shaft Panel 1.
B. Make sure that the standoffs, pillow block mounting surface, and mounting
area of the work surfaces, shown in figure 24, are free of dirt, rust and
burrs.
C. Place the four standoffs on the 950-ME work surface over the hole loca-
tions shown for Shaft 1.
D. Remove two pillow block bearings from Shaft Panel 1.
E. Place the pillow block bearings on the standoffs.
F. Locate four bolts with the specifications of 3/8-16UNC-2A x 4-1/2 Hex
Head, along with the compatible flat washers, lock washers, and nuts.
G. Fasten the pillow block bearings and the standoffs to the work surface by
assembling the bolts, washers, and nuts.
Hand tighten only.
H. Select a 12-inch long shaft from Shaft Panel 1.
I. Slide the shaft through the two pillow block bearings. Position it as shown
in figure 24.
J. Tighten the set screws on each bearing collar to lock the collar and prevent
it from turning.
K. Tighten the pillow block bearing mounting bolts.
L. Turn the shaft by hand to make sure it turns freely.
If not, loosen the bolts and adjust the positions of the bearings.
M. Check the driven shaft for run-out.
Run-out: ____________________________________________ (in/mm)
The shaft should have no more than 0.002 inches run-out.

N. Level the driven shaft. Shim the bearing standoffs as needed.
Place the shims between the work surface and the standoffs.
Shim Ratio _________________________________________________

 6. Repeat Step 5 in a similar manner to mount Shafts 2 and 3 on their pillow
block bearing, as shown in figure 24. Note the shaft length specified in figure
24 for each shaft.
 7. Mount the prony brake.
 8. Obtain Gears 1 (Quantity 2), 2, and 3 from the Gear Drive Panel 1.
 Inspect them and clean if needed.
 9. Attach the gears to the following shafts, as shown in figure 25.
 Loosen the mountings on Shafts 1 and 2 if needed.
 Gear 1 (36N) - Shaft 1
Figure 25. Gear and Shaft Setup

 10. Adjust the position of Shaft 3 so that Gears 1 and 3 mesh smoothly and have
a minimum of backlash.
 Shaft 4 is considered the stationary shaft. For this skill, you will adjust the
backlash by feel rather than by indicator measurement. This is being done to
save time, but it is an acceptable method for many applications, especially
those that drive in one direction only.
 11. Use a straight edge to align Gears 1 and 3 (mounted to shafts 3 and 4), as
shown in figure 26. Then tighten the mounting bolts for Shaft 3.
Figure 26. Aligning the Gears

 12. Now adjust the position of Shaft 2 so that Gears 2 and 3 mesh smoothly and
have a minimum of backlash.
 13. Use a straight edge to align Gears 1, 2, and 3. Then tighten the mounting bolts
on Shaft 2.
 14. Adjust the position of Shaft 1 so that Gears 1 and 2 mesh smoothly and have
a minimum of backlash. Now Shaft 2 is the stationary shaft.

 15. Use a straight edge to align gears 1, 2, 3 , and 1. Then tighten the mounting
bolts on Shaft 1.
Figure 27. Variable Speed Motor Setup

 16. Perform the following substeps to couple the Variable Speed Motor to the
shaft.
A. Loosen the bolts on the Variable Speed Motor and pull the motor back
away from the shaft and pillow block bearings.
B. Obtain the flexible jaw hub for the Variable Speed Motor, located on the
Shaft Panel 2.
It is the same as the coupling hub you used with the Constant Speed
Motor, except that the bore is 1/2 inch instead of 5/8 inch.
C. Slide the hub onto the Motor Shaft and lock it on the shaft by turning its
set screw.
D. Locate one of the two flexible jaw coupling hubs which have a 5/8-inch
bore and slide it on the shaft. Lock it into place using the set screw.
E. Place the spider on one of the hubs.
F. Move the motor forward so that the two hubs engage.
G. Set the gap to 0.5 inches using a rule.
H. Tighten the motor mounting bolts.
I. Use the straight-edge and feeler gauge method to align the coupling.
NOTE
Review LAP 3 if needed for the details of this procedure.
J. Apply a small piece of reflective tape to the faces of both #1 gears.

 17. Lightly apply Teflon lubricant to the gears.
 18. Perform the following substeps to start the Variable Speed Motor.
A. Make sure that the safety switch power cord is plugged into a wall outlet.
B. Connect the Gear Motor’s power cord to the Motor Control Unit through
the Motor Port.
C. Adjust the speed control knob on the Motor Control Unit to zero (fully
CCW).
D. Make sure that the Motor Power switch is in the OFF or down position.
E. Install the guard.
WARNING
Do not operate the mechanical drive system without the guard in place.
Also, do not attempt to open or bypass the guard at any time during operation.
Performing any of these actions will create a hazard situation.
F. Remove the lockout/tagout.

G. Turn on the safety switch.
H. Make sure that no one is near the motor.
I. Turn on the Gear Motor by moving the Motor Power switch to the ON or
up position.
The motor should run slowly or not at all.
 19. Gradually increase the motor speed by turning the speed control knob
clockwise.
 20. Measure the speeds of the driver shaft (Shaft 1) and the driven shaft (Shaft 4).
Driver Rotation Direction ______________________________ (CW/CCW)
Driven Rotation Direction ______________________________ (CW/CCW)

 Compare these readings to the data you took in the previous LAP. You should
see that the speed is unaffected by the idler gear. But notice that the rotation
direction of the driver and driver gear is the same.
 21. Reduce the speed to minimum and turn off the motor.
 22. Perform a lockout/tagout and remove the guard.

 23. Now rearrange the shafts and gears so that it forms the compound gear drive
shown in figure 28.
 Start your alignment from shaft 4 and work backwards and apply small pieces
of reflective tape to the faces of gears 3 and 7.
SHAFT 4
8"
PRONY
BRAKE
GEAR 7
SHAFT 3
GEAR 2 12"
SHAFT 2 GEAR 6
6"
GEAR 1 GEAR 3 SHAFT 1

12"
Figure 28. Compound Gear Drive

 Your setup should be as shown in figure 29.

Figure 29. Current Setup
 24. Install the guard.
 25. Remove the lockout/tagout.
 26. Start the motor and increase the speed to the maximum.
 27. Record the speed and direction of rotation of the drives and driven.
Driver Rotation Direction ______________________________ (CW/CCW)
Driven Rotation Direction ______________________________ (CW/CCW)

 28. Reduce the speed to minimum and turn off the motor.
 29. Perform a lockout/tagout.
 30. Remove the guard.
 31. Calculate the theoretical output speed given the actual driver speed you
measured in step 27 and given the following:
 Gear 1:36 Teeth
 Gear 2:24 Teeth
 Gear 3:48 Teeth
 Gear 6:64 Teeth
 Gear 7:80 Teeth
Theoretical Output Speed __________________________________ (RPM)
How does this compare with your actual readings?

_____________________________________________________________
_____________________________________________________________
 32. Disassemble the components and store them.

SEGMENT 2
SELF REVIEW
1. Each gear that is added to a gear train causes the direction of rotation
to _____________.
2. An even number of gears in a train causes the driven shaft to rotate in

the direction _____________ to that of the driver shaft.
3. An odd number of gears in a gear train causes the driven shaft to rotate
in the _______________ direction as the driver shaft.
4. The exception to the even/odd gear rules is found in ______________

gear drives.
5. Each shaft in a multiple shaft drive must be individually

__________________.
6. The order of alignment of a multiple shaft drive is to start with the

___________ shaft first.

SEGMENT 3
SLEEVE COUPLINGS
OBJECTIVE 6 DESCRIBE THE FUNCTION OF A SOLID COUPLING

AND LIST TWO TYPES
Solid couplings rigidly connect two shafts together to make them a rigid unit.
They are used when it is necessary to either extend the length of a shaft or provide
a means of disconnecting the shaft. Solid couplings are rarely used to connect
motors to driven components such as pumps and gearboxes because they do not
allow any misalignment. The only exception is when there is the need for absolute
alignment.
SOLID
SHAFT COUPLING HAFT 2
Figure 30. Connection of Two Shafts Using a Solid Coupling

The two most common types of solid couplings are sleeve couplings and flange
couplings, as shown in figure 31.
Figure 31. Sleeve and Flange Couplings
OBJECTIVE 7 DESCRIBE THE OPERATION OF A SLEEVE COUPLING

AND GIVE AN APPLICATION
Sleeve couplings can either be solid or split. The solid sleeve coupling is a
solid cylinder of metal which is designed to slide over the two shafts and clamp
them together by means of a set screw on each shaft, as shown in figure 32. To
install this type, the two shafts must be able to be moved away from each other.
Figure 32. Solid Sleeve Couplings

The split sleeve coupling clamps the two shafts together using two half-round
pieces which clamp to each other using bolts, as shown in figure 33. The split
feature allows them to be removed without moving the two shafts away from each
other. It usually has ribs on its outer casing, as shown in figure 33.
Figure 33. Split Sleeve Couplings
Sleeve couplings are mainly used on smaller shafts having diameters less than
6 inches, while larger shafts use flange couplings. Since they do not allow any
misalignment, they are mainly used on longer shafts. This is due to the fact that
any misalignment in longer shafts can be compensated by the distance between the
bearings.

OBJECTIVE 8 DESCRIBE THE ALIGNMENT PROCEDURE OF
A SLEEVE COUPLING
The basic procedure for installing and aligning a sleeve coupling is first to level
the two shafts and make them the same height. Before doing this, place the sleeve
coupling on one of the two shafts to be coupled and to slide it back on the shaft, as
shown in figure 34. Then level and align the shafts. The process is completed by
sliding the coupling onto the other shaft and clamping it to each shaft.
LEVEL
SOLID
COUPLING
Figure 34. Shaft Alignment for Sleeve Coupling Installation
In some cases, the sleeve coupling is used to extend the length of a shaft by
connecting another shaft which is not independently supported, as shown in figure
35. Here, there is not any alignment to be done. Simply insert the extension shaft
through the bearing on its end, slide the sleeve onto the other end of the shaft; and
bring the two shafts together so that each shaft is inserted into the coupling and the
gap between the two shafts is approximately 0.125 inch.
MOTOR
COUPLING BEARINGS
GEAR
Figure 35. Sleeve Coupling Connection of Two Shafts

Another application of this concept is a floating shaft which is not supported
directly by any bearings, as shown in figure 36. This shaft connects two other
shafts using two solid couplings. After the two supported shafts are aligned, the
floating shaft can be installed without any further alignment.
FLOATING
SHAFT
SOLID SOLID
COUPLING COUPLING
Figure 36. Floating Shaft

SKILL 5 INSTALL AND ALIGN A SLEEVE COUPLING AND SHAFT
Procedure Overview
In this procedure, you will attach the Constant Speed Motor to a drive shaft
using a solid sleeve coupling. The alignment method used will be a variation of
the straight edge and feeler gauge method.
 1. Perform the following safety checkout to prepare for working with power
transmission equipment. Make sure that you are able to answer yes to each
item before proceeding.
YES/NO SAFETY CHECKOUT

Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
 2. Perform a lockout/tagout on the Motor Control Unit’s safety switch.

 3. Place Shaft Panel 1 on the 950-ME Mechanical Drives System’s overhead
rack.

 4. Perform the following substeps to mount and level the Constant Speed Motor.
A. Locate the Constant Speed Motor and place it on the work surface.
B. Select four Constant Speed Motor Risers from Shaft Panel 1.
C. Make sure that the motor base, risers, and mounting area of the work
surface shown in figure 37 are free of dirt, rust, and burrs.
D. Position the Constant Speed Motor over the set of holes on the 950-ME
work surface, as shown in figure 37.
The outlines of the other components to be mounted are also shown.
SLEEVE
COUPLING
Figure 37. Location of Components on 950-ME Work Surface
E. Place one Constant Speed Motor Riser under each of the motor feet.
F. Locate four bolts with the specifications 5/16-18UNC-2A x 1-1/2 Hex
Head, along with compatible flat washers, lock washers, and nuts.
G. Fasten the motor and risers to the work surface by assembling bolts,
washers, and nuts.
Use a criss-cross pattern to tighten the bolts.

H. Check the shaft for run-out. Record below the amount of run-out.
Run-out: ____________________________________________ (in/mm)
The run-out should be less than 0.002 inches.
I. Check for motor shaft end float.
End Float ___________________________________________ (in/mm)
It should be less than 0.005 inches.
J. Check the level of the motor shaft. Shim the motor feet as needed.
Shim Ratio _________________________________________________

 5. Perform the following substeps to mount the shaft and pillow block bearings.
A. Select four Bearing Standoffs from Shaft Panel 1.
B. Make sure that the standoffs, pillow block mounting surface, and mounting
area of the work surfaces, shown in figure 37, are free of dirt, rust and
burrs.
C. Place the four standoffs on the 950-ME work surface in the location shown
in figure 37.
D. Remove two pillow block bearings from Shaft Panel 1.
E. Place the pillow block bearings on the standoffs.
F. Locate four bolts with the specifications of 3/8-16UNC-2A x 4-1/2 Hex
Head, along with the compatible flat washers, lock washers, and nuts.
G. Fasten the pillow block bearings and the standoffs to the work surface by
assembling the bolts, washers, and nuts.
Hand tighten only.
H. Select a 12-inch long shaft from Shaft Panel 1.
I. Slide the shaft through the two pillow block bearings. Position it as shown
in figure 37.
J. Tighten the set screws on each bearing to lock the bearing.
K. Tighten the pillow block bearing mounting bolts.
L. Turn the shaft by hand to make sure it turns freely.
If not, loosen the bolts and adjust the positions of the bearings.
M. Check the driven shaft for run-out.
Run-out: ____________________________________________ (in/mm)
The shaft should have no more than 0.002 inches run-out.

N. Level the driven shaft. Shim the bearing standoffs as needed.
Place the shims between the work surface and the standoffs.
Shim Ratio _________________________________________________

 6. Perform the following substeps to prepare the sleeve coupling to be mounted.
A. Locate the sleeve coupling, as shown in figure 38, from Shaft Panel 2.
Figure 38. Amatrol Sleeve Coupling
B. Use a hex key wrench to back out the two set screws on the coupling so
that it can slide smoothly over the shaft.
C. Clean the shafts’ keyseats and the coupling’s keyseat with a wire brush to
make sure that no dirt or burrs are in the keyseats.
D. Obtain two 3/16-inch x 1-inch long square keys
E. Make sure the keys fit by sliding each key into the keyseat of one shaft and
one side of the coupling.
They should slide in without forcing and have no play.
F. Remove the keys from the keyseats and set them aside for now.
G. Slide the coupling without the keys onto one of the shafts and pull it back
from the shaft as far as it will go.
You will complete the mounting of the coupling after you have aligned the
shafts.

 7. Perform the following substeps to align the two shafts.
A. Slide the motor forward until the ends of the shaft are within about 1/8
inch of each other.
B. Tighten the motor mounting bolts.
C. Rotate the shafts so that their keyseats line up with each other at the 90
degree position, as shown in figure 39.
D. Place a straight edge across the two shafts and measure the gap on the
lower shaft with a feeler gauge at two points, as shown in figure 39.
Gap at Point 1 _______________________________________ (in/mm)
Gap at Point 2 _______________________________________ (in/mm)
FEELER SOLID
GAUGE STRAIGHT EDGE
COUPLING
3 2 1
POINT POINT
1 2
Figure 39. Measurement of Vertical Alignment

E. If the gap is the same, the shafts are in vertical angular alignment and you
can proceed to substep F. If the gap is different, shim two of the motor’s
feet so that the gaps are the same.
The shims needed can be calculated by multiplying the shim ratio by the
difference in gaps at the two points. The shim ratio in this case uses the
length between the points where the gap was measured and the length
between the motor mounting bolts, as shown in figure 40.
3 2 1
L
E
L LB
B SHIM RATIO =
L
E
Figure 40. Calculation of Shim Ratio

F. Measure the gap again and shim the motor’s four feet equally by the
amount of the gap. This corrects for vertical parallel alignment.
G. Recheck the vertical alignment again by placing the straight edge across
the two shafts again.
The straight edge should rest on top of the two shafts with no daylight
showing between the straight edge and the shafts. If there is, correct it
with shims.
3 2 1
Figure 41. Shafts in Vertical Alignment, Both Angular and Parallel

H. Now check the horizontal alignment by placing a straight edge against the
sides of the two shafts at 270 degrees, as shown in figure 42.
If there is no gap along the straight edge, you are done with the alignment.
Proceed to substep J. If there is a gap, go to substep I.
OVERHEAD VIEW
STRAIGHT
EDGE
3 2 1
Figure 42. Measurement for Horizontal Alignment
I. Loosen the motor mounting bolts and adjust the motor position so that the
two shafts are in horizontal alignment.
J. Tighten the motor mounting bolts.
K. Recheck the vertical alignment again to make sure it is still good. Correct
it if needed.
 8. Perform the following substeps to mount the coupling.
A. Rotate the two shafts so that their keyseats are positioned at 0 degrees.
B. Slide a key into the keyseat of each shaft and line up each key flush with
the end of its shaft.

C. Grasp the sleeve coupling and line up its keyseat with the keys. Then slide
the coupling over the keys until it is positioned equally over each shaft, as
shown in figure 43.
SOLID
COUPLING
Figure 43. Mounting Position of Sleeve Coupling
D. Tighten coupling’s two set screws onto the keys to complete the assembly.
 9. Perform the following substeps to connect and start the Constant Speed
Motor.
A. Make sure that the safety switch power cord is plugged into a wall outlet
B. Connect the Constant Speed Motor’s power cord to the Motor Control
Unit through the Motor Port.
C. Make sure that the Motor Power switch is in the OFF or down position.
D. Install the guard.
WARNING
Do not operate the mechanical drive system without the guard in place.
Also, do not attempt to open or bypass the guard at any time during operation.
Performing any of these actions will create a hazardous situation.
E. Remove the lockout/tagout.

F. Turn on the safety switch.
G. Make sure that no one is near the motor.
H. Turn on the Motor by moving the power switch to the ON or up position.
You should observe that the motor accelerates quickly to full speed. The
coupling should hold. There should be no more vibration than with the
flexible jaw coupling.
 10. Turn off the motor and allow it to coast to a stop.
 11. Perform a lockout/tagout.
 12. Remove the guard.
 13. Disassemble the components and store them.
 14. Remove the lockout/tagout.

SEGMENT 3
SELF REVIEW
1. A(n) ________________ coupling is used when it is necessary to

extend the length of a shaft or to provide a means of disconnecting a
shaft.
2. Sleeve and flange couplings are two types of _______________

couplings.
3. A(n) _______________ coupling can either be split or solid.
4. The two halves of a split-sleeve coupling allow it to be ___________

without moving the shafts away from each other.
5. Sleeve couplings do not allow any __________________.


BB502 Xd07aen E1

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MECHANICAL

MULTIPLE SHAFT DRIVES

MULTIPLE SHAFT DRIVES

Amatrol or School Supplied

FIRST EDITION, LAP 7, REV. B

BB502-XD07AEN MULTIPLE SHAFT DRIVES 2

SEGMENT 1 MULTIPLE SHAFT GEAR ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 MULTIPLE SHAFT DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SEGMENT 3 SLEEVE COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

BB502-XD07AEN MULTIPLE SHAFT DRIVES 3

OBJECTIVE 1 DESCRIBE HOW TO CALCULATE THE SPEED AND TORQUE

Figure 1. Idler Gears

BB502-XD07AEN MULTIPLE SHAFT DRIVES 4

Figure 2. Lathe Gear Drive

BB502-XD07AEN MULTIPLE SHAFT DRIVES 5

Figure 3. Effect of Idler Gears

BB502-XD07AEN MULTIPLE SHAFT DRIVES 6

OUTPUT OUTPUT OUTPUT

Figure 4. Gear Drive with Three Output Shafts

BB502-XD07AEN MULTIPLE SHAFT DRIVES 7

SKILL 1 CALCULATE THE SHAFT SPEED AND TORQUE OF

Gear 2 Shaft Speed _______________________________________ (RPM)

INPUT GEAR 1 IDLER GEAR GEAR 2

Figure 5. Gear Drive System

The solution is:

Gear 1=250 RPM

BB502-XD07AEN MULTIPLE SHAFT DRIVES 8

The solution is 175 in-lbs.

Figure 6. Gear Drive System

The solution is 667 RPM.

The solution is 750 in-lbs.

BB502-XD07AEN MULTIPLE SHAFT DRIVES 9

Output Shaft 2 Speed _____________________________________ (RPM)

Figure 7. Gear Drive System

The solution is Output 1 = 133 RPM.

Output 2 = 267 RPM.

The solution is 400 in-lbs.

BB502-XD07AEN MULTIPLE SHAFT DRIVES 10

Figure 8. Compound Gear Drive

BB502-XD07AEN MULTIPLE SHAFT DRIVES 11

Figure 9. Compound Gear Drive Applications

Figure 10. Reverted Gear Drive

BB502-XD07AEN MULTIPLE SHAFT DRIVES 12

FORMULA: COMPOUND GEAR DRIVE SPEED

Where: Com Output = Compound Output Gear

BB502-XD07AEN MULTIPLE SHAFT DRIVES 13

Figure 11. Compound Gear Drive Application

FORMULA: COMPOUND GEAR DRIVE TORQUE

Driven Torque ⎡ Pitch Dia. Driven ⎤ ⎡ Pitch Dia. Com Input ⎤

Driven Torque ⎡ No. Teeth Driven ⎤ ⎡ No. Teeth Com Input ⎤

BB502-XD07AEN MULTIPLE SHAFT DRIVES 14

Figure 12. Gear Drive System

The solution is 750 RPM.

BB502-XD07AEN MULTIPLE SHAFT DRIVES 15

The solution is 1500 in-lbs.

Figure 13. Gear Drive System

The solution is 370 RPM.

BB502-XD07AEN MULTIPLE SHAFT DRIVES 16

The solution is 1250 in-lbs.

Figure 14. Gear Drive System

The solution is 2000 RPM.

The solution is 200 in-lbs.

BB502-XD07AEN MULTIPLE SHAFT DRIVES 17