CONSTRUCTION

TRANSMISSION RE-DESIGN ASSIGNMENT

COURSE ID: 201500230

LEARNING GOAL
Use a practical example of a
servo motor to apply knowledge
learned in lecture 3 and 4:
❑ Kinematics of gears
❑ Mechanical drives – Spur gear
design.
GOAL:
1) Re-design the transmission of a
servo-motor considering changes in
operating condition – Torque/speed
changes.
2) Apply structured design steps and
calculations on stress factors to
motivate new gear dimensions, OR
3) A different material selection for the
gears.
2017nov 2
WHAT YOU RECEIVE
You receive:
❑ An assignment which you need
to work in groups of two.
❑ You also ‘borrow’ a motor
which you need to return on the
date of the final exam.
REQUIRED:
1) A 8-page max. report which you
need to upload in Canvas (a link will
be created to assist you to do this).
2) The report should be prepared in
word/pdf.
3) It should document your logic/steps
for the re-design assignment.
4) 15% of total grade of construction.
2017nov 3
TASKS NEEDED
STEPS

Prerequisites:
❑ Find a colleague to work with.
❑ You only do the tasks which
are marked (unique for different
groups).
Step 1:
❑ Visit the workshop and
open/disassembly the servo
motor.
❑ Take apart the gears and
measure their dimensions.
❑ Take photos for your memory,
i.e. different stages, how they
mesh, etc.
❑ The photos should help you
assemble the motor back to its
original state.

2017nov 4
TASKS NEEDED
STEPS

Step 2:
❑ Make basic calculations to
determine gear dimensions,
transmission ratio, torque/speed
transmitted.
❑ For an inspiration, use the slide
from lecture 3 on kinematics of
gears.

2017nov 5
 KINEMATICS OF GEARS
DIMENSIONS

https://www.myodesie.com/wiki/index/retur
nEntry/id/3000
2019nov 6
 KINEMATICS OF GEARS
DIMENSIONS

Metric module system DIN867

table is for standard gears.

▪ m - metric module (mm)

𝐷 = 𝑚𝑁 Pitch Diameter ▪ D - pitch diameter (mm)
𝐷𝑂 = 𝑚𝑁 + 2𝑚 Outside Diameter ▪ Do - outside diameter (top)
𝐷𝑅 = 𝐷 − 2𝑏 Root Diameter ▪ DR - root diameter (bottom)
ℎ𝑡 = 𝑎 + 𝑏 Whole Depth ▪ ht - height of tooth
ℎ𝑘 = 𝑎 + 𝑎 Working Depth ▪ hk - projected tooth height
𝑡 = 𝜋. 𝑚/2 Tooth Thickness ▪ t- tooth thickness

Preferred values for m

0,5 0,8 1 1,25 1,5 2,5 3 4 5 6 8 10 12 16 20 25 32 40 50
2019nov 7
KINEMATICS OF GEARS
VELOCITY RATIO

𝜔𝑃 𝑁𝐺 VR is ratio of input speed to

𝑉𝑅 = = the output speed of two gears.
𝜔𝐺 𝑁𝑃
𝑇𝑉 = 𝑉𝑅1 . 𝑉𝑅2 . . 𝑉𝑅𝑛 ▪ VR - velocity ratio
VR > 1 reduces speed
▪ TV - train value
(system property)

In DIN-base literature
▪ i - Űbersetzung
▪ ω - Winkelgeschwindigkeit
▪ z(N) - Zähnezahl
1 z2
i= =
2 z1
2018nov 8
TASKS NEEDED
STEPS

Step 3:
❑ Calculate the moments
(transmission torque) at each
stage:
❑ Be careful of the motor
specification you have.
❑ Maximum stalled torque,
transmission speed,……
❑ !!! Only consider the
operating torque and radial
speed!!!!!!!
❑ 65% (of max. speed) and
35% (of max. torque).
2017nov 9
TORQUE-SPEED RELATIONSHIP

Point to note:
• Max torque (Tmax) when stalled
• T = 0 at maximum speed ωmax
• So we use operating torque and speed (radial) 2019jan 10
TASKS NEEDED
STEPS

Step 3:
❑ Also note:
❑ The maximum torque (stalled
torque is at the output gear of
the last stage.
❑ Tip: remember to use the
calculated transmission ratio
to determine the torque/speed
transmitted by each gear.
❑ Tip: the pinion connected to
the motor normally will
transmit the lowest
torque/highest speed of the
entire transmission.
2017nov 11
TASKS NEEDED
STEPS

Step 3:
❑ Next calculate the bending and
contact stresses for each stage:
𝐹𝑡 ❑ Require:
❑ Tangential forces transmitted
per stage!!!
❑ Tip, only one tangential force
at each stage!!!!!

2017nov 12
TASKS NEEDED
STEPS

Step 4:
❑ Determine the safety factor at
bending and contact:
❑ Require:
❑ Material properties for the
gears you have.
❑ Gear dimensions, and
tangential forces.

2017nov 13
 𝜎𝐹𝑙𝑖𝑚 - limiting bending stress
𝜎𝐻𝑙𝑖𝑚 - limiting contact stress
SPUR GEAR DESIGN
FACTOR OF SAFETY (BENDING AND CONTACT STRESSES)

2 F lim
SF =  S F min SF - safety factor bending stress
bKA SH - safety factor contact stress
 H lim
SH =  S H min
H KA
DIN 3990

▪ On average a minimum safety factor of between 1.5 is valid, up to 3 for high risk
applications (𝑆𝐹𝑙𝑖𝑚 ) and (𝑆𝐻𝑙𝑖𝑚 ).

2019nov 14
TASKS NEEDED
STEPS

Step 5:
❑ Re-design task:
❑ Select the stage with the
lowest safety factor
(bending/contact).
❑ Re-design to fit new operating
conditions:
❑ Higher torque?
❑ Higher/lower transmission
speeds?
❑ Higher safety factors?
❑ Lighter weight gears?

2017nov 15
TASKS NEEDED
STEPS

Step 5:
❑ Re-design task:
❑ What gear dimensions would
you recommend considering
new retro-fitting?
❑ Do you require to re-design to
have stronger gears (larger
module, or thickness)?
❑ …………….
❑ Show/document in your report
your logic or argumentation.

2017nov 16
DIY
EXPECTED SERVICE LIFE

2017nov 17