Case Study 2: Design of Transmission Systems for loads chain system

Technical features: (Option 2)

Force on chain F (N):..............8400..............
Chain velocity, v (m/s): ............0.8...............
Number of sprocket teeth, z :....10................
Chain pitch, 𝑝𝑐 (mm):........101.6.................
Service time L, years: ...........5...............
One-way rotation, two work shifts (1 year
working 300 days, 1 shift working 8 hours)

The loads chain system includes: 1- Motor; 2- V Belt drive; 3- Helical Spur Reducer;
4- Elastic coupling; 5- Loads chain sprocket; 6- Loads chain.

1) Working power of system according to formular:

𝐹𝑣 8400 × 0.8
𝑃= = = 6.72 𝑘𝑊
1000 1000
2) Drive system efficiency:
ƞ𝑔𝑒𝑛𝑒𝑟𝑎𝑙 = ƞ𝑐𝑜𝑢𝑝𝑙𝑖𝑛𝑔 × ƞ𝑉−𝑏𝑒𝑙𝑡 × ƞ𝑔𝑒𝑎𝑟 × ƞ𝑠𝑙𝑖𝑑𝑖𝑛𝑔 × ƞ𝑟𝑜𝑙𝑙𝑖𝑛𝑔 2
= 0.98 × 0.94 × 0.96 × 0.98 × 0.992
= 0.8494183273 ≈ 0.85
3) Required power of motor:
𝑃 6.72
𝑃𝑐𝑡 = ƞ = = 7.91 𝑘𝑊
𝑔𝑒𝑛𝑒𝑟𝑎𝑙 0.85

4) Rotational speed of the loads chain:

60000𝑣 60000 ×0.8
𝑛= = = 47.24 𝑟𝑝𝑚
𝑧×𝑃𝑐 10×101.6
According to the calculated required power, we choose the standard
motor power as 𝑃 = 11 > 𝑃𝑐𝑡 = 7.91
With that standard motor power, we have the following options to
choose our motor as well as its rotational speed and transmission
ratio.

Rotational General transmission V- Spur gear

speed u belt 𝒖𝒈
Rpm 𝒖𝒃

Motor
2935 62.13 5.55 11.2
1

Motor
1460 30.9 3.86 8
2

Motor
970 20.53 2.57 8
3

Motor
730 15.13 2.4 6.3
4

Based on table 3.1 Motor SGA (Company CMG, Australia). We choose

Motor 3 with a rotational speed of 970 rpm.
Parameters of transmission system
Power P on shafts:
𝑃𝑚𝑜𝑡𝑜𝑟 = 7.91 𝑘𝑊
𝑃𝐼𝐼 = 𝑃⁄ƞ × ƞ = 6.72⁄0.98 × 0.98 = 7 𝑘𝑊
𝑠𝑙𝑖𝑑𝑖𝑛𝑔 𝑐𝑜𝑢𝑝𝑙𝑖𝑛𝑔

𝑃𝐼𝐼
𝑃𝐼 = ⁄ƞ𝑔𝑒𝑎𝑟 × ƞ𝑟𝑜𝑙𝑙𝑖𝑛𝑔 = 7⁄0.96 × 0.99 = 7.37 𝑘𝑊
𝑃𝐼
𝑃𝑚𝑜𝑡𝑜𝑟 = ⁄ƞ𝑏𝑒𝑙𝑡 × ƞ𝑟𝑜𝑙𝑙𝑖𝑛𝑔 = 7.37⁄0.94 × 0.99

= 7.91 𝑘𝑊 (𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑)
Rotational speed on shafts:
𝑛𝑚𝑜𝑡𝑜𝑟 = 970 𝑟𝑝𝑚
𝑛
𝑛𝐼 = 𝑚𝑜𝑡𝑜𝑟⁄𝑢𝑏𝑒𝑙𝑡 = 970⁄2.57 = 377.43 𝑟𝑝𝑚
𝑛
𝑛𝐼𝐼 = 1⁄𝑢𝑔𝑒𝑎𝑟 = 377.43⁄8 = 47.18 𝑟𝑝𝑚

𝑛𝑤𝑜𝑟𝑘𝑖𝑛𝑔 = 𝑛𝐼𝐼 = 47.18 𝑟𝑝𝑚

Torque on shafts:
𝑃 7.91
𝑇𝑚𝑜𝑡𝑜𝑟 = 9550 𝑛𝑚𝑜𝑡𝑜𝑟 = 9550 970 = 77.88 𝑁𝑚
𝑚𝑜𝑡𝑜𝑟
𝑃 7.37
𝑇𝐼 = 9550 𝑛𝐼 = 9550 377.43 = 186.48 𝑁𝑚
𝐼
𝑃 7
𝑇𝐼𝐼 = 9550 𝑛𝐼𝐼 = 9550 47.18 = 1416.91 𝑁𝑚
𝐼𝐼
𝑃𝑤𝑜𝑟𝑘𝑖𝑛𝑔 6.72
𝑇𝑤𝑜𝑟𝑘𝑖𝑛𝑔 = 9550 𝑛 = 9550 47.18 = 1358.51 𝑁𝑚
𝑤𝑜𝑟𝑘𝑖𝑛𝑔
 Parameters Shaft

Motor I II working

Power P, kW 7.91 7.37 7 6.72

Ration u 2.57 8 1

Rotational speed n
970 377.43 47.18 47.24
rpm

Torque T, Nm 77.88 186.48 1416.91 1358.51

Design and select for belt drives
1.From the first table, depends on the
Parameters P = 7.91 kW, 𝑛1 = 970 𝑟𝑝𝑚, 𝑢 = 2.57
We choose Type B belt with the parameters according to the
table 4.5:
𝑏𝑝 = 14 𝑚𝑚
𝑏𝑜 = 17 𝑚𝑚
ℎ = 10.5 𝑚𝑚
𝑦𝑜 = 4 𝑚𝑚
𝐴 = 138 𝑚𝑚2
𝑑1𝑚𝑖𝑛 = 125 𝑚𝑚

2. Calculate the diameter of the small pulley

𝑑1 = 1.2𝑑𝑚𝑖𝑛 = 1.2 × 125 = 150 𝑚𝑚
According to standard value, we choose 𝑑1 = 160𝑚𝑚
3. Calculate the belt velocity :
𝜋𝑑1 𝑛1 𝜋 × 160 × 970
𝑣= = = 8.126 𝑚⁄𝑠
60000 60000
4. Suppose choosing the relative creep factor ξ = 0.01. The large
pulley diameter:
𝑑2 = 𝑢𝑑1 (1 − 𝜉 ) = 2.57 × 160 ( 1 − 0.01) = 407.088 𝑚𝑚
According to the standard value, we choose 𝑑2 = 400 𝑚𝑚
 𝑑2 400
The ration: 𝑢 = = = 2.53
𝑑1 (1− 𝜉) 160(1−0.01)
The error with the previous value is 1.74%
5. The center distance a is given according to the formula:
2(𝑑1 + 𝑑2 ) ≥ 𝑎 ≥ 0.55(𝑑1 + 𝑑2 ) + ℎ
2(160 + 400) ≥ 𝑎 ≥ 0.55(160 + 400) + 10.5
1120 ≥ 𝑎 ≥ 318.5
According to diameter 𝑑2 , we can choose 𝑎 = 𝑑2 = 400 𝑚𝑚
6. Determination of belt length
𝜋(𝑑2 + 𝑑1 ) (𝑑2 − 𝑑1 )2
𝐿 = 2𝑎 + +
2 4𝑎
𝜋(400 + 160) (400 − 160)2
= 2 × 400 + + = 1715.65 𝑚𝑚
2 4 × 400
According to the standard value of belt length (mm)
determined by neutral class of belt, we choose
𝐿 = 1800 𝑚𝑚 = 1.8 𝑚
7. Check the number of turns i of the belt in 1 second
𝑣 8.126
𝑖= = = 4.514 𝑠 −1 , [𝑖 ] = 10𝑠 −1 , 𝑖 < [𝑖] (𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑)
𝐿 1.8
8. Calculating the contact angle 𝛼1 and check slip conditions by
formula 𝐹0
𝑘+√𝑘 2 −8∆2
Recalculating the center distance 𝑎 = 4
 (𝑑1 + 𝑑2 ) 400 + 160
𝑘 =𝐿−𝜋 = 1800 − 𝜋 = 920.35 𝑚𝑚
2 2
𝑑2 − 𝑑1 400 − 160
∆= = = 120 𝑚𝑚
2 2
920.35 + √920.352 − 8 × 1202
=> 𝑎 = = 443.96 𝑚𝑚
4
The value 𝑎 still in the acceptable range

9. The contact angle

𝑑2 −𝑑1 (400−160)
𝛼1 = 180° − 57 = 180° − 57 = 149.19° = 2.6 𝑟𝑎𝑑
𝑎 443.96

10. Calculation of the factors 𝐶𝑖

Velocity factor
𝐶𝑣 = 1 − 0.05(0.01𝑣 2 − 1) = 1 − 0.05(0.01 × 8.1262 − 1) = 1.01698
Contact angle factor
𝛼 149.19
− 1 −
𝐶α = 1.24 (1 − 𝑒 110 ) = 1.24 (1 − 𝑒 110 ) =0.921

Ratio factor
𝐶𝑢 = 1.14 𝑑𝑢𝑒 𝑡𝑜 𝑢 = 2.57 > 2.5
Length Factor
6
𝐶𝐿 = √𝐿⁄𝐿 = √1715.65⁄2240 = 0.957
6

0
Factor taking into account the influence of uneven load distribution
between the belts
𝐶𝑧 = 1
Factor taking into account the influence of the load conditions
𝐶𝑟 = 0.85 (working in 2-shift)
Accoding to Graph 4.2 we have:
Allowable effective power
[𝑃0 ] = 3.8
10. The number of belts is determined by the formula
𝑃
𝑧≥
[𝑃0 ]𝐶v 𝐶α 𝐶u 𝐶l 𝐶z 𝐶r
7.91
≥
3.8 × 1.01698 × 0.921 × 1.14 × 0.957 × 1 × 0.85
≥ 2.4
We choose 𝑧 = 3 → 𝐶𝑧 = 0.95
11. Tensions and stresses on belt
Initial force 𝐹0 = 𝐴𝜎0 = 𝑧𝐴1 𝜎0 = 3 × 138 × 1.5 = 621𝑁
𝐹0
Force on each belt: = 207𝑁
3
1000𝑃 1000×7.91
Useful load: 𝐹𝑡 = = = 973.42 𝑁
𝑣 8.126
𝐹𝑡
Useful load on each belt: = 324.47𝑁
3
To prevent slippage with the arc of creep angle equal to the
belt contact angle 𝛼 = 𝛼1 = 2.6 𝑟𝑎𝑑 and from the formula:
𝐹𝑡 (𝑒 𝑓′𝛼1 +1)
[𝜎0 ]𝐴 ≥ 𝐹0 ≥
2(𝑒 𝑓′𝛼1 −1)
The belt slip does not occur when

𝐹𝑡 (𝑒 𝑓′𝛼1 + 1)
𝐹0 ≥
2(𝑒 𝑓′𝛼1 − 1)
The coefficient of friction is 𝑓 = 0.3 => 𝑓 ′ = 0.3 × 3 = 0.9

324.47(𝑒 0.9×2.6 + 1)
𝐹0 ≥
2(𝑒 0.9×2.6 − 1)
𝐹0 ≥ 196.82 𝑁
The initial force on each belt 𝐹0 = 207𝑁 is satisfied
Force on shaft:
𝛼 2.6
𝐹𝑟 ≈ 2𝐹0 sin ( 21 ) = 2 × 590.47 sin ( 2 ) = 1137.9𝑁

Total stress diagram:

𝜎𝑚𝑎𝑥 = 𝜎1 + 𝜎𝑣 + 𝜎𝑢1 = 𝜎0 + 0.5𝜎𝑡 + 𝜎𝑣 + 𝜎𝑢1
𝜎𝑣 𝑖𝑠 𝑛𝑜𝑡 𝑠𝑖𝑔𝑛𝑖𝑓𝑖𝑐𝑎𝑛𝑡 𝑏𝑒𝑐𝑎𝑢𝑠𝑒 𝑣 = 8.126 < 30 𝑚⁄𝑠
We choose elastic modulus 𝐸 =100 MPa
𝐹0 𝐹𝑡 2𝑦0
=> 𝜎𝑚𝑎𝑥 = + 0.5 + 𝐸
𝐴 𝐴 𝑑
207 324.47 2 × 4
= + 0.5 + 100
138 138 160
= 7.67 𝑀𝑃𝑎
12. Service life
𝑚
𝜎 9 8
(𝜎 𝑟 ) ×107 (7.67) ×107
𝑚𝑎𝑥
𝐿ℎ = = =1105.82 hours
2×3600𝑖 2×3600×4.514