EXPERIMENT 7

DETERMINATION OF GEAR EFFICIENCY

LEARNING OUTCOMES

At the end of this experiment, students should be able to,

1. Calculate the mechanical efficiency of gears by comparing the

mechanical driving system and braking power for spur gear (two-stage)
and worm gear. (LOD 1, PLO 1, C3)
2. Plot the torque/current characteristic curve for a magnetic particle brake
using appropriate instruments and methods. (LOD 4, PLO4, P4)
3. Demonstrate work effectively and cooperate in group to complete the
laboratory task. (LOD 7, PLO 9, A3)

CONTENT

7.1 INTRODUCTION [1]

Gears are very popular mechanical parts, used in various assemblies and
systems. There are many kinds of gears as students had learned in the
related fundamental course.

At the end of this experiment, student should also be able to

• Understand the mechanisms of drive technology in mechanical
engineering, encompassing of transmissions and motors related to
measurement and control technology.
• Implement and analyze the required data collectively within the
group and produce good technical report according to the required
standard.
7.1.1 Gunt Hamburg, AT 200 Determination of Gear Efficiency

The Gunt Hamburg, AT 200 Determination of Gear Efficiency will be

used in this experiment. The modules comprising the drive unit, spur gear,
worm gear and magnetic powder brake are mounted on a profile frame as
shown in Figure 7.1a and Figure 7.1b. All modules are fastened at the bottom
by means of clamping levers permitting easy alignment. The modules are
coupled by means of positive-fit elements. The drive unit is electrically
powered via a display and control unit. Its target speed is set by means of a
potentiometer on this display and control unit. Its actual speed is measured
and indicated by means of an inductive proximity switch and evaluation unit.

Figure 7.1a: The components configuration of device [1]

 Figure 7.1b: The components configuration of device [1]

The transmission units consist of a 2-stage spur gear ratio, n = 1 :

13.5 and a single-stage worm gear with n = 1 : 15 (where gear ratio is the
ratio of no. of driver gear teeth : no. of driven gear teeth) Due to design
constraints, the spur gear requires a straight, outstretched arrangement, the
worm gear an oblique arrangement. The transmission torque can be
determined on the drive side as well as the brake side. To facilitate
adjustment of the brake torque, the brake characteristic (current torque) is
recorded in a preliminary experiment. Moments are determined through
power measurements (spring balance) with a known lever arm. The
moments, measure input speeds and transmission ratios are used to
determine power and efficiency.

7.1.2 THREE-PHASE AC MOTOR

The three-phase AC motor has a swivel bearing. The reaction torque exerted
on the drive housing is measured by means of a spring balance connected to
a lever arm. The speed is measured inductively and indicated by a digital
display element on the display and control unit. The desired speed is set by
means of a potentiometer on the display and control unit. Figure 7.2 shows
the configuration for investigating characteristic data (curves) of various
consumers, for instance, efficiency of a gear unit as a function of load or
speed.

Figure 7.2: Location of input and output torque of the module [1]

7.1.3 SPUR GEAR AND WORM GEAR

In Figure 7.3, the spur gear is designed as a 2-stage unit with a

transmission ratio, i = 13.5 : 1. The worm gear is designed as a single-
stage unit with a transmission ratio 15 : 1, i = ni / no. (ni is the input speed and no
is the output speed, at constant velocity). All its shafts have ball bearings.

(a) (b)

Figure 7.3: (a) Spun Gear & (b) Worm Gear [1]

7.1.4 MAGNETIC BRAKE POWDER – MAGNETIC POWDER

COUPLING

The magnetic powder coupling as shown in Figure 7.4 consists of two

independently mounted rotors, i.e. a primary and a secondary rotor, both
furnished with ball bearings. The primary rotor also serves as a coil carrier. If
one of these two rotors is deactivated, the magnetic powder coupling can
also be used as a brake. The air gap between the two rotors contains a
special magnetic powder.

Figure 7.4: Magnetic brake powder – magnetic powder coupling [1]

7.1.5 SAFE USE OF THE EQUIPMENT

Please adhere to these safety practices,

• Exercise caution when opening transmission housings and working

on the electrical circuits. There is a danger of electric shock. Make
sure to disconnect the equipment from the mains beforehand. This
type of work should only be performed by qualified personnel.

• Before connecting the display and control unit to the mains, ensure
that the device is off and the target-value potentiometer is at its
lowest setting.

• There is danger of injury by rotating parts.

• Always turn off the equipment before re-assigning power and data
cables.

• Only change the direction of rotation at a standstill.

• The brake must not be overheated, even though it is equipped with

thermal protection. On no account should the brake be subjected to
continuous slippage for indefinite periods.

• When operating the magnetic powder brake, ensure that its maximum
permissible temperature is not exceeded.

7.1.6 START-UP

This has probably been set up for you but you should check the module if it is
functioning properly, e.g. the rotation speed at the powder brake is correct.

1. Begin with ensuring the motor, transmission and brake are aligned on
the frame and fasten them at the bottom by means of the clamping
levers.
2. Establish the line connection between the motor and the display and
control unit. The connection socket is located on the control unit’s
rear panel.
3. Ensure the mains cable are connected. The drive unit is now ready
for operation.
4. Ensure the display and control unit and brake are connected by
means of the cable.
5. Turn on the display and control unit and brake.
6. Turn on the motor (5).
7. Adjust the speed (6).
8. Adjust the excitation current.
9. Once these steps have been completed, the motor is ready for
operation.

Because some of the magnetic powder might be displaced out of the

air gap during transport or assembly work, use the procedure described
below to optimize the distribution of the powder in the air gap:

1. With the coil in the non-excited state, operate the device for roughly
half a minute at the maximum speed (while observing the speed limit
for the magnetic powder coupling).

2. Turn off the device and switch the current several times between I = 0
and I = 0.37 A at a speed of 0.

3. Repeat steps 1 and 2.

4. Excite the coupling or brake at 5-second intervals for roughly 3

minutes with approximately ¼ x Nominal at n = 200 rpm.

The arrangement for configuring the magnetic powder brake after

assembly in Figure 7.5.
Figure 7.5: Configuration involving the drive unit, transmission unit,
magnetic powder brake, display and control unit with an ammeter [1].

The drive unit’s speed can be adjusted continuously in the range

between 0 to 3000 rpm with spur gear, transmission ratio, i, = 13.5 : 1. This
adjustment is performed by means of a potentiometer on the display and
control unit. The speed is indicated directly in revolutions per minute, rpm, by
a digital display unit.

The speed n2 is: n2 = n1/i

7.1.7 MEASUREMENT OF THE TORQUE ON THE DRIVE UNIT

The motor is suspended from swivel bearings on the base frame. These ball
bearings permit nearly frictionless rotation of the motor about its longitudinal
axis. When the motor generates a torque, it is subjected to a reaction torque
of the same magnitude and opposite direction (action = reaction). The
reaction torque is measured by means of a spring balance connected to a
lever arm.

7.1.7.1 READING THE MEASURED VALUES

1. Prepare the drive unit as described in Figure 7.6 or Figure 7.7.

2. Connect the test object (for instance, gear unit) to the motor coupling.
Refer to the Figure 7.1 for components identification.

3. After ensuring the module is set-up properly as in 5.1.6, activate the

display and control unit and set the required speed.
4. The reaction torque causes the motor to tilt in the opposite direction to
the drive shaft’s direction of rotation. The lever arm comes to rest
against its lower stop.

5. Now the spring balance needs to be moved up until the lever arm is
horizontal again. For this purpose, loosen the knurled screw (12) (refer
to Figure 7.1) and push the spring balance up.

6. Read the force once the lever arm has returned to the horizontal
position.

The configuration involving a spur gear as shown in Figure 7.6 and worm
gear unit in Figure 7.7.

Figure 7.6: Configuration involving a 2-stage spur gear unit with i = 13.5 [1]

Figure 7.7: Configuration involving a single-stage worm gear unit [1].

7.1.7.2 DETERMINING THE DRIVING TORQUE

The driving torque generated by the motor is equal in value to the reaction
torque and calculated as shown below. The drive torque is that supplied by
the drive unit to the test object (for instance, gear unit), i.e. that generated by
the motor. The output torque is the product of the force (F) and the length of
the lever arm (l) on which the force acts.

Output torque (M) = F.l [Nm]

Where, l = 50 mm (lever arm) = 0.05 m

F = Measured force (as described in 5.1.7.1) in Newton (N)

Output torque (M) in Nm

7.1.7.2 MEASURING THE BRAKING TORQUE

The magnetic powder brake is furnished with swivel bearings which permit
external measurements of effective braking torque. During measurement, the
primary rotor (external rotor) is held in position by a spring balance. The
effective braking torque can thus be read directly on the spring balance as
shown in Figure 7.8.
 Figure 7.8: Measurement of brake force / torque [1]

7.1.7.3 DETERMINING THE OUTPUT POWER

The output power of a rotating shaft is the product of the torque (M) and
angular frequency (ω). The output torque calculated above, and the
corresponding speed are used to determine the output power as follows:

Output power (P) = ω.M

Where, M = F.l

l = 100 mm (length of lever arm) = 0.1 m

ω = 2.π.f

f = no / 60 seconds [s-1]

no = ni / i
where ni is the motor speed, no is the output speed, i , is the gear ratio. Spur
gear transmission ratio, i, = 13.5 : 1 and worm gear transmission ratio, i, = 15
: 1.

7.1.7.4 DETERMINING THE EFFICIENCY

The efficiency (η) is defined as the ratio between the output and input
powers. It has a maximum theoretical value of 1.

Efficiency (η) = Pout / Pin

7.1.8 SHUTDOWN

All users should follow these steps in shutting down the system,

1. Set the brake’s excitation current to zero and then press off the switch
current.

2. Set the motor control potentiometer to zero and then press off the
switch motor.

3. Turn off the equipment and disconnect it from the mains network.

7.2 EQUIPMENT LIST

Gunt Hamburg, AT 200 Determination of Gear Efficiency

7.3 PROCEDURES [1]

7.3.1 EXPERIMENT 1: TORQUE vs. CURRENT CHARACTERISTIC
(SPUR GEAR)

1. Turn on the drive unit. Set the drive unit to the required speed. Refer
to Table 7.1

2. Set the excitation current by means of the potentiometer on the

magnetic powder brake’s control unit. Using a spring balance,
determine the holding force of the magnetic powder brake on the
lever arm. Fill in Table 7.1.

3. During recording of the measurement values, increase the current

from zero to its maximum limit, and then decrease it back to zero.

4. Note down all the values in Table 7.1 and Table 7.2.

5. Plot the characteristic graphs for Excitation Current vs. Force and
Excitation Current vs. Torque.

6. Refer to 7.1.8 to shut down the system.

7.3.2 EXPERIMENT 2: Determine the efficiency of 2-stage spur gear

transmission ratio (13.5 :1) and single-stage worm gear transmission
ratio (15 :1).

1. Set the drive unit (spur gear) as shown in Figure 7.6.

2. Set the motor speed at 1520 rpm and excitation current at 0.32 A

3. Record the motor holding force (F1) and brake holding force (F2)

4. Determine the driving torque and efficiency using the formula in

7.1.7.3 & 7.1.7.4.

5. Now set up for drive unit (worm gear) as shown in Figure 7.7. Then
repeat to find the efficiency.

6. Refer to 7.1.8 to shut down the system.

7. Compare and discuss the results.

7.4 ACTIVITIY

In groups determined by the lecturer / instructor, you are to perform the

experiment in the lab and handwrite a lab report that consist of these
following items;

1. Front page
2. Theory
3. Methodology
4. Observation
5. Results
6. Calculations
7. Discussions
8. Conclusion and recommendations
9. Reference

7.5 BIBLIOGRAPHY AND REFERENCE

[1] G.U.N.T. Gerätebau GmbH, 2015, Hamburg AT 200

Experiment Instructions, AT 200 Determination of Gear
Efficiency, Publication No.: 910.000 00 200 12 (A), 07/2015,
Hamburg, Germany.
 FACULTY OF ENGINEERING TECHNOLOGY
Department of Mechanical Engineering Technology

Subject Name ENGINEERING LABORATORY IV

Title of Experiment DETERMINATION OF GEAR EFFICIENCY

Course Code BNJ 37301 Section :

Semester and session

Lecturer/Instructor Name

Group Members Matric No.

2
3

To be filled in by lecturer

No. Item Mark Weightage Score

1 Theory (C2) /5 2
2 Methodology (P2) /5 1

3 Observation (P3) /5 3

4 Results (P2) /5 2

5 Calculation (P4) /5 3
Assessment of
7 Discussion (C3) /5 5
Laboratory
8 Conclusion (C3) /5 3
Report
9 References (C1) /5 1
(Group Report)
Total cognitive (55%)

Total physhomotor (45%)

7.4.1 THEORY

(Write a short theory, or concepts, and insert background related to the

experiment, related science, physics and/or equations, and real-life
applications. Related diagrams and formulas should be stated. All your
sources need to be cited according to the American Psychological
Association (APA) system.)

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7.4.2 METHODOLOGY

(Write in passive voice, the flow of the experiment conducted. The writing of
the methodology can be guided of the procedures given in sub-topic 7.3.
Students may add extra procedures that has been actually done in the lab
(i.e. if not stated discreetly in sub-topic 7.3. Write in paragraphs instead of
numbers).

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7.4.3 OBSERVATIONS

(Write down your observation for the data collected from both results data.
Compare with theory. Write down the relationships between s. Also write down
your observation of the surroundings, environment and of the experiment
while in operation.)

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7.4.4 RESULTS

(Fill in Table 7.1. and Table 7.2 for experiment 1.)

Reminders: wait for the results to stabilise before writing them down. Be
very careful changing configuration between spur gear and worm gear.
Do not drop the components and carefully tighten the clamping leaver.
Do not force the screw into the tread. Patiently screw the clamping leaver
into the tread properly.

Finally, remember to draw all graphs as required. If variables are

proportional, use a ruler and try to get the best fit line. If it is a curve line,
learn how to use a flexible curve ruler. Remember to label the axis and
write the title of each graph.
Table 7.1: Results for Increasing Value of Current [1]

Speed: 1500 rpm

Brake Serial Number:
Lever arm length = 100 mm = 0.1 m
Excitation Current, I Force on the Lever Output Torque, M
[A] Arm, F [N] [Nm]
0
0.05
0.1
0.15
0.2
0.25
0.3

Table 7.2: Results for Decreasing Value of Current [1]

Speed: 1500 rpm

Brake Serial Number:

Lever arm length = 100 mm = 0.1 m

Excitation Current, I Force on the Lever Output Torque, M

[A] Arm, F [N] [Nm]

0.3

0.25

0.2

0.15

0.1

0.05
 0

Experiment 2

2-stage spur gear transmission ratio (13.5 : 1)

F1 (motor) = _________________

F2 (brake) = _________________

Single-stage worm gear transmission ratio (15 : 1)

F1 (motor) = _________________

F2 (brake) = _________________

7.4.5 CALCULATIONS

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7.4.6 DISCUSSIONS

(Discuss comprehensively your reasons towards your observation and

results as mentioned. Fill it with 5 W’s, what, why, when, where and who’s.
Give scientific and theoretical relationships to explain your observations and
results. In your discussions, refer to the graphs, tables and calculations.)

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7.4.7 CONCLUSIONS AND RECOMMENDATIONS

(Write a summary and relate to the objective, theory, procedure set up,
result and discussion that you have discuss previously.

Write recommendations on how to improve this experiment in terms of better

procedures to get better results)
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7.4.8 REFERENCES

Sources that are referred to in your work, whether published or not, must be
stated. The source of information must be acknowledged in the text as well
as in the reference list. Proper acknowledgement is important because it will
help others locate and verify the original sources. Furthermore, proper
citation can avoid allegations of plagiarism. Acknowledgements in your work
must be linked to the list of reference using the “Author (Date)” system.
References should be cited in all parts of the lab report whenever the
sources are referred in your work.
The Author (Date) System also known as the American Psychological
Association (APA) system. Write a minimum of 5 references. Make sure the
references are cited as required in your report not just limited to the theory
section. At least 50% of references are recent, i.e. within past 5 years of
current study.
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