EPICYCLIC GEAR TRAIN AND

WORM WHEEL REDUCER

THEORY OF MACHINES – INDIVIDUAL REPORT I

SANTHOSH.D [22R237]
SHANMUGAM.S[22R240]
SHARAN ADITHYA.S [22R242]
Epicyclic Gear Train
Introduction:
Epicyclic gearing also called as planetary gearing. It is a gear system that
consists of one or more outer gear (planet gear) rotating about a central
(sun gear). The planet gear are mounted on a moveable arm (carrier)
which itself may rotate relative to the sun gear. Epicyclic gearing systems
may also incorporate the use of an outer ring gear or annulus, which
meshes with the planet gears.
Figure show an example of epicyclic gearing. It is used to increase output
speed. The planet gear carrier is driven by an input torque. The sun gear
provides the output torque, while the ring gear is fixed.

Gear ratio:
The gear ratio in an epicyclic gearing system can be different by the
design of the gear teeth and the ways of input rotation to the gear.
Epicyclic Gearbox Parts :
The three basic components of the epicyclic gear are:
1. Sun: The central gear
2. Planet carrier: Holds one or more peripheral planet gears, of the same
size, meshed with the sun gear
3. Annulus or Ring Gear: An outer ring with inward-facing teeth that mesh
with the planet gear or gears
In many epicyclic gearing systems, among the three basic components,
one component is held stationary; one component is input, provide power
to the system and last component is output, receive the power from the
system. The ratio of input rotation to output rotation is dependent upon the
number of teeth in each gear, and upon which component is held
stationary.

Epicyclic Gearbox Diagram :

Construction of epicyclic Gearbox:
In the epicyclic gearbox, the epicyclic gear train is a very general term.
Basically, it involves 3 gears: a sun gear, a planet gear and a ring gear,
the underlying concept being many gear ratios can be obtained from a
small volume as compared to other types of gear trains which take up
more space. Unlike simple gear trains, an epicyclic gear train requires
defining more than one input to obtain a specific output, hence making the
analysis a little difficult and non-intuitive.
Working of epicyclic gearbox:
The working principle of the epicyclic gearbox is based on the fact the
fixing any of the gears i.e. sun gear, planetary gears, and annular gear is
done to obtain the required torque or speed output. As fixing any of the
above causes the variation in gear ratios from high torque to high speed.
So let’s see how these ratios are obtained
First gear ratio:
This provide high torque ratios to the vehicle which helps the vehicle to
move from its initial state and is obtained by fixing the annular gear which
in turn causes the planet carrier to rotate with the power supplied to the
sun gear.
Second gear ratio:
This provides high-speed ratios to the vehicle which helps the vehicle to
attain higher speed during a drive, these ratios are obtained by fixing the
sun gear which in turn makes the planet carrier the driven member and
annular the driving member in order to achieve high-speed ratios.
Reverse gear ratio:
This gear reverses the direction of the output shaft which in turn reverses
the direction of the vehicle, this gear is achieved by fixing the planet gear
carrier which in turn makes the annular gear the driven member and the
sun gear the driver member.

Note- More speed or torque ratios can be achieved by increasing the

number of planet and sun gear in epicyclic gearbox.
One situation is when the planetary carrier is held stationary, and the sun
gear is used as input. In this case, the planetary gears simply rotate about
their own axes at a rate determined by the number of teeth in each gear.
If the sun gear has S teeth, and each planet gear has P teeth, then the
ratio is equal to -S/P. This rotation of the planet gears can inturn drive the
annulus, in a corresponding ratio. If the annulus has P teeth, then the
annulus will rotate by P/A turns for each turn of the planet gears.

In summarize:

1. One turn of the sun gear results in – S / P turns of the planets

2. One turn of a planet gear results in P / A turns of the annulus

3. One turn of the sun gear results in –S / A turns of the annulus

One situation is when the annulus may also be held fixed, with input
provided to the planetary gear carrier; output rotation is then produced
from the sun gear. This configuration will produce an increase in gear ratio,
equal to 1+A/S.

These are all described by the equation:

(2+n)ωa + 2ωs – 2(1+n) ωc = 0

Where n is the form factor of the planetary gear, defined by: n = Ns/Np

Advantages and Disadvantages of the epicyclic gear

system

Advantages of Epicyclic Gearbox :

The planetary gearbox offers a set of distinct advantages which makes it
an interesting alternative to traditional gear types such as helical and
parallel shaft gearboxes in applications requiring:

• High reduction ratios

• Compact and lightweight with high torque transmission
• High radial loads on the output shaft
 • It is quieter in operation
• Uniform distribution of load over all gears having greater tooth
contact.
• All gears are constantly in mesh, so a change of one gear to
another is possible without any loss.
Disadvantages of planetary gear systems
• Complexity
• Assembly of gears is limited to specific teeth per gear ratios
• Efficiency calculations are difficult
• Driver and driven equipment must be in line to avoid additional gearing

Application of Epicyclic Gear train :

• A good example of the everyday application of a planetary gear

system is the automatic transmission of a car.

• The epicyclic gear trains are used in the back gear of lathe,
differential gears of the automobiles, hoists, pulley blocks, wrist
watches, etc.
• The epicyclic gear trains are useful for transmitting high-velocity
ratios with gears of moderate size in a comparatively lesser
space.
 WORM WHEEL REDUCER
Worm gears are used when large gear reductions are needed. It is
common for worm gears to have reductions of 20:1, and even up to 300:1
or greater.

Many worm gears have an interesting property that no other gear set has:
the worm can easily turn the gear, but the gear cannot turn the worm. This
is because the angle on the worm is so shallow that when the gear tries
to spin it, the friction between the gear and the worm holds the worm in
place.

A worm gear (or worm drive) is a specific gear composition in which a

screw (worm) meshes with a gear/wheel similar to a spur gear. The set-
up allows the user to determine rotational speed and also allows for higher
torque to be transmitted. This mechanism can be found in devices both at
home and in heavy machinery; the simplest form evident in the tuning
mechanism of an acoustic guitar.

What is Worm and Worm Wheel?

• A worm drive is a gear arrangement in which a worm (which is a

gear in the form of a screw) meshes with a worm gear (which is
 similar in appearance to a spur gear, and is also called a worm
wheel).
• Like other gear arrangements, a worm drive can reduce rotational
speed or allow higher torque to be transmitted. The image shows
a section of a gear box with a worm gear being driven by a worm.
A worm is an example of a screw, one of the six simple machines.

There are three different types of worm gear:

• Non-throated – this involves a straight worm without a groove

machined around the circumference. A single moving point is
what provides tooth contact, meaning this particular type of worm
gear is subjective to high unit load wear and tear.
• Single-throated – concave helical teeth are wrapped around the
worm for line contact, meaning higher unit loads with less
excessive wear.
• Double-throated – usually called a cone of hourglass, this type
has concave teeth on both the worm screw and the gear itself.
Increasing the contact area in such a way allows for increased
unit loads with lower wear and tear.

This feature is useful for machines such as conveyor systems, in which

the locking feature can act as a brake for the conveyor when the motor is
not turning. One other very interesting usage of worm gears is in the
Torsen differential, which is used on some high-performance cars and
trucks. They are used in right-angle or skew shaft drives. The presence of
sliding action in the system even though results in quieter operation, it
gives rise to considerable frictional heat, hence they need good lubrication
for heat dissipation and for improving the efficiency. High reductions are
possible which results in compact drive
CONTRUCTION :

The construction of a worm wheel reducer involves several key

components that work together to achieve the desired reduction in
rotational speed and an increase in torque. Here's an overview of the
construction of a typical worm wheel reducer:

1. Worm Screw (Input Shaft): This is the primary driving component

of the worm wheel reducer. The worm screw is a threaded shaft with
a helical groove, which resembles a screw. It is typically connected
to the input source, such as an electric motor or a manual crank.
2. Worm Wheel (Worm Gear): The worm wheel is the driven
component of the reducer. It is a cylindrical gear with teeth that
mesh with the threads of the worm screw. The worm wheel is usually
connected to the output shaft, which delivers the reduced rotational
speed and increased torque.
3. Housing: The worm screw and worm wheel are enclosed within a
sturdy housing or casing. The housing serves several important
functions, including:
• Providing support and protection for the worm screw and
worm wheel.Maintaining proper alignment between the
two components to ensure efficient operation.
• Preventing contamination from dust, debris, and
moisture by sealing the internal components.
• Providing a space for lubrication, which is essential to
reduce friction and wear between the moving parts.
4. Bearings: Bearings are often used at both ends of the worm screw
and worm wheel to support their rotation. These bearings reduce
friction and ensure smooth and efficient operation.
5. Lubrication System: A lubrication system is essential to minimize
friction and wear between the worm screw and worm wheel. It
typically involves the use of grease or oil, which is distributed to the
gear meshing surfaces through channels and lubrication points
within the housing.
 6. Output Shaft: The output shaft is connected to the worm wheel and
extends from the worm wheel reducer. This is the part of the reducer
that transmits the reduced speed and increased torque to the load
or the application being driven.
7. Input and Output Flanges or Shafts: Depending on the specific
design and application, flanges or shafts may be attached to the
input and output ends of the reducer to facilitate connection to
external components or equipment.

8. Seals and Gaskets: Seals and gaskets are used to prevent the
ingress of contaminants and the escape of lubricants from the
housing, ensuring the longevity and reliability of the worm wheel
reducer.

ADVANTAGES OF WORM AND WORM WHEEL

1. Worm gear drives operate silently and smoothly.

2. They are self-locking.
3. They occupy less space.
4. They have good meshing effectiveness.
5. They can be used for reducing speed and increasing torque.
6. High velocity ratio of the order of 100 can be obtained in a single
step.

DISADVANTAGES OF WORM AND WORM WHEEL

1. Worm gear materials are expensive.

2. Worm drives have high power losses.
3. A disadvantage is the potential for considerable sliding action,
leading to low efficiency.
4. They produce a lot of heat.
APPLICATION OF WORM GEARS

Worm gears are used widely in

1. Material handling and transportation machinery

2. Machine tools
3. Automobiles Industry

• Tuning Instruments – most guitars, basses, banjos and other

stringed instruments use a worm gear for the tuning mechanism
to work. The gear’s force reduction is the main reason for this,
coupled with the locking capability that keeps the desired string
tightness in place. This type of worm gear is different to most as
you can tune both up and down; whereas most worm gears can
only be turned in one direction.
• Elevators/Lifts – worm gears can often be found in the
machinery of common elevators/lifts because of their compact
size and non-reversible properties. As the gear/load cannot
transmit motion back through the worm/hoist, using this type of
gear can act as a secondary braking system. This means the load
cannot free fall and load speed is easily regulated.
• Torsen Differentials – Large trucks or off-road vehicles, such as
the Hummer, often need to deliver different amounts of torque to
the each wheel, depending on what action the vehicle is
performing. For example, wheels need to spin at different speeds
whilst turning a corner as the inside wheels travel a shorter
distance. A vehicle’s Torsen differential will handle this movement
via a combination of worms and worm gears that separate each
individual wheel’s performance.
• Gates and Conveyor Belts – Typical worm drives can only be
turned in one direction.