TOPIC 3

COMPUTERIZED GEAR SYSTEM

TOPIC LEARNING OUTCOMES

At the end of this topic, the students will be able to:
1. Describe the different type of gear system and some of their application
(LO4,LO5,LO3)
2. Calculate gear ratios, angular velocity, input and output torque (LO3, LO4,
L05)
3. Calculate the efficiency of the gears (LO3, LO4, L05)
4. Understand the concept of gear system, types of gears and its related
function and application (LO3, LO4, L05)

CONTENTS

3.1 INTRODUCTION
Gears are a means of changing the rate of rotation of a machinery shaft.
They can also change the direction of the axis of rotation and can
change rotary motion to linear motion. A gear is a toothed wheel designed to
transmit torque to another gear or toothed component. Different size gears
are often used in pairs, allowing the torque of the driving gear to produce a
large torque in the driven gear at lower speed, or a smaller torque at higher
speed. The larger gear is known as wheel and the smaller gear as a pinion

3.2 EXPERIMENTAL THEORY

Consider a simple schematic of a gear box with an input and output shaft as
shown in Figure 3.1.

Figure 3.1: Simple Schematic of Gear Box

BDA 37401-Edition I/2022 19
Gear ratio, G.R = Input Speed / Output Speed , = N1 / N2
Gear ratio , G.R = (product of driven teeth )/ (product of driver teeth)
Gear ratio, G.R = Input Speed / Output Speed, = ω1 /ω2
The power transmitted by a torque, T (Nm) applied to the shaft rotating at N
(rev/min) is given by:
Power, P = Tω
P = [ 2π N T] / 60
In the ideal gearbox, the input and output power are the same so,
[ 2π N1 T1] / 60 = [ 2π N2 T2] / 60
In a real gear box, power is lost through friction and the power output is
smaller than the power input.
The efficiency is defined as;

η = Power Output / Power Input

η = [ 2πN2T2 x60 ] / [ 2πN1T1x60]
η = T2ω2 / T1ω1
Note;- N - speed in rev/ min ω - angular velocity ( rad/s )

Table 3.1 Technical Specification of Equipment

0 1 2 3

33 EXPER MENTAL EQU PMENTS

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 Figure 3.2 Connecting diagram

Figure 3.3 Simple Schematic of Gear Box

3.3 EXPERIMENTAL PROCEDURES

3.3.1 EXPERIMENTS FOR 4 STAGE GEAR WITH SAME SIZE GEAR -

GEAR SET 1

a. Make sure gear set 1 is in place. If not, install the gear set 1 into the
system according to the following steps:-
i. Remove the transparent protective cover of the system.
ii. Remove the locking bolts of the gear set.
iii. Remove the gear set by lifting it using the handles.
iv. Put the removed gear set by lifting on storage table.

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 v. Take the new gear set and put it on the system. Make sure the
gear set is completely in place.
vi. Tighten the locking bolts.
vii. Put the transparent protective cover of the system. The new set
is ready to operate.
b. Turn on the system by pressing ON button. The controller and motor
displays will ON.
c. Slowly increase the speed until it reaches 100rpm. Let the system run
and stabilize for an about 10 seconds. Using a Tachometer, take the
rotational speed of the gear by pointing the beam-pointer to the
reflector. Record the speed into the lab sheet accordingly.
d. Slowly increase the speed until it reaches 200rpm. Let the system run
and stabilize for about 10 seconds. Again use Tachometer to get
rotational speed. Record the speed into the lab sheet 1.
Follow the step 3.4.1.d to 3.4.1.g for the speed adjustment of 300rpm,
400rpm, 500rpm, 600rpm and 700rpm.
e. Turn OFF the potentiometer slowly
f. Record all values in Table 3.2.

3.3.2 EXPERIMENTS FOR 4 STAGE GEAR WITH DIFFERENT SIZE GEAR -

GEAR SET 2
a. Make sure gear set 2 is in place. If not, install the gear set 2 into the
system according to the steps 3.4.1.a ( i - vii )
b. Turn on the system by pressing ON button. The controller and motor
displays will ON.
c. Slowly increase the speed until it reaches 100rpm. Let the system run
and stabilize for an about 10 seconds. Using a Tachometer, take the
rotational speed of the gear by pointing the beam-pointer to the
reflector. Record the speed into the lab sheet accordingly.
d. Slowly increase the speed until it reaches 200rpm. Let the system run
and stabilize for about 10 seconds. Again use Tachometer to get
rotational speed. Record the speed into the data sheet.
e. Follow the step 3.4.2.a to 3.4.2.g. for the speed adjustment of 300rpm,
400rpm, 500rpm, 600rpm and 700rpm.

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f. Turn OFF the potentiometer slowly.
g. Record all values in Table 3.3.

Table 3.2 4 Stage Gear with Same Size Gear – Gear Set 1

Table 3.3 4 Stage Gear with Different Size Gear – Gear Set 2

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3.4 ACTIVITIES

3.4.1 RESULTS (30 %)

a. Fill in the experimental result in the Table 3.2 and 3.3

3.4.2 DISCUSSIONS (70%)

a. From Table 3.1 and 3.2, calculate gear ratio theoretically
and experimentally and compare the results. (15%)
b. What are the input torque and the output torque of the gear system.
Given that the input power Pin equal to 20kW and the efficiency, η
equal to 0.7. (10%)
c. Calculate the efficiency of gear system (gear set 1 and 2) of the
following combination gear. Given Pin = 20kW and system are idle,
(15%)
a. Gear 1 to gear 0
b. Gear 2 to gear 0
c. Gear 3 to gear 0
d. Beside than compound gear train, give another type of gearbox
constructions and also describe the applications. (30%)

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