DESIGN OF A TRANSMISSION SYSTEM FOR CHAIN CONVEYOR

System components:
1-Electric motor 2. Flexible shaft coupling 3. Dual-stage gear reducer
4. Roller chain drive 5. Chain conveyor
Operating condition: one-direction working, light-impact loading, 8-hour shift
Tangential force on conveyor chain, F (N): 3000
Tangential velocity on conveyor chain, v (m/s): 2,74
Number of teeth of the drive conveyor sprocket, Z: 11
Pitch of conveyor chain, p (mm): 150
Service life, L (years): 7
Number of working days per year: 338
Number of shifts per working day: 2
(seconds): 20
(seconds): 56
(seconds): 49
:T
: 0,7T
: 0,3T
 ABSTRACT

Nowadays, the development of technology has received growing interest by

governments from many countries. With the help of technology, we can easily
increase our productivity and create more safe conditions in workplaces. To
reach these accomplishments, it takes us a lot of time to practice, do research
and improve our technological skills from the beginning of our university life.
Design project of transmission system is a helpful subject which allows
mechanical engineering students to apply some theoretical knowledge from the
previous subject machine elements. It also helps students to get familiar with
calculating each element for a realistic mechanical design.
Thanks to Dr Le Thanh Long, with his instruction, I could totally complete
this project. During the period of doing this project, I could reinforce all
knowledge, approach and learn how to use some engineering softwares such as
Autocad, Solidworks, etc. Also, I was able to learn to accomplish the mindset of
an engineer which plays a pivotal role in my future career.
I have tried my best to perform this project. However, due to limited time and
my lack of practical experience, there still are some minor errors in this report.
Therefore, I look forward to receiving suggestions in order to enrich my
knowledge.
 CONTENTS

ABSTRACT.......................................................................Error! Bookmark not defined.

CHAPTER 1: MOTOR SELECT AND TECHNICAL SPECIFICATIONS OF
TRANSMISSION SYSTEM .............................................Error! Bookmark not defined.
1.1 General efficiency of transmission system .......................................................... 4
1.2 Required power of motor ..................................................................................... 4
1.3 Motor selection and transmission ratio ................................................................ 5
1.4 Parameters of transmission system ...................................................................... 6
1.5. Technical specification of the transmission ........................................................ 7
CHAPTER 2: DESIGN CHAIN DRIVES ....................................................................... 11
2.1 Basic parameters ................................................................................................ 11
2.2 Calculate chain drive parameters ....................................................................... 11
2.3 Checking the chain durability ............................................................................ 12
2.4 Calculate the diameters of chain plates .............................................................. 12
2.5 Checking the contact chain durability of chain plates ....................................... 12
2.6 Determine the force acting on the shafts ............................................................ 12

CHAPTER 3: CALCULATE AND DESIGN DUAL STAGE HELICAL REDUCER .. 15

3.1 Technical specification....................................................................................... 15
3.2 Select gear material, heat treatment method, material mechanical properties ... 16
3.3 Determine the allowable stresses ....................................................................... 16
3.4 Design and analysis of fast-stage helical spur gears .......................................... 16
3.5 Design and analysis of slow-stage straight spur gears ....................................... 24
 CHAPTER 1: MOTOR SELECT AND TECHNICAL
SPECIFICATIONS OF TRANSMISSION SYSTEM

1.1 General efficiency of transmission system

The efficiency of the transmission system:

According to Table 3.3 (Giáo trình Cơ sở thiết kế máy, 2020, p. 96), we have the
efficiency for each type of machine element as follow:
From that we choose the efficiency:

The efficiency of chain drive:

𝜂ch = 0,93

The efficiency of one pair of helical gears and spur gear:

𝜂g = 0,96

The efficiency of the one pair of roller:

𝜂rl = 0,99

The efficiency of coupling:

𝜂c = 0,98

The general efficiency of transmission system:

1.2 Required power of motor

The working power on the chain conveyor:

The equivalent power :

√∑ ( )
√
∑
Required power of motor:

1.3 Determine the preliminary number of revolutions:

The number of revolutions of the chain conveyor:

The transmission ratio of the system:

According to the table 2.4:

: The transmission ratio of the chain
: The transmission ratio of the Dual-stage gear reducer
We have:

The preliminary number of revolutions of the motor:

1.4 Motor selection and transmission ratio

The electric motor has to satisfy these parameters:

{ {

According to the table P1.3 , we choose the motor: 4A132M2Y3.

The parameters of the electric motor:

Name Power Rotation Cos

speed
(kW)
(rpm)

4A132M2Y3 11,0 2907 0,90 88 2,2 1,6

Table 1.1

The transmission ratio of the system:

 Choose 

With the transmission ratio of the reducer , according to the table 3.1 (Hệ dẫn động
cơ khí – Tập một), so the dual-stage gear reducer has:
The transmission ratio of fast stage: 3,58
The transmission ratio of slow stage: 2,79

1.5 Parameters of transmission system

Power 𝑃 on each shaft :

Rotational speed on each shaft :

Torque on each shaft :

1.6 Technical specification of the transmission
We have the following table of parameters of the transmission system:
Shaft
Parameters
Motor I II III Working
Power
𝑷 (𝒌𝑾)
Transmission
ratio 1 3,58 2,79 2,72
𝒖
Rotational speed
𝒏 (𝒓𝒑𝒎)
Torque
𝑻 (𝑵𝒎)
Table 1.2
 CHAPTER 2 : DESIGN ROLLER CHAIN DRIVES
2.1 Basic parameter
Power input :
Rotational speed :
Transmission ratio of chain drive :
Torque :
Operating conditions: one-direction working, light-impact loading, 8-hour shift (2 shift per day)

2.2 Calculate chain drive parameters

2.2.1 Calculate teeth number
Number of teeth of driving sprocket :
, choose
Number of teeth of driven sprocket :
, choose
Transmission ratio :

Error:
| | | |

2.2.2 Operation correction factor :

light-impact loading
– Choose the shaft distance a = 40p
inclination angle
adjustable axle
choose a satisfactory lubrication method, dusty environment
shift operation
2.2.3 Calculate transmitting power

With:
tooth number coefficient
rotation number coefficient

According to the table 5.5 with = 200 rpm, select one-series chain transmission has the chain
pitch p = 31,75 mm that satisfies the wear-resistant condition.
[ ]

Simultaneously, according to the table 5.8:

The axis distance:

2.2.4 Determine the number of chain link and the axis distance
Following the 5.12 formula, number of chain link:

( ) ( )

Choose the chain link number is even x = 124, recalculate the axis distance following the 5.13
formula:

* √ [ ] +

[ √ [ ] ]

Must reduce an amount of to not let the chain handle too much stress.
So
Number of impacts following the 5.14 formula:

[]

2.3 Checking the chain durability

Following the 5.15 formula:

According the table 5.2, failure load Q = 88,5 (kN), mass of 1 meter of chain q = 3,8 (kg)
(Starting load is 2 times the nominal load).
Tangential force
The tension due to the weight of the passive chain branch (N)

Where:
The transmission system is horizontal
The tension due to centrifugal force (N)
So that:

According to the table 5.10 with and , the safety factor [ ] .

So that [ ] The chain transmission is satisfied.

2.4 Calculate the diameters of the chain plates

Pitch diameter of the chain disc:
Following formula 5.17 and table 13.4 (page 86 [1])

( ) ( )

( ) ( )

Outer diameter of chain disc:

[ ( )] * ( )+

[ ( )] * ( )+

Inter diameter of chain disc:

with

2.5 Checking the contact durability of chain plates

Following the 5.18 formula:

Where:
(depend on z)
 Dynamic load factor
Coefficient of unequal potting load on the rows ( one-series chain )
Impact load on chain row (N)

Projection area of hinges

elastic modulus (the material of chain plates is steel)

So that:

√ √

Thus, using quenching 45 steel to improve the hardness of HB210 will achieve the allowable
contact stress [ ] , satisfies the contact strength.
2.6 Determine the forces acting on the shaft:

With because of the transmission inclined an angle less than 40°.

With because of the transmission inclined an angle less than 40°

Symbol Driving gear Driven gear

Chain pitch; mm 31,75

Number of teeth z 23 63

Reference diameter d 233,1702 636,9633

Tip diameter; mm 246,8734 652,0645

Root diameter; mm 213,9250 632,8013

Center distance; mm a 1232

Number of chain link X 124

Root radius, mm r 9,6226

CHAPTER 3: CALCULATE AND DESIGN DUAL-STAGE GEAR
REDUCER
3.1. Technical specification
From chapter 1, we have specified the requirements for designing our reducer as follows:
Technical specifications

Parameters Fast stage Slow stage

Power

Transmission ratio 3,58 2,79

Driving gear

Driven gear
Rotational speed

Driving gear
Torque
Driven gear

Service time
4

Working condition one-direction working, light-impact loading, 2 8-hour

shift
338 days
3.2 Select gear material, heat treatment method, material mechanical properties
Because there are no special requirements and from the point of view of unification in design,
here we choose the same materials for the two stage gears.
According to table [6.1] References [2], we have:
- Driver gear: improved tempered C45 steel achieves hardness HB 241...285 have
, . We can take that the medium hardness of driver gear is 𝐻𝐵1 = 245.
- Driven gear: improved tempered C45 steel achieves hardness HB 192...240 have
, . We can take that the medium hardness of driver gear is 𝐻𝐵1 = 230.
Data Driving gear Driven gear

Hardness HB(MPA)

Contact endurance limit

Bending endurance limit

Factor of safety for bending

1,1

Factor of safety for bending

1,75

3.3 Determine the allowable stress

Using formula (6.5) & (6.7), Calculating

-
-
-
-

∑( )

( )

∑( )

( )

∑( )

( )

∑( )

( )

We can calculate the allowable contact stresses by this formula :

[ ]

[ ]

Because the fast-stage gears use helical gear so we have :

[ ] [ ]
[ ]

With the slow-stage gear uses spur gear so and all bigger than , so that:
[ ] [ ]
We also determine the allowable bending stresses by this formula :

[ ]

[ ]

We can calculate the allowable overload stress :

[ ]
[ ]
[ ]

3.4 Calculate the fast stage: Helical gear transmission

3.4.1 Determine the center distance
We obtain the center distance through the formula :

√ √
[ ]

With:

( ) coefficient depended on the gear tooth and material, based on table (6.5)
[1].
is bending momentum on driving shaft of speed reducer,
based on standard and table 6.6 [1]
[ ]: Allowable contact stress, [ ]

: coefficient about the unbalanced load distribution over the ring width when contact.

According to table 6.7 with:

Determine: (Table 6.7)

We choose the center distance base on standard SEV229-75, = 105 (mm)

We have: {
3.4.2 Determine the matching parameters
We have that :

According to the standard set value, we choose m = 2

From the condition:

We have :

We choose: = 18 (𝑡𝑒𝑒𝑡ℎ𝑠)
So, we have: = = 64,44 (𝑡𝑒𝑒𝑡ℎ𝑠). Choose (teeths)

So, the real transmission ratio:

Recalculated the angle :

3.4.3 Testing the calculated contact strength

Due to formula 6.33, contact stress on working surface of tooth is:

Where:
: coefficient about mechanical properties of material, due to table 6.5 we have
: coefficient about the contact shape, following 6.34 we have:

√
Where:
: inclination angle of teeth on basis cylinder
Due to formula 6.35, we have:

Therefore, due to the following formula, we have:

: coefficient about tooth matching, determined through formula 6.36c:

We have

So, we have √ √

While

[ ( )] [ ( )]

Pitch diameter of small pulley:

: load coefficient when calculating contact, determine through formula 6.39:

Where:
: The coefficient accounts for the uneven load distribution between pairs of teeth that are
simultaneously meshing, the value is looked up according to table 6.14, we get
: coefficient about the unbalance distribution of load on the width of internal tooth,
searching in table 6.7 we have

: coefficient about the affection of flexible load in matching zone, due to formula 6.41, we
have:
Where:

: coefficient about the matching error due to table 6.15, we have

: coefficient about the affection of pitch, take due to table 6.16.

: pitch velocity . Due to table 6.13, we choose the

degree of accuracy as 8.

√ √

So:

Substituting values to the formula we have:

[ ]
Determine exactly the contact stress:

Due to 6.1 and 6.1a we have:

[ ] [ ]
Because of then condition for contact stress is secured
3.4.4 Testing the calculated bending (beam) strength

Due to formula 6.43, we have:

Where:
: bending momentum on driving pulley, (N.mm)
: module
: width of pitch
: pitch diameter of driving pulley, (mm)

coefficient about the tooth matching

: coefficient about the inclination

: Coefficient about type of tooth on pulley 1 and 2

{
So due to table 6.18 with coefficient of correction
We have:
: load coefficient when calculating bending.

due to table 6.14

due to table 6.7

When √

Due to table 6. 15 and table 6.16 we have:

 √

We have:

Seeing that:
[ ]
{
[ ]
Bending stress condition is secured.

3.4.5 Testing teeth for overload

According to 6.48 we have: √ [ ]

With:

So that: √ [ ]
[ ]

So that:
[ ]

[ ]

Overload endurance is secured.

3.4.6 Parameter table of fast stage
Center distance

Module

Ring width
{

Speed ratio
 Angle of teeth

Number of teeth

Coefficient of
correction

Accurate levels 8

Pitch diameter

Outer diameter

Base diameter

3.5 Calculate the slow stage: Straight spur gear transmission

3.5.1 Determine the center distance
We obtain the center distance through the formula :

√ √
[ ]

With:

( ) coefficient depended on the gear tooth and material, based on table (6.5)
[1].
is bending momentum on driving shaft of speed reducer,
based on standard and table 6.6 [1]
[ ]: Allowable contact stress, [ ]

: coefficient about the unbalanced load distribution over the ring width when contact.

According to table 6.7 with:

Determine: (Table 6.7)

We choose the center distance base on standard SEV229-75, = 140 (mm)

We have: {

3.5.2 Determine the matching parameters

We have that :

According to the standard set value, we choose m = 2

From the condition:

We have :

We choose: = 30 (𝑡𝑒𝑒𝑡ℎ𝑠)
So, we have: = = 83,7 (𝑡𝑒𝑒𝑡ℎ𝑠). Choose (teeths)

So, the real transmission ratio:

Recalculated the angle :

3.5.3 Testing the calculated contact strength

Due to formula 6.33, contact stress on working surface of tooth is:

Where:
: coefficient about mechanical properties of material, due to table 6.5 we have
 : coefficient about the contact shape, following 6.34 we have:

Where:
: inclination angle of teeth on basis cylinder
Due to formula 6.35, we have:

Therefore, due to the following formula, we have:

: coefficient about tooth matching, determined through formula 6.36c:

We have

So, we have √ √

While

[ ( )] [ ( )]

Pitch diameter of small pulley:

: load coefficient when calculating contact, determine through formula 6.39:

Where:
: The coefficient accounts for the uneven load distribution between pairs of teeth that are
simultaneously meshing, the value is looked up according to table 6.14, we get
 : coefficient about the unbalance distribution of load on the width of internal tooth,
searching in table 6.7 we have

: coefficient about the affection of flexible load in matching zone, due to formula 6.41, we
have:

Where:

: coefficient about the matching error due to table 6.15, we have

: coefficient about the affection of pitch, take due to table 6.16.

: pitch velocity . Due to table 6.13, we choose

the degree of accuracy as 8.

√ √

So:

Substituting values to the formula we have:

[ ]
Determine exactly the contact stress:
Due to 6.1 and 6.1 a we have:
[ ] [ ]
Because of then condition for contact stress is secured

3.5.4 Testing the calculated bending (beam) strength

Due to formula 6.43, we have:

Where:
: bending momentum on driving pulley, (N.mm)
: module
: width of pitch
: pitch diameter of driving pulley, (mm)

coefficient about the tooth matching

: coefficient about the inclination

: Coefficient about type of tooth on pulley 1 and 2

{
So due to table 6.18 with coefficient of correction
We have:
: load coefficient when calculating bending.

due to table 6.14

due to table 6.7

When √
Due to table 6. 15 and table 6.16 we have:

We have:

Seeing that:
[ ]
{
[ ]
Bending stress condition is secured.

3.5.5 Testing teeth for overload

According to 6.48 we have: √ [ ]

With:

So that: √ [ ]
[ ]

So that:
[ ]

[ ]

Overload endurance is secured.

3.5.6 Parameter table of slow stage
Center distance

Module

Ring width
{

Speed ratio

Angle of teeth

Number of teeth

Coefficient of
correction

Accurate levels 8

Pitch diameter

Outer diameter

Base diameter