Design of Gear Box

Using PSG Design Data Book

Sample Problem
Design a gearbox to give 9 speed output from a
single input speed. The required speed range is
180 rpm to 1800 rpm.
Given:
n =9
Nmin = 180 rpm
Nmax = 1800 rpm
Step - 1 “Calculation of Step ratio”
Nmax
= Ø n-1
Nmin

1800 = Ø 9-1
180
Ø = 1.333
Refer PSG Data Book P. No : 7.20 to check
whether, the calculated step ratio is a std. value
 Since its not a std. value, Lets find a multiples
of std. value come close to calculated step ratio
1.6 - Cannot be used
1.25 - Cannot be used
1.12 - 1.12 x 1.12 = 1.254
1.06 - 1.06 x 1.06 x 1.06 x 1.06 x 1.06 = 1.338

Multiples of 1.06 gives nearest value of 1.333

As 1.06 is multiplied 4 times we skip 4 speed
Hence std. Ø = 1.06 & R 40 series is selected
 Step - 2 “Selection of Speeds”
100 106 112 118 125 132 140 150 160 170 180 190 200 212 224

236 250 265 280 300 315 335 355 375 400 425 450 475 500 530

560 600 630 670 710 750 800 850 900 950 1000 1060 1120 1180 1250

1320 1400 1500 1600 1700 1800 1900

The selected speeds are;

180,236,315,425,560,750,1000,1320,1800
No need to check for deviation
Step - 3 “ Structural formula & Ray
Diagram ”
The structural formula for 9 speed gear box is
3 (1) 3 (3)

Stage 1 - Single input is splitted into 3 speeds

Stage 2 - 3 input is splitted into 9 speeds
ie., each input is splitted into 3 speed
 1800 Selected speeds are;
1320 180,236,315,425,560,
750,1000,1320,1800
1000

750
Lets group the final
560 output speeds into 3,
425 since the structural
315
formula is
3 (1) 3 (3)
236

180
Stage 1 Stage 2
Lets select the input speed of stage 2. For that the
input speed should satisfy two following conditions.
At Least one output speed should be greater than
input speed. (1 for 3 o/p and 2 for 4 o/p)
The input and output must satisfy the following ratios

Nmin Nmax
≥ 0.25 ≤2
Ni/p Ni/p
 Stage - 2
1800
Lest find input speed for the
1320 lowest output speed set.
For the first condition, possible
1000 input speeds are 750 & 560.
For the second condition,
750

560 Nmin 180

= = 0.32 ≥ 0.25
425 Ni/p 560

315 Nmax
= 1000 = 1.78 ≤2
236 Ni/p 560
180 The conditions are satisfied
Stage 1 Stage 2
 Stage - 1
1800
Lest find input speed for the
1320 lowest output speed set.
For the first condition, possible
1000 input speeds are 1338 & 1790
For the second condition,
750

560 Nmin 560

= = 0.41 ≥ 0.25
425 Ni/p 1320

315 Nmax
= 1000 = 0.74 ≤2
236 Ni/p 1320
180 The conditions are satisfied
Stage 1 Stage 2
Step - 4 “ Kinematic Arrangement ”

3
1 5
Shaft - 1 / Input

9
7
11
4 Shaft - 2 / Intermediate
2
6

10 Shaft - 3 / Output
8
12
Step - 5 “ Calculation of number of
number of teeth in gears ”
Start from the final stage
First find the number of teeth for maximum
speed reduction pair.
Assume the number of teeth in the driver gear
(It should be above 17)
The sum of number of teeth in meshing gears
in a stage is always equal.
 Stage - 2 “First Pair - Maximum Speed Reduction”
Assume number of teeth in driver = 20
z11 N12 20 180
= =
z12 N11 z12 560

z12 = 62.2 ≅ 63
 Stage - 2 “Second Pair - Minimum Speed Reduction”

z7 N8 z7 425
= =
z8 N7 z8 560

z7 = 0.76 z8
 Stage - 2 “Third Pair - Maximum Speed Increment”

z9 N10 z9 1000
= =
z10 N9 z10 560

z9 = 1.78 z10
 Stage - 2

z7 + z8 = z9+ z10 = z11+ z12 z11 = 20

z7 + z8 = z9+ z10 = 20 + 63 = 83 z12 = 63
z7 + z8 = 83 z7 = 0.76 z8
0.76 z8 + z8 = 83 z9 = 1.78 z10
z8 = 47.16 ≅ 48 z7 = 35
z9+ z10 = 83
1.78 z10+ z10 = 83
z10 = 29.79 ≅ 30 z9 = 53
 Stage - 1 “First Pair - Maximum Speed Reduction”
Assume number of teeth in driver = 20
z5 N6 20 560
= =
z6 N5 z6 1338

z6 = 47.14 ≅ 48
 Stage - 1 “Second Pair – Intermediat Speed Reduction”

z1 N2 z1 750
= =
z2 N1 z2 1338

z1 = 0.57 z2
 Stage - 1 “Third Pair - Minimum Speed Increment”

z3 N4 z3 1000
= =
z4 N3 z4 1338

z3 = 0.74 z4
 Stage - 1

z1 + z2 = z3+ z4 = z5+ z6 z5 = 20
z1 + z2 = z3+ z4 = 20 + 42 = 68 z6 = 48
z3 + z4 = 68 z1 = 0.57 z2
0.76 z4 + z4 = 68 z3 = 0.74 z4
z4 = 38.64 ≅ 39 z3 = 29
z1 + z2 = 68
0.57 z2 + z2 = 68
z2 = 43.3 ≅ 44 z1 = 24
Solution
z1 = 24 z7 = 35

z2 = 44 z8 = 48

z3 = 29 z9 = 53

z4 = 39 z10 = 30

z5 = 20 z11 = 20
z6 = 48 z12 = 63