Ptitchener Gearboxreport Full

O LIN C OLLEGE OF E NGINEERING
Gearbox Study
Paul Titchener
October 23, 2014
Figure 0.1: Gearbox render
C ONTENTS
1 Executive Summary
2 Brief System Overviews

2.1
2.2
2.3
2.4
Mouth . . . . . . . . . .
Front Legs . . . . . . .
Rear Leg Transmission
Clock . . . . . . . . . .
4
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3 Tail Gearbox Mechanical Design
4
4
5
5
3.1 Motor Selction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Gear Ratio Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Shaft Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Analysis
7
8
8
10
4.1 Housing Optimization . . . . . . .

4.2 Gear Pitch Selection . . . . . . . .
4.2.1 First Stage Calculations . .
4.2.2 Second Stage Calculations .
4.2.3 Third Stage Calculations . .
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10
12
12
12
12
5 Structure
13
6 Power
13
7 Appendix I: Free Body Diagrams for Force Calculation
13
8 MatLab Bearing Reaction Force Solver
14
L IST OF F IGURES
0.1
1.1
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
3.5
3.6
Gearbox render . . . . . . . . . . . . . . . . . . . . .
Example of Gearbox Simulation . . . . . . . . . . .
Alligator Mouth . . . . . . . . . . . . . . . . . . . . .
Alligator Legs . . . . . . . . . . . . . . . . . . . . . .
Alligator Back Leg Transmission . . . . . . . . . . .
Alligator Clock . . . . . . . . . . . . . . . . . . . . . .
Example of a MiniBajaGearbox . . . . . . . . . . . .
One of the gearbox side plates. . . . . . . . . . . . .
Nema 56 Face mount motor, McMaster 59845K540
Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Design . . . . . . . . . . . . . . . . . . . . . . .
Example Shaft . . . . . . . . . . . . . . . . . . . . . .
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1
3
4
4
5
6
6
7
7
8
9
9
4.1 Factor of Safety for the Gearbox Housing. The pocketing pattern is noticeable
in the coloring, but the FS never drops below 10. . . . . . . . . . . . . . . . . . .
4.2 Stress applied to the gearbox. Areas of high stress are made stronger by webbing
patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Displacement of the gearbox. This metric is why the gearbox was not lightened
further. Displacement does not excede .05mm (.002") . . . . . . . . . . . . . . .
7.1 Free Body Diagram of Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
13
14
14
1 E XECUTIVE S UMMARY
The purpose of this study was to design a gearbox to be used in a robotic fish. We decided
that we wanted to focus more on the gearbox side of the project than the aquatic fish, so we
designed five gearboxes and focused less on topics such as waterproofing, system integration
and buoyancy. With this end in mind, we decided to build a robotic alligator, and create a
large baseplate to mount everything on. The alligator is modeled after the alligator in Peter
Pan, so it also has a ticking clock inside of it.
The five gearboxes we designed were a gearbox to open the mouth, a gearbox to move the
front legs, a gearbox to move the back legs, a gearbox to move the hands on a clock inside the
alligator and a gearbox to actuate the tail.
My personal goal in this project was to use more of the analysis techniques that we learned
in Mechanics of Solids and Structures to drive mechanical design. Because of this, I chose to
design a simpler gearbox, that simply converted a high speed motor to a high torque output,
but to both use a very high power motor (2 horsepower) and to analyze the system to see if
and where if could fail. I calculated the radial and axial forces on the gears and used these
numbers to create a robust housing for a very high force gear-train.
Figure 1.1: Example of Gearbox Simulation
2 B RIEF S YSTEM O VERVIEWS

While we did not integrate all of our systems together, out team did design five discrete transmissions. A quick overview is provided here of their forms and functions.
2.1 M OUTH
Eric designed a mouth that can both open and stick out its tongue. This is accomplished
with a gearbox that both turns a rotary joint to open the mouth and pushes on a rack gear in
order to extend the tongue. The gearbox has a gear stacking of 12:72, 21:72, for a total ratio of
1:20.57.
Figure 2.1: Alligator Mouth
2.2 F RONT L EGS

David designed a pair of front legs that rotate. A clockcage gearbox converts low torque, high
speed motion from the motor to high torque, low speed motion at the legs.
Figure 2.2: Alligator Legs
2.3 R EAR L EG T RANSMISSION

Amanda was interested in creating a multiple speed transmission, so she designed a system
that can switch between different gear ratios for the rear leg transmission. The CAD for this
design is not quite finished at this point, but the current revision of it is pictured below.
Figure 2.3: Alligator Back Leg Transmission
2.4 C LOCK
Alex wanted to design a system with an unusual gear mechanism, so he chose to look into
designing a Geneva drive. This mechanism was first developed by Swiss clockmakers, and is
used to make a clock tick. Fittingly, he used in in the clock that identifies our alligator as the
animal from Peter Pan. The clock is made up of a motor driving a gear train that controls the
speed of the three hands. The second hand moves 60 times as fast as the minute hand, which
in turn moves 12 times as fast as the hour hand.
Figure 2.4: Alligator Clock
3 TAIL G EARBOX M ECHANICAL D ESIGN

I was interested in making a very high torque, high power gearbox for this project and analyzing it to ensure that it can withstand the loads applied to it. To do this I mimicked the
style of many MiniBaja gearboxes. These gearboxes are generally created out of a CNC machined aluminum box with bearings on the box and on the "lid" of the box. The gearboxes
are entirely enclosed so that they can be filled with oil to reduce friction.
Figure 3.1: Example of a MiniBajaGearbox
With this inspiration in mind, I designed a gearbox that has two CNC machined aluminum
side plates. One of these side plates also integrates sidewalls that retain oil. Both side plates
are lightened using a triangular pattern of webbing.
Figure 3.2: One of the gearbox side plates.
The motor bolts to one of these side plates and drives the geartrain. Bearings are pressed into
each sideplate. They are located using precision bored bearing holes and the bearing flange.
3.1 M OTOR S ELCTION

Part of my goal in this project was to design a system with a very large amount of force. Because of this I chose a 2 HP motor to drive the tail. It spins at a rated speed of 1750 RPM and
can sustain a torque of 72 in-lbs at max power.
Figure 3.3: Nema 56 Face mount motor, McMaster 59845K540
3.2 G EAR R ATIO S ELECTION

The gear ratio used is a three stage system with an overall reduction of 1:150. This results in
a torque of 900.3 ft*lbs and a speed of 11.6 RPM at the output shaft. General gearing guidelines are not to use a gear larger than 80-100 teeth and to not use pinion gears smaller than
10-12 teeth because otherwise they will be undercut. Therefore the three ratios selected were:
14:84
14:70
12:60
These ratios gave the desired speed without exceeding either of the gear guidelines for sizing.
They also fit the physical profile of the gearbox well. The second stage is slightly larger than
it needs to be, however, it is this size because additional distance was needed between the
pinion and the driven gear to allow for clearance in the third stage.
Figure 3.4: Gear Ratios
3.3 S HAFT D ESIGN

The three shafts in the gearbox are all designed similarily. The shafts used are hex shafts in
order to transfer torque between the gears without introducing the stress concentration of a
key. They are held in place laterally using a boss machined into the shaft and spacers. The
bearings are flange bearings that have the inner race extended slightly from the outer race.
Therefore they can be used without bearing washers. Finally, there is a Belville washer on
each shaft that preloads the bearings and ensures that the bearings run precisely.
Figure 3.5: Shaft Design
Figure 3.6: Example Shaft
4 A NALYSIS
Loads were calculated on both the housing of the gearbox to determine how much weight
could reasonably be removed from the side plates. The gears themselves were also analyzed
to ensure that the gear teeth will not shear under the loads applied to them.
4.1 H OUSING O PTIMIZATION

The gearbox was first analyzed statically using F = M A = 0 and then the reaction forces determined through this analysis were used to simulate the system in Solidworks (The MatLab
code and free body diagrams for this process are located in Appendix I). Through this process, the weight of the main gearbox plate was reduced from 26 lbs to 16 lbs. The weight of
the outer plate was likewise reduced.
The final simulation shows the gearbox deflecting by less than .002". The minimum safety
factor is 10. Additional weight reduction could be accomplished without physically breaking
the gearbox. However, this point was determined acceptable because if the gearbox deforms
significantly more than it currently does the gears will not run as efficiently.
Figure 4.1: Factor of Safety for the Gearbox Housing. The pocketing pattern is noticeable in
the coloring, but the FS never drops below 10.
10
Figure 4.2: Stress applied to the gearbox. Areas of high stress are made stronger by webbing
patterns.
Figure 4.3: Displacement of the gearbox. This metric is why the gearbox was not lightened
further. Displacement does not excede .05mm (.002")
11
4.2 G EAR P ITCH S ELECTION

Given the amount of force moving through the gearbox, there is a risk that the gear teeth
will shear off of the gears or otherwise deflect and break the gearbox. Therefore, gear tooth
strength was calculated using the Lewis formula. This formula says that the strength of a
tooth is dependent on the pitch of the gear, the number of teeth on the gear, the face width of
the gear and a constant known as the lewis form factor. The lewis form factor is a measured
quantity and can be looked up for various tooth geometry.
Sa f eLoad =
(1/3 Tensi l eSt r eng t h) F aceW i d t h Lewi sF ac t or

P i t ch
(4.1)
4.2.1 F IRST S TAGE C ALCULATIONS

The first section had a pinion with radius of .583". There is a torque of 72 in-lbs generated by
the motor. Therefore:
72i n l bs
= 124l bs
(4.2)
.583"
From the lewis formula, we can calculate that the safe load for a gear with 14 teeth, face width
of .75" and pitch of 12 is 477lbs. Therefore, we have a safety factor of 3.85.
4.2.2 S ECOND S TAGE C ALCULATIONS
The first section had a pinion with radius of .875". There is a torque of 432 in-lbs generated
by the motor. Therefore:
432i n l bs
= 493l bs
(4.3)
.875"
From the lewis formula, we can calculate that the safe load a gear with 14 teeth, face width of
1.25 and pitch of 8 is 1835 Lbs. Therefore, we have a safety factor of 3.72.
4.2.3 T HIRD S TAGE C ALCULATIONS
The first section had a pinion with radius of .1". There is a torque of 2160 in-lbs generated by
the motor. Therefore:
2160i n l bs
= 2160l bs
(4.4)
1"
From the lewis formula, we can calculate that the safe load for a gear with 12 teeth, face width
of 1.5" and a DP of 6 is 3026 lbs. Therefore, we have a safety factor of 1.4.
12
5 S TRUCTURE
All of the components of the alligator are mounted on a large extrusion. This gives us a very
large, open space to work with and also connects all of our components effectively.
6 P OWER
The motor selected was a 2 HP face mount, Nema 56 motor from McMaster. More details are
available in the Motor Power section.
7 A PPENDIX I: F REE B ODY D IAGRAMS FOR F ORCE C ALCULATION

Each free body diagram applies to one gear. From these diagrams (which were turned into
three dimensional free body diagrams not shown) bearing reaction forces were determined
using the MatLab script in Appendix II.
Figure 7.1: Free Body Diagram of Shaft 1.
13
8 M AT L AB B EARING R EACTION F ORCE S OLVER

This MatLab code was used to solve for the force applied to the housing from the bearings.
%% Motor Torque Calcs
HP = 2;
W = HP * 745.699872;
14
RPM = 1750
RadPS = 1750 /60 * 2*pi; %radians/second
%1 kg
um2/s3 - so watts/radps = torque
MaxTorque = W/RadPS;
T = MaxTorque * 8.8507457
%% Stage 1
T1 = T
DP1 = 12;
Teeth1 = 14;
FW1 = .75;
R1 = Teeth1/DP1/2;
F1 = T1/R1;
Fa1 = F1*tand(14.5);
%% Stage2
T2 = T1*6
DP2 = 8;
Teeth2 = 14;
FW2 = 1.25;
R2 = Teeth2/DP2/2;
F2 = T2/R2;
Fa2 = F2*tand(14.5);
%% Stage3
T3 = T2*5;
DP3 = 6;
Teeth3 = 12;
FW3 = 1.5;
R3 = Teeth3/DP3/2;
F3 = T3/R3;
Fa3 = F3*tand(14.5);
%% Output
Tout = T3*5
%% ForceSolver for Shaft 3

% origin is in the rear bearing
F31A = asin(.625/6);
F31 = [Fa3*cos(F31A) ; Fa3*sin(F31A); 0];
F31pos = [-5*cos(F31A) ; -5 * sin(F31A) ; (.1275 + 1.943)/2 ] ;
15
%F2 is perpendicular to F1, so invert sin and cos

F32 = [-F3*sin(F31A) ; F3*cos(F31A) ; 0];
F32pos = F31pos;
syms F3b1x F3b1y F3b2x F3b2y
F3b1 = [F3b1x ; F3b1y ; 0];
F3b2 = [F3b2x ; F3b2y ; 0];
F3b2pos = [0 ; 0 ;2.7675];
SumF3 = F31 + F32 + F3b1 + F3b2;

SumM3B1 = cross(F31pos, F31) + cross(F32pos, F32) + cross(F3b2pos , F3b1);
SumM3B1(3) = 0;
B3Forces = solve(SumF3(1) == 0, SumF3(2) == 0, SumM3B1(1) == 0, SumM3B1(2) == 0, F3b1x, F3b1y,
%% Force Solver for Shaft 2
%origin is far bearing
F21A = F31A;
F21 = [-Fa3 * cos(F21A) ; -Fa3 * sin(F21A) ; 0];
F21pos = [cos(F21A) ; sin(F21A) ; .0975 + .75];
F22A = asin(2.125/5.25);
F22 = [Fa2 * cos(F22A) ; -Fa2 * sin(F22A) ; 0];
F22pos = [-3.75 * cos(F22A) ; 3.75 * sin(F22A) ; 2.8475 - 1.25/2];
F23A = F31A; %perpendicular, just switch cos and sin
F23 = [F3*sin(F23A) ; -F3 *cos(F23A) ; 0];
F23pos = F21pos;
F24A = F22A %perpendicular see above
F24 = [-F2*sin(F24A) ; -F2 *cos(F24A) ; 0];
F24pos = F22pos;

F2b1 = [F2b1x ; F2b1y ; 0];
F2b2 = [F2b2x ; F2b2y ; 0];
F2b2pos = [0 ; 0 ;2.9875];
SumF2 = F21 + F22 + F23 + F24 + F2b1 + F2b2;

SumM2B1 = cross(F21pos, F21) + cross(F22pos, F22) + cross(F23pos, F23) + cross(F24pos, F24) + c
16
%% Force Solver for Shaft3

%origin is far bearing
F11A = F22A;
F11 = [-Fa2 * cos(F11A) ; Fa2 * sin(F11A) ; 0];
F11pos = [14/12/2 * cos(F11A) ;-14/12/2* sin(F11A) ; 1.5475 + 1.25/2];
F12A =atan(1.5/3.798);
F12 = [Fa1 * cos(F21A) ; Fa1 * sin(F21A) ; 0];
F12pos = [-4.5 * cos(F12A) ; -4.5 * sin(F12A) ; .975 + .75/2];
F13A = F11A; %perpendicular, just switch cos and sin
F13 = [F2*sin(F13A) ; F2 *cos(F13A) ; 0];
F13pos = F11pos;
F14A = F12A %perpendicular see above
F14 = [-F1*sin(F14A) ; F1 *cos(F14A) ; 0];
F14pos = F12pos;

F1b1 = [F1b1x ; F1b1y ; 0];
F1b2 = [F1b2x ; F1b2y ; 0];
F1b2pos = [0 ; 0 ;2.9875];
SumF1 = F11 + F12 + F13 + F14 + F1b1 + F1b2;

SumM1B1 = cross(F11pos, F11) + cross(F12pos, F12) + cross(F13pos, F13) + cross(F14pos, F14) + c
Result = [B1Forces.F1b1x , B1Forces.F1b1y, B1Forces.F1b2x, B1Forces.F1b2y;

B2Forces.F2b1x , B2Forces.F2b1y, B2Forces.F2b2x, B2Forces.F2b2y;
B3Forces.F3b1x , B3Forces.F3b1y, B3Forces.F3b2x, B3Forces.F3b2y;]
VPARES = vpa(Result,3)
17
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
CROC-920
TailMotor 59845K540
CROC-402
14T 12DP Spur Gear
CROC-404
SecondStagePinion
CROC-405
GEAR 8DP 60 TEETH
CROC-403
8DP 60 TOOTH SPUR GEAR
CROC-406
GEAR 6DP X 60 TEETH
CROC-407
GEAR 6 DP 12 TEETH
95584A211
3/8 TOOTH LOCK WASHER
91251A621
SHCS - 3/8-16 x .625
10
9712K82
BELVILLE WASHER 5/8 ID
11
CROC-409
Stage 1 Shaft
12
.625x.0775
Stage 1 Spacer
13
.75 x .035
Stage 1 Spacer
14
1x.065
Stage 1 Spacer
15
CROC-411
2nd Stage Shaft
16
9712K86
NONE
17
9712K94
BELVILLE WASHER 1" ID
18
CROC-412
Output Shaft
19
CROC-413
LargeGearboxSideAssembly
20
CROC-414
SmallSideAssembly
19
10
11
14
10
17
18
20
13
12
15
16
DO NOT SCALE OFF DRAWING
NOTES:
F
1.
2.
3.
SolidWorks Student Edition.

For Academic Use Only.
1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/14/2014
10/23/2014
ANGULAR: MACH () 0.5 BEND ()

CONCENTRICITY (TIR): 0.125
REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F. SCHENEIDER
MACHINED SURFACES (OR BETTER): 64
PROJECTION
DATE
APPROVED BY
"DESIGNED BY" DESIGNEE

PROPRIETARY AND CONFIDENTIAL
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
FOR OFFICIAL USE ONLY
DATE
P.TITCHENER
ALL DIM. ARE [IN] AND APPLY AFTER FINISH
DIMESNIONS APPLY AFTER FINISH

INSPECTION REPORT REQUIRED FOR ALL SPECIFIED DIMENSIONS.
REFERENCE SOLID GEOMETRY FOR ALL UNSPECIFIED DIMENSIONS. STANDARD
TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
ASSEMBLY
TailGearBox
FINISH
SIZE
FILENAME
PART #
NONE
CROC-400
CROC-400
1000 OLIN WAY, NEEDHAM, MA 02492

TITLE (PART NAME)
SCALE
1:8
SHEET
REV
10
1 OF 1
A-000
ITEM NO.
PART NUMBER
10
DESCRIPTION
QTY.
TailGearBoxHousingA
CROC-401
6383K244
5/8ID ROLLER BEARING 6383K244
6383K251
.75ID BALL BEARING 6383K251
6383K257
1"ID BALL BEARING
97395A485
DOWEL PIN .25 x .75
3
D
NOTES:
F
1.
2.
3.

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/23/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F. SCHENEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
ASSEMBLY
LargeGearboxSideAssembly
FINISH
SIZE
FILENAME
PART #
NONE
CROC-413
CROC-413

TITLE (PART NAME)
SCALE
1:4
SHEET
REV
10
1 OF 1
B
ITEM NO.
PART NUMBER
10
DESCRIPTION
QTY.
TailGearBoxTopPlate
CROC-408
6383K244
5/8ID ROLLER BEARING 6383K244
6383K251
.75ID BALL BEARING 6383K251
6384K373
1" SEALED BALL BEARING
2
C
1
3
D
NOTES:
F
1.
2.
3.

TOLERANCE 0.005


1

REMOVE ALL BURRS

AND BREAK ALL EDGES

DRAWN BY
DATE
APPROVED BY
DATE
10/23/2014
FIRST INITIAL DOT LAST NAME
PROJECTION
DATE
FIRST INITIAL DOT LAST NAME
STANDARD TOLERANCES
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
DESIGNED BY
P.TITCHENER
MATERIAL

TITLE (PART NAME)
ASSEMBLY
SmallSideAssembly
FINISH
SIZE
FILENAME
PART #
NONE
CROC-414
CROC-414
SCALE
1:8
SHEET
REV
10
1 OF 1
A
A
5.086
5.063
4.906
4.883
2.077
1.500
C
B
.000
C
10
MACHINE ACCORDING TO SOLID FILE AT:

P:\CROC\CROC-401
stANDARD PROFILE TOLERANCE
OF .010" APPLIES
3.500
6.000
6.500
2.707
3.632
4.132
7.994
7.494
5.967
10.768
12.489
14.566
16.643
17.816
17.316
2.077
.625
C
.003 A B C
3.288
3.772
.397 THRU ALL

.625
.375
.010 A B C
.003 A B C
.003 A B C
6X
RIGHT
+.000
.250 - .001
1.
2.
3.
.500
.005 A B C
ISO FOR REFERENCE ONLY
NOTES:
F
BACK
6X
.313
1.500
3/8-16 UNC
.750
.005 A B C
3.201
4X
3.274
12.489
12.202
12.075
16.643
4.998
5.493

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401

TITLE (PART NAME)
SCALE
1:3
SHEET
REV
10
2 OF 3
A
1.80
+.000
2.000 - .001
10
2.750
2.813
3.200
3.225
2.750
2.813
3.320
3.345
0
2.750
2.830
3.280
3.305
3.438
3.500
+.020
1.520 - .000
+.000
1.375 - .001
+.020
1.875 - .000
+.000
1.750 - .001
+.020
2.125 - .000
1.18
1.55
SECTION B-B
SCALE 1 : 3
SECTION A-A
SCALE 1 : 3
SECTION C-C
SCALE 1 : 3
NOTES:
F
1.
2.
3.

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401

TITLE (PART NAME)
SCALE
1:3
SHEET
REV
10
2 OF 3
A
10
0
.300
.430
14.566
6.875
4.500
SECTION D-D
SCALE 1 : 3
LEFT
NOTES:
F
1.
2.
3.

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401

TITLE (PART NAME)
SCALE
1:3
SHEET
REV
10
2 OF 3
A
10
MODIFY FROM RUSH GEARS A884 OR EQUIVALENT

84 TOOTH, 8 DP ,14.5 DEGREE
PRESSURE ANGLE SPUR GEAR
1.25
4.50 BCD
+.005
.750 - .000
4X
2.36
NOTES:
F
1.
2.
3.

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/20/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
4130 STEEL
GEAR 8 DP 60 TEETH
FINISH
SIZE
FILENAME
PART #
NONE
CROC-405
CROC-405

TITLE (PART NAME)
SCALE
1:2
SHEET
REV
10
1 OF 1
A
10
.625" HEX
1.250
.625
+.000
.625 - .003
.625
3.813
3.313
1.235
.582
NOTES:
F
1.
2.
3.

1
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014

REMOVE ALL BURRS

AND BREAK ALL EDGES
DATE
F.SCHENEIDER
PROJECTION
DATE
APPROVED BY

DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER

TOLERANCE 0.005
DESIGNED BY
10/23/2014
MATERIAL
AISI 4130 Steel, normalized at 870C
Stage 1 Shaft
FINISH
SIZE
FILENAME
PART #
NONE
CROC-409
CROC-409

TITLE (PART NAME)
SCALE
1:1
SHEET
REV
10
1 OF 1
A

Ptitchener Gearboxreport Full

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O LIN C OLLEGE OF E NGINEERING

Figure 0.1: Gearbox render

2 Brief System Overviews

3 Tail Gearbox Mechanical Design

3.1 Motor Selction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Housing Optimization . . . . . . .

7 Appendix I: Free Body Diagrams for Force Calculation

8 MatLab Bearing Reaction Force Solver

Figure 1.1: Example of Gearbox Simulation

2 B RIEF S YSTEM O VERVIEWS

Figure 2.1: Alligator Mouth

2.2 F RONT L EGS

Figure 2.2: Alligator Legs

2.3 R EAR L EG T RANSMISSION

Figure 2.3: Alligator Back Leg Transmission

Figure 2.4: Alligator Clock

3 TAIL G EARBOX M ECHANICAL D ESIGN

Figure 3.1: Example of a MiniBajaGearbox

Figure 3.2: One of the gearbox side plates.

3.1 M OTOR S ELCTION

Figure 3.3: Nema 56 Face mount motor, McMaster 59845K540

3.2 G EAR R ATIO S ELECTION

Figure 3.4: Gear Ratios

3.3 S HAFT D ESIGN

Figure 3.5: Shaft Design

Figure 3.6: Example Shaft

4.1 H OUSING O PTIMIZATION

4.2 G EAR P ITCH S ELECTION

(1/3 Tensi l eSt r eng t h) F aceW i d t h Lewi sF ac t or

4.2.1 F IRST S TAGE C ALCULATIONS

7 A PPENDIX I: F REE B ODY D IAGRAMS FOR F ORCE C ALCULATION

Figure 7.1: Free Body Diagram of Shaft 1.

Figure 7.2: Free Body Diagram of Shaft 2.

Figure 7.3: Free Body Diagram of Shaft 3.

8 M AT L AB B EARING R EACTION F ORCE S OLVER

%% ForceSolver for Shaft 3

%F2 is perpendicular to F1, so invert sin and cos

SumF3 = F31 + F32 + F3b1 + F3b2;

syms F2b1x F2b1y F2b2x F2b2y

SumF2 = F21 + F22 + F23 + F24 + F2b1 + F2b2;

%% Force Solver for Shaft3

syms F1b1x F1b1y F1b2x F1b2y

SumF1 = F11 + F12 + F13 + F14 + F1b1 + F1b2;

Result = [B1Forces.F1b1x , B1Forces.F1b1y, B1Forces.F1b2x, B1Forces.F1b2y;

14T 12DP Spur Gear

GEAR 8DP 60 TEETH

8DP 60 TOOTH SPUR GEAR

GEAR 6DP X 60 TEETH

3/8 TOOTH LOCK WASHER

SHCS - 3/8-16 x .625

BELVILLE WASHER 5/8 ID

2nd Stage Shaft

BELVILLE WASHER 1" ID

DO NOT SCALE OFF DRAWING

SolidWorks Student Edition.

ANGULAR: MACH () 0.5 BEND ()

REMOVE ALL BURRS

MACHINED SURFACES (OR BETTER): 64

"DESIGNED BY" DESIGNEE

FOR OFFICIAL USE ONLY

ALL DIM. ARE [IN] AND APPLY AFTER FINISH

DIMESNIONS APPLY AFTER FINISH

1000 OLIN WAY, NEEDHAM, MA 02492