Transmission

Copyright by IPEK Institute of Product Engineering.
All rights reserved. Unauthorised copying prohibited.

K.6.12.1.1.0.0.0.0_GLEA
General_Fundamentals_of_Transmissions_Introduction
6.12.1 General Fundamentals of Transmissions
6.12.1.1 Introduction
Definition:
A transmission is a mechanical setup that transmits
movements and forces, or it guides points of a body on
defined paths. It consists of connected components
(elements), whereby their mutual degrees of freedom are
determined by the nature of the link (joints). One element is
always the point of reference (stand) and the minimum
amount of elements and joints are 3 respectively.
6.12 Transmissions
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Guidance of a Point
Ident-Nr.
floating bearing locating bearing
point P
K.6.12.1.1.0.0.0.0_GLEA
Guidance of a Point
Ident-Nr.
P
e
3
e
2
e
1
e
1
= e
2
= e
3
K.6.12.1.1.0.0.0.0_GLEA
Transmission with varying velocity ratio
Ident-Nr.
slider crank mechanism
s
geneva motion

K.6.12.1.1.0.0.0.0_GLEA
Principle of a Petrol Engine
Ident-Nr. K.7.3 111_056E 990824
K.6.12.1.1.0.0.0.0_GLEA
example of a
slider crank mechanism
Principle of an in-line engine
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Windscreen Wiper Arrangement
windscreen
front end motor compartment
brake booster, particle filter,
liquid reservoir, strut support,
air conditioning plant,heater,
battery, main driving switch,
scuttle-dash
Source: Bosch
Setup in a vehicle
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Selsyn (self-synchronizing)
Wiper Arm Assembly
Ident-Nr.
serial arrangement
parallel arrangement
Quelle: Bosch
K.6.12.1.1.0.0.0.0_GLEA
Quelle: Bosch
Sectional View
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Different Projection
Ident-Nr.
Quelle: Bosch
K.6.12.1.1.0.0.0.0_GLEA
Quelle: Vogel Sitze
Future Perspectives in the Design Of Coach
Seats and Busses
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Patented Crash Element
Ident-Nr. K.6.7.5. 101_1066E 980712
Quelle: Vogel Sitze
adjustment
lever
adjustment mechanism
chair cushion
backrest
force of a
crash
sleeping position
upright position
pivot
new adjustment
lever
A
old
A
new
old adjustment lever
K.6.12.1.1.0.0.0.0_GLEA
Quelle: Vogel Sitze
Tension Tests ECO and Accent
Ident-Nr. K.6.7.5. 101_1067E 980712
K.6.12.1.1.0.0.0.0_GLEA
Transmission of Forces and Movements
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Ship transmission, 3 diesel, 35 000 kW
Ident-Nr.
K.6.12.1.1.0.0.0.0_GLEA
Ident-Nr.
P
E
, n
E
P
A
, n
A
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
6.12.1.2.1 Basic Functions
Transmissions (uniformly translating) transmit power and
rotation by conversion of
torque and speed
and/or
direction of rotation
and/or
rotational axis
6.12.1.2 Basic Functions and Principles
Ident-Nr.
M, n
conversion
substance
energy
information
substance
energy
information
D-Tip:
The transmission changes torque and speed of a power
machine motor) and adjusts both to the requirements
of the machine.
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Thereby always transforming n !
Transformation of M only, results in power losses!
( with n1 = n2; M2 = M1 - Pv / 1)
application:
For power transmissions adjustment of drives to the
working machine
i. e. adjustment of the characteristic curves / fields
Torque converter
Ident-Nr.
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Passenger Car with Drive Assembly
Ident-Nr. K.7.3 101_117E 980722
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Transmission Systems in the Powertrain of
Passenger Cars
Ident-Nr. K.6.12.1.3101_1829E 050404
ASG
CVT
Automat
HSG
EKM
DSG / PSG
Quelle: ZF-Sachs,
LuK, AutoMagazin24
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Source: J ohn Deere
Combustion engine
Common-Rail technology
Ident-Nr. K.7.6.3 101_1528 E 030710
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Combustion engine
Common-Rail technology
Ident-Nr. K.7.6.3 101_1529 E 030710
Source: J ohn Deere
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Trans-axle Drive of a Passenger Vehicle
Ident-Nr. K.6.12.7.8111_006E 990804
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Front-wheel Drive Passenger Vehicle
Ident-Nr. K.6.12.7.8111_004E 990804
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Vehicle powertrain
Ident-Nr.
MOTOR GEAR BOX FINAL DRIVE
S
T
A
R
T
-
U
P
E
L
E
M
E
N
T
c
o
m
b
u
s
t
i
o
n
e
n
g
i
n
e
d
r
y

c
l
u
t
c
h
p
r
i
m
a
r
y

t
r
a
n
s
m
i
s
s
i
o
n
m
a
i
n
t
r
a
n
s
m
s
s
i
o
n

m
e
c
h
a
n
i
c
a
l

r
e
v
e
r
s
i
n
g

t
r
a
n
s
m
i
s
s
i
o
n
d
i
s
t
i
b
u
t
o
r
t
r
a
n
s
m
i
s
s
i
o
n
a
x
l
e

d
r
i
v
e
w
i
t
h
d
i
f
f
e
r
e
n
t
i
a
l
M
M
(n
M
) i
A
i
S
i
E
i
G,V
i
G,H
i
G,N
i
E,V
i
E,A
i
G
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Example: Transmission shaft system
Ident-Nr. K.7.3 101_1757E 40709
View turned into the plane
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Example: Transmission shaft system
Ident-Nr. K.7.3 101_1758E 40709
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Characteristic diagrams of combustion
engines: torque
Ident-Nr.
0
50
100
150
200
2500 5000 0 7500
1/min
Nm
e
n
g
i
n
e

t
o
r
q
u
e
M
petrol driven engine speed n
0
50
100
150
200
2000 4000 0 6000
1/min
Nm
e
n
g
i
n
e

t
o
r
q
u
e
M
diesel driven engine speed n
250
300
20%
30%
40%
50%
60%
100%
10%
5%
accelerator pedal position
accelerator pedal position
20%
10%
30%
40%
50%
60%
70%
80%
90%
100%
a)
b)
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Characteristic diagram of a combustion engine:
fuel consumption
Ident-Nr.
5
10
20
40
60
80
100
110
M(P[kW])
e
n
g
i
n
e

t
o
r
q
u
e
M
100
50
0
150
200
500 1500 2500 3500 4500 5500 6500
1/min
Nm
engine speed n
500
450
400
350
325
300
275
250
2
1
b
e,min
b
e
=const
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Secondary Characteristic Fields of a
Combustion Engine without Transmission
Ident-Nr.
Quelle: Lehnen, Mannheimer
Force closure limit
tractive force F
Z,A
provided
by the combustion engine
velocity v
t
r
a
c
t
i
v
e

f
o
r
c
e
F
Z
with power train losses:
effective tractive force hyperbola
F
Z,Ae
=
ges
.
P
max
/ v
without power train losses:
ideal tractive force hyperbola
F
Z,Aid
= P
max
/ v
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Secondary Characteristic Fields of a
Combustion Engine with Transmission
Ident-Nr.
Quelle: Lehnen, Mannheimer
velocity v
t
r
a
c
t
i
v
e

f
o
r
c
e
F
Z
s
t
a
r
t
i
n
g

a
r
e
a
1.
2.
3.
4. gear
tractive force availability F
Z,A
in 2nd gear
curve of traveling resistance
tractive demand F
Z,A
at 0 % inclination
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
another application for transmissions is the speed
conversion
( e.g. camshaft drive 1:2; clockwork, sewing-machine, packaging-
machines, ..)
change of rotational direction
possible even without torque-conversion for co-axial shafts
(absolute value) (e.g. reverse gear unit of a ship)
Basic Functions
Ident-Nr.
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
conversion of n and M possible
(transmission of rotational movement onto non-coaxial shafts)
point of interception of shaft axial:
infinite (parallel shaft)
finite
non-existent (skewed position)
Change of rotational axis
Ident-Nr.
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Change of rotational axis
Ident-Nr.
Bevelled gear pair External gear pair Internal gear pair
Spur gears (cylinder gears)
Axes parallel
Axes intersect
Hypoid gear pair
(conical toothed gear wheel)
Skew gear pair Worm gear
Transverse axes
K.6.12.1.2.1.0.0.0_GLEA
Basic_Functions
Transfer case / Power divider
Ident-Nr.
rigid connectable
conical gear
differential
spur gear
differential
speed-
ratio
50% : 50%
speed-
ratio
0% : 100%
50% : 50%
torque-
ratio
50% : 50%
torque-
ratio
unequal, e.g.:
33% : 67%
K.6.12.1.2.2.2.0.0_GLEA
Working_Principles_Mechanical_Gears
6.12.1.2.2.2 Principles of Mechanical Gears
Transfer of motion through direct or indirect rolling or
screwing motion of wheel pairs which are coupled in
Working Surface Pairs
6.12.1.2.2 Principles
Ident-Nr.
contact can be a
force- or form closure
Functional contact
WSP
2
K.6.12.1.2.2.2.0.0_GLEA
indirect contact of wheel pairs
(by two Working Surface Pairs)
Belt and Chain Drives:
WSP-force closure (fric.): flat-, round- and v-belt (slip)
WSP-form closure: chain (roller, inverted tooth chain), toothed belt
Principles of Mechanical Gears
Ident-Nr.
1

2
WSP 1 WSP 2
K.6.12.1.2.2.2.0.0_GLEA
Belt Drives
picture 4/1- open
picture 4/2- crossed
picture 4/3- half crossed
picture 4/4- v-belt
Belt- and Chain Drives
Ident-Nr.
Chain Drives
picture 3/7- roller chain
picture 3/8- tooth chain
picture 3/7 picture 3/8
K.6.12.1.2.2.2.0.0_GLEA
WSP-
principles
design efficiency applicatio
dynamic
system
behaviour
force closure
friction drives,
belt drives
ca. 80-95%
per step
machinery manuf.
car industry
material handling
production tech.
with slip
form closure
toothed
transm.,
chain transm.
ca. 96-99%
per step
machinery manuf.
car industry
without slip
Ident-Nr.
K.6.12.1.2.2.3.0.0_GLEA
Working_Principles_Hydraulic_Transmissions
The linkage for the force and motion
transfer is a fluid (e.g. oil).
6.12.1.2.2.3 Principles of Hydraulic Transmissions
Ident-Nr.
LSS
Fluid
K.6.12.1.2.2.3.0.0_GLEA
Hydrostatic vane cell transmission. a- drive (pump), b- power take-off
(motor). Change of volume flow through adjustment of eccentricities e
a
(and e
b
).
Hydrostatic Transmission
Ident-Nr.
D-Tip:
pressure high
velocity low
Quelle: Nieman
K.6.12.1.2.2.3.0.0_GLEA
Hydrodynamic Transmission (Fttinger-
transmission)
Ident-Nr.
drive
pump
fluid
stator
turbine
take-off
Quelle: Lechner, Naunheimer
D-Tip:
pressure low
velocity high
K.6.12.1.2.2.3.0.0_GLEA
The link between force and motion transfer is a fluid (oil).
Evaluation:
+ i infinitely variable
+ high power density
- efficiency, costs
Principles of Hydrostatic Transmissions
Ident-Nr.
principles design efficiency application
dynamic system
behaviour
force closure
(impulse force)
hydrodynamic
transmission
70-90%
passenger
vehicle
Fttinger-
converter
with slip
form closure
(pressure force)
hydrostatic
transmission
(pump + motor)
70-90%
construction
machinery
drives,
snow cat
without slip
K.6.12.1.2.2.4.0.0_GLEA
Working_Principles_of_Electric_Transmissions
6.12.1.2.2.4 Working Principles of Electric
Transmissions
Ident-Nr.
K.6.12.1.3.0.0.0.0_GLEA
Characteristic_Features_And_Classifications
transmissions
6.12.1.3 Characteristic Features and Classification
Ident-Nr.
transmission with
nonuniform
conversion
transmission
with uniform
conversion
hydraulic
transm.
electrical
transm.
mechanical
transm.
mechanical
transm.
with inversion of
direction e.g.:
slider crank
with dwell time
e.g.: geneva
motion
hydrodynamic
transmission
hydrostatic
transmission
K.6.12.1.3.0.0.0.0_GLEA
Characteristic_Features_And_Classifications
Characteristic Features and Classification
Ident-Nr.
mechanical
transmissions
friction wheel
transmission
Belt and chain
drives
toothed gear
transmission
spur gear
transmission
helical gear transm.
bevel gear
transmission
planet gear system
belt drive
chain drive
wormgear set
K.6.12.1.4.0.0.0.0_GLEA
Types
Friction Wheel
Drive
6.12.1.4 Types
Ident-Nr.
K.6.12.1.4.0.0.0.0_GLEA
Types
Friction Wheel Drive
Ident-Nr.
K.6.12.1.4.0.0.0.0_GLEA
Types
Classification of Tooth Gear Mechanism
Ident-Nr.
3
spur
gears
spiral /
helical
gears
axes parallel
axes intersect
tranverse
axes
flank trace:
a) circle
b) spiral
c) involute
d) epicycloid
skew
gear
drives
worm
gear
drives
K.6.12.1.4.0.0.0.0_GLEA
Types
1- spur toothing
2- paired with an internal
geared wheel
3- paired with a toothed
rack
4- spiral or helical
gearing
5- double helical gearing
6- herringbone gearing
Cylinder gear wheels
Ident-Nr.
K.6.12.1.6.1.0.0.0_GLEA
Selection_of_Transmission_Type_Procedure
The selection of a transmission type depends on the boundary
conditions of the field of application. There is however no
general methodology.
Important criteria are:
transferred power and torque
slip
available lubrication
construction space
power density
transmission precision
variable or constant transmission ratio
The most common transmissions in mechanical engineering are
gear drives!
6.12.1.6 Selection
Ident-Nr.
6.12.1.6.1 Procedure
K.6.12.1.6.2.0.0.0_GLEA
Selection_of_Transmission_Type_Selection_Criteria
Quelle: Maschinenelemente Band III Niemann; Winter
6.12.1.6.2 Selection criteria
Ident-Nr.
K.6.12.1.6.2.0.0.0_GLEA
Transmission type
Transmission type
in kW
Transmission
normal
(norm/series)
extreme
normal
(norm/series)
extreme
cylinder gears (=spur and bevelled
g.)
3000 65000 1800
a.b.
1000
planetary gear transmission 2000 35000 313
d
335
e
A
n
g
u
l
a
r

g
e
a
r
d
r
i
v
e
bevel gears
G
e
a
r
d
r
i
v
e
s
500 4000 15
a
8
a
Hypoidgears 300 500
h
15
a
150
a
1000
j
cylinder and bevel gears 500 3000 5700
k
800
b
Worm gear 120 1000 550
l
1300
l
Worm and cylinder
gears
100
p
250
p
(40280
b
) >1000
b
cylinder and skewgears 8 80 15 100
Chain transmission 200 4000 16 10
Flat belt transmission
B
e
l
t

d
r
i
v
e
s
150 3600 15 20
V-belt transmisssion 100 4000 18 15
Synchronous belt transm. 100 400 s 18 12
Friction wheel drive (25)/10
r
200 16 (10)/18
Ident-Nr.
K.6.12.1.6.2.0.0.0_GLEA
Transmission type
Max. circumferential
speed in m/s
Max. rotations min
-1
Overall
effiency
in %
q
normal
f
extreme
g
from to
cylinder gears (=spur and
bevelled g.)
50 210 150000 93
e
99
e
planetary gear transmission 50 100 100000 98 99
A
n
g
u
l
a
r

g
e
a
r
d
r
i
v
e
s
bevel gears
G
e
a
r
d
r
i
v
e
s
130 50000 97 98
Hypoidgears 40 50 20000 50
h
90
h
30 85
j
96
j
cylinder and
bevel gears
----- see spur and bevel gears
Worm gear 25 70 40000 5096
m
2097
Worm and
cylinder gears
----- see worm and cylinder gears
cylinder and
skewgears
20 50 20000 50 95
Chain transmission 10 40 10000 97 98
B
e
l
t

D
r
i
v
e
s 60 120 200000 96 98
V-belt transmisssion 25 40 8000 92 94
Synchronous belt
transm.
40
t
70
t
30000 96 98
Friction wheel drive 25 50 10000 90 98
Ident-Nr.
K.6.12.1.6.2.0.0.0_GLEA
Transmission type
Volume
Power
Mass
Power
dm3/kW kg/kW
cylinder gears (=spur and bevelled
g.)
0,60,2 1,80,4
planetary gear transmission 0,40,15 1,00,2
A
n
g
u
l
a
r

g
e
a
r
bevel gears
G
e
a
r
d
r
i
v
e
s
0,70,4 2,50,6
Hypoidgears 0,80,5 3,00,7
cylinder and bevel gears 0,70,3 2,00,3
Worm gear 0,50,2 4,50,2
Worm and cylinder gears 0,60,3 104,0
cylinder and skewgears 2,51,0 3,01,5
Chain transmission 2,00,3 106
B
e
l
t

d
r
i
v
e
s
4,00,3 6,01,5
V-belt transmisssion 3,00,4 5,01,0
Synchronous belt transm. 1,00,25 4,01,0
Friction wheel drive 203,0 308,0
Ident-Nr.
K.6.12.1.6.2.0.0.0_GLEA
a: single stage
b: dependent on the number of stages
c: normal, oil lubrication 98...99%; large slow revolving wheels
d: simple planet gear, single stage
e: planet gear with double planet, single stage
f: machine construction
g: turbines, aeroplanes
h: for large translation ratios
j: for small translation ratios
k: with 3 spur gear stages
l: slower, faster: 515
m: falling with increasing transmission
n: also compare pictures 20/12...14
o: 18000, radio telescope i=2,2*106
p: usually as geared motor ( no air cooling )
q: per stage;at full load; at partial load in part substantially less
r: combination steel-steel / steel-soft material
s: belt width limited
t: normal v-belt ( narrow v-belt + 20%)
Selection criteria
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
6.12.1.7 Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
1- straight bevel gears
2- helical bevel gears
3- spiral bevel gears
4- hypoid bevel gears
Bevel Gears
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
bevel, spur and helical gears, i = 1400:1
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Axle drive of a tractor:
spiral bevel gears and helical gears
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Example of a slider
crank mechanism
Principle of an in-line engine
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Hypoid Bevel Gears
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Skew gears and worm gears
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Worm Gears
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
(as per DIN 868)
a- sun gear
b- planet gear
c- revolving arm / planet
carrier
d- ring gear
e- casing
Planetary transmission / planetary gear train /
epicyclic gear system
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Planetary transmission
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Bevel gears and planetary transmission
Ident-Nr.
1 planets
2 sun gears
1
power take-off power take-off
2
3
3 planet carrier
K.6.12.1.7.0.0.0.0_GLEA
Applications
Transmissions Differential Gear
Ident-Nr. K.7.4 111_013E 990809
K.6.12.1.7.0.0.0.0_GLEA
Applications
Ident-Nr.
Chain Drives
picture 3/7- roller chain
picture 3/8- inverted tooth chain
Belt Drives
picture 4/1- open-belt
picture 4/2- crossed-belt
picture 4/3- half crossed-belt
picture 4/4- v-belt
picture 4/1
picture 4/2
picture 3/8
picture 3/7
K.6.12.1.7.0.0.0.0_GLEA
Applications
Synchronous Belt Drive
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Synchronous Belt Drive
Ident-Nr.
fibre glass tension ply
neoprene back
neoprene
tooth
nylon coating
K.6.12.1.7.0.0.0.0_GLEA
Applications
Toothed Belt Camshaft Drive
Ident-Nr. K.6.12.4.7111_065E 990824
K.6.12.1.7.0.0.0.0_GLEA
Applications
The Toothed Belt
Ident-Nr. K.6.12.4.7111_064E 990824
K.6.12.1.7.0.0.0.0_GLEA
Applications
The V-belt
Ident-Nr. K.6.12.4111_045E 990824
K.6.12.1.7.0.0.0.0_GLEA
Applications
The Petrol Engine
Ident-Nr. K.7.3 111_068E 990824
K.6.12.1.7.0.0.0.0_GLEA
Applications
V-belt drive
Ident-Nr.
K.6.12.1.7.0.0.0.0_GLEA
Applications
Torque Converter Clutch
Ident-Nr.
Combined converter-clutch with six
gears in block assembly
Quelle: ZF
K.6.12.2.1.1.0.0.0_GLEA
General_Fundamentals_of_Tooth_Gear_Mechanisms
6.12.2.1 General Fundamentals on Tooth Gear Mechanisms
6.12.2.1.1 Introduction
Economical significance:
car gear boxes: 10 bill. 8% of sales in machinery manufacturing
gear wheels + stat. transmissions 5 bill.
6.12.2 Toothed Gear Mechanisms
Ident-Nr.
vehicle design
car gear box
differential gear
steering device
overhead camshaft
marine reversing gear
precision mechanics/microsystems technology
householdappliances
measuring instruments
sensors
industry
stationary transmissions for materials-handling
rolling mills turbines
machine tools
Applications
K.6.12.2.1.2.1.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Basic_Functions_and_Principles
6.12.2.1.2.1 Basic Functions
Operating principle:
Tooth gear mechanisms convert
torque and speed by accordingly
shaped working surface pairs which
are connected to bearings with
support structures!
6.12.2.1.2 Basic Functions and Principles
Ident-Nr.
1
driving
driven
2
O
2
O
1
C
r
2
r
1
E
K.6.12.2.1.2.2.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Basic_Functions_and_Principles_Working
Principles
Principle:
Tooth gear mechanisms use form closure for force transmission
between the coupled support structures!
The working surfaces are shaped in such a way that the
transmission ratio the ratio of the input (torque, speed) to the
output is constant!
6.12.2.1.2.2 Principles Rule of the Common
Normal
Ident-Nr.
K.6.12.2.1.2.2.0.0_GLEA
Principles
Thus the following applies:
d
v1
2

1
=
d
v2
2

2
and a =
d
v1
+d
v2
2
transmission ratio (velocity ratio): i =
m
1
m
2
=
d
v2
d
v1
Rule of the Common Normal
Ident-Nr.
driving
driven
C pitch point
center distance
pitch circle diameter
d
w1
d
w2
a
1
O
1
O
2
O
1
, O
2
: center points
O
1
power source
O
2
power take-off
K.6.12.2.1.2.2.0.0_GLEA
Principles
2
= const. , if
The profile of a tooth must have such a geometry, that
this condition is fulfilled in any point of contact!
Theoretically, any curve can be used for a tooth profile,
since according to the Rule of the common normal, an
appropriate mating flank can always be found!
Rule of the Common Normal:
(basic law of conjugate gear-tooth action)
Ident-Nr.
Rule of the common normal:
The common normal on the tooth profiles at the current point of
contact E must pass through the pitch point C.
K.6.12.2.1.2.2.0.0_GLEA
Principles
Derivation of the Rule of the common normal
Ident-Nr.
provided that the normal
at the current point
of contact passes through
pitch point C during the
whole meshing!
driving
driven
N
2
r
b2
r
w2
r
w1
r
b1 r
1
r
2
C
O
2
O
1
t N
1
E
t
2
t...t: tangent of profile in E
N
1
..N
2
: normal on profile in
From the similarity of the
triangles 0
2
N
2
C and 0
1
N
1
C
it follows:
r
b2
r
b1
=
0
2
C
0
1
C
=

1
2
= const.
K.6.12.2.1.2.2.0.0_GLEA
Principles
1. Two pitch circles and pitch point C
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
K.6.12.2.1.2.2.0.0_GLEA
Principles
2. Point of contact at time t1 = E (point of contact)
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
K.6.12.2.1.2.2.0.0_GLEA
Principles
3.Tooth profile 1 assumed straight: tooth profile 1
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
K.6.12.2.1.2.2.0.0_GLEA
Principles
4. Tooth profile 2 assumed: red
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
K.6.12.2.1.2.2.0.0_GLEA
Principles
5. Normal drawn in the point of contact
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
N
tooth profile 1
tooth profile 2
K.6.12.2.1.2.2.0.0_GLEA
Principles
6. Tangent in the point of contact: T - T
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
T
T
K.6.12.2.1.2.2.0.0_GLEA
Principles
7. Radii from O1 and O2 to the point of contact E
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
r
1E
r
2E
T
T
K.6.12.2.1.2.2.0.0_GLEA
Principles
8. Current circumferential speeds of E1 and E2 (=
absolute speeds) around O1 and O2
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
r
1E
r
2E
v
2
= i
2E

2
v
1
= i
1E

1
T
T
K.6.12.2.1.2.2.0.0_GLEA
Principles
9. Decomposition into tangential and normal
velocity components
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
r
1E
r
2E
v
2
= i
2E

2
v
1
= i
1E

1
T
T
v
n2
v
n1
v
t1
v
t2
Contradiction: v
n2
< v
n1
i.e. tooth profile 1 would
penetrate tooth profile 2
K.6.12.2.1.2.2.0.0_GLEA
Principles
Normal N on tooth
profile 1 shall pass
through C, this
yields point on
tooth profile 2, new
point of contact E
10. New attempt
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
T
T
N
K.6.12.2.1.2.2.0.0_GLEA
Principles
11. Radii r1E and r2E to E
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
T
T
r
1E
r
2E
K.6.12.2.1.2.2.0.0_GLEA
Principles
12. Circumferential speeds: (
1
,
2
as before
because of the same ratio of pitch circles)
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
T
T
r
1E
r
2E
v
2
= i
2E

2
v
1
= i
1E

1
v
2
= i
2E

2
v
1
= i
1E

1
K.6.12.2.1.2.2.0.0_GLEA
Principles
Now:
v
1n
= v
2n
! no penetration
v
t1
v
t2
i.e. nevertheless
slipping on the teeth
velocity components
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
point of contact E
tooth profile 1
tooth profile 2
N
T
T
r
1E
r
2E
v
2
= i
2E

2
v
1
= i
1E

1
v
t2
v
t1
v
n2
v
n1
K.6.12.2.1.2.2.0.0_GLEA
Principles
now:
v
n1
= v
n2
, i. e. no penetration of tooth profiles
however, still (as in general)
v
t1
v
t2
, i. e. slipping on tooth profiles!
Condition for E:
The following applies to any point of contact:
v
1n
= v
2n
= v
n
(no penetration of tooth profiles)
This velocity in normal direction can be interpreted as
peripheral speed about the centers of rotation O
1
and
O
2
, whereas the radii r
n1
and r
n2
are the normal lines to
the normal on the WFP in the point of contact!
velocity components
Ident-Nr.
K.6.12.2.1.2.2.0.0_GLEA
Principles
v
n
= i
1n

1
= i
2n

2
m
1
m
2
=
r
2n
r
1n
= i = const. as a uemanu!
r
2n
r
1n
=
r
2
r
1
= i = const. as iequesteu!
The similarity of the blue triangles yields
r
2n
r
1n
=
r
2
r
1
i. e. i = const.
Rule of the common normal
Ident-Nr.
orange - triangles are similar
i. e. here the following applies:
This is not valid for the old geometry, since the normal
does not pass through C.
K.6.12.2.1.2.2.0.0_GLEA
Principles
Rule of the common normal
Ident-Nr.
O
1
O
2
2
pitch circle 1
driving
pitch point C
pitch circle 2
driven
tooth profile 1
N
T
T
v
2
= i
2E

2
v
1
= i
1E

1
N
N
N
r
2E
r
1n
r
2n
r
1E
E
K.6.12.2.1.2.2.0.0_GLEA
Principles
In general, sliding occurs on the tooth profiles, i. e. tangential
relative velocities on the tooth profile.
friction, heating, dissipation and wear, seizure
Pure rolling only at pitch point C
Observation:
Ident-Nr.
K.6.12.2.1.2.2.0.0_GLEA
Principles
LoA is the geometrical
location of all points of
contact (poc) during
meshing (= absolute path
of E; the tooth profiles are
the relative paths of E)
Definition: Line of action LoA
Ident-Nr.
Example:
Curved line of action
with permanently
changing pressure angle!
O
2
d
w2
C
B
A
d
w1
O
2
wB
wB
K.6.12.2.1.2.2.0.0_GLEA
Principles
is the angle between the
normal in the poc and the
tangent to the working circles
in the pitch point C.
(and therefore also between
the tangent in the poc and
distance 0
1
0
2
)
If a special shape for the
tooth profile is chosen:
Line of action becomes a
straight line with constant
pressure angle
w
!
Definition: Pressure angle
Ident-Nr.
O
2
d
w2
C
d
w1
O
2
w
F
N2
K.6.12.2.1.2.2.0.0_GLEA
Principles
A
2
Given: 2 pitch circles
and tooth profile 1
1. Choose point A
1
on
tooth
profile 1, normal line to
tooth profile 1 through
A
1
intersection point
with PC1 1
2. Strike circle of radius
A
1
1 about C A
1
3. Lay off the arc 1C
on PC2 2
4. Strike circle of radius
A
1
1 about 2 A
2
Construction of line of action and mating flank
Ident-Nr.
driving
O
1
PC1
PC2
driven
O
2
1
A
1
2
C
K.6.12.2.1.2.2.0.0_GLEA
Principles
Condition:
in the point of contact, rule of
the commoon normal fulfilled
(NN through C)
hence: v
n1
= v
n2
Result: v
t2
v
t1
, i.e.
sliding on tooth profiles
Rolling and sliding on the tooth profile - Summary
Ident-Nr.
driving
WK 1
WK 2 O
2
O
1
E
N
N
C
u
1
v
n2
v
n1
v
t1
v
t2
Given: 2 pitch circles
2 tooth profiles
K.6.12.2.1.2.2.0.0_GLEA
Principles
In general, sliding occurs on the tooth profiles, i. e. tangential
relative velocities on the tooth profile.
friction, heating, dissipation and wear, seizure
Pure rolling only at pitch point C
Observation:
Ident-Nr.
K.6.12.2.1.3.0.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Characteristic_Features_and_Classificatio
gear ratio: i =
o
1
o
2
=
uiiving
uiiven
diameter of pitch circle: d
w
pitch point: C
6.12.2.1.3 Characteristic Features and Classification
Ident-Nr.
a
O
1
O
2
C pitch point
driven
driving
d
w1
d
w2
2
O
1
- axis wheel 1
O
2
- axis wheel 2
Consider sense of rotation! For
external gear pair, i is negative!
| i | > 1 transmission into low
| i | < 1 transmission into high
K.6.12.2.1.3.0.0.0_GLEA
Fixed-axis gear transmission:
A fixed-axis gear transmission (or gear train) is a single- or
multiple-stage transmission where all wheel axles are run
unchangeable in position, and rotatable.
Definitions for tooth gear mechanisms (DIN 868)
Ident-Nr.
Single-stage
transmission:
A single-stage transmission
contains a gear pair,
consisting of gear and
mating gear in a
housing(frame) with
bearings for both shafts.
K.6.12.2.1.3.0.0.0_GLEA
A multiple-stage (two-stage, three-stage etc.) gear train contains several
(two, three, etc.) gear pairs, arranged in series in in one housing.
The five-stage fixed-axis gear transmission is connected to the output shaft
of the plate belt of a twin shaft hammer crusher. It is driven by a hydraulic
motor.
Multiple-stage transmission
Ident-Nr.
K.6.12.2.1.3.0.0.0_GLEA
A planetary gear train or epicyclic gear system is a transmission
with at least three gearwheels, arranged in series connection in
effective direction, where the wheel axles of two wheels are aligned
coaxially. The third wheel is run as an intermediate wheel (planet
wheel) in a support (planet carrier), which is rotatable about the
coaxial wheel axles, and
circulates together with the support.
Planetary gear system (from DIN 868)
a- sun gear
b- planet gear
c- revolving arm / planet carrier
d- ring gear
e- casing
Ident-Nr.
K.6.12.2.1.3.0.0.0_GLEA
toothed gear mechanisms
Classification of toothed gear mechanisms
Ident-Nr.
planetary
gear
spur/helical
gear
skew gear bevel gear
worm gear
K.6.12.2.1.3.0.0.0_GLEA
s: tooth thickness
e: tooth space
p: pitch
d
a
: addendum circle/tip
diameter
d: pitch circle
d
f
: dedendum circle
/root diameter
h
f
: dedendum
h: depth of tooth
h
a
: addendum
b: width of tooth
face
Terms for toothed wheels
addendum flank
dedendum flank
gearing
right flank
left flank
d
a
d
d
f
Ident-Nr.
K.6.12.2.1.3.0.0.0_GLEA
pitch circle diameter: u = m z
modulus (scaling quantity): m =
p
addendum circle diameter: u

a
= u +2 h
a
addendum: h
a
normal: h
a
= m
pitch: p =
d
z
= m
Parameters Associated with Cylindrical Gears
Ident-Nr.
Values specified in DIN 780
m = ...1,...1,25...1,5...
Preferred numbers!
K.6.12.2.1.3.0.0.0_GLEA
dedendum circle diameter: u
I
= u -2 h
I
dedendum: h
I
normal: h
I
= 1,1 -1,S m
tooth thickness on the reference circle: s
spacewidth on the reference circle: e
Parameters Associated with Cylindrical Gears
Ident-Nr.
K.6.12.2.1.3.0.0.0_GLEA
Quelle: Dub1
Parameters Associated with a Cylindrical Gear Pair
Ident-Nr.K.6.12.2.2 101_228 E 000407
a
r
1
r
a1
h
f1
h
a1
h
1
h
a2
h
f2
O
2
c
1
c
2
O
1
K.6.12.2.1.3.0.0.0_GLEA
center distance: a =
d
1
+d
2
2
a =
1
2
u
1
+u
2
=
m
2
(z
1
+z
2
)
depth of tooth: h = h
a
+h
I
working depth of tooth: h
w
= h
a
1
+h
a
2
tip clearance: c
c
1
= h
2
-h
w
c
2
= h
1
-h
w
Parameters Associated with a Cylindrical Gear Pair
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Types_and_Properties
6.12.2.1.4 Types and Properties
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
toothed gear
mechanisms
Builds of transmissions
Ident-Nr.
planetary
gear
Spur/helical
gear
Skewgear Bevel gear
Worm gear
K.6.12.2.1.4.0.0.0_GLEA
Quelle: Haberhauer-Maschinenelemente
Builds of transmissions
Ident-Nr.101_1477D030623
axes parallel
axes intersect
Tranverse axes
K.6.12.2.1.4.0.0.0_GLEA
Passenger Car Manual Transmission
Ident-Nr.104_1409D030709
Quelle: INA
K.6.12.2.1.4.0.0.0_GLEA
6.12.2.2.4.2 Tooth Traces of Cylindrical Gears
6.12.2.2 Cylindrical Gear Mechanisms
6.12.2.2.4 Designs
Ident-Nr.
a) b) c) d) e)
Arrangement of teeth for cylindrical gears
a) spur gear, b) cluster gear,
c) helical gear, d) herringbone gearing (double helical gear),
e) circarc gear (round-flank toothing)
K.6.12.2.1.4.0.0.0_GLEA
6.12.2.3.1.4 Types and Properties
6.12.2.3.1.4.1 Tooth ProfilesTraces of Bevel Gears
6.12.2.3 Bevel Gear Mechanisms
Ident-Nr.
Tooth shapes for bevel gears (on the unrolled cylinder generated surface)
a-straight bevel gear, b- helical bevel gear, c-spiral gear,
d-palloid gear (involute tooth trace), e-circarc gear (round-flank toothing)
Quelle: Maschinenelemente, Decker
K.6.12.2.1.4.0.0.0_GLEA
spur gearing
Examples for tooth traces
Ident-Nr.
cyclo-palloid-
spiral gearing
K.6.12.2.1.4.0.0.0_GLEA
d
ae
external tip diameter
d
e
external reference diameter
d
fe
external root diameter
d
m
mean reference diameter
d
ai
internal root diameter
b face width
z tooth number
t
b
locating distance
t
H
auxiliary plane distance
t
E
tip diameter distance
alternative names:
external outside
internal inside
Straight Toothed Bevel Gears
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
6.12.2.4.1.4.2 Types of Worm Gears
a - cylindrical worm gear (cylinder worm globoid worm wheel)
b - contrate worm gear (enveloping worm and spur gear),
c and d double enveloping worm gear pair (enveloping worm
globoid worm wheel)
6.12.2.4 Worm Gear Mechanisms
Ident-Nr.
Quelle: Habenhauer, Bodenstein
K.6.12.2.1.4.0.0.0_GLEA
Design requirements:
manufacturing precision surface
mating material (hardened, ground,
wormagainst phosphor- or Al- multi-alloy bronze)
rigid bearing arrangement and accurate assembly
best lubrication (hypoid oil)
sufficient heat dissipation
Worm gear pair
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
Cylindrical Worm Gear
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
6.12.2.4.1.7 Applications
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
gear ratio: u =
z
2
z
1
z
1
: tooth number of worm
z
2
: tooth number of worm gear
common tooth numbers of the worm for
different transmission ratios:
6.12.2.4.1.4.3 Dimensions of the Cylindrical Worm
Ident-Nr.
i= 510 1015 1530 >30
z
1
4 3 2 1
K.6.12.2.1.4.0.0.0_GLEA
6.12.2.5.1.4.2 Planetary Gears
Ident-Nr.
Planetary Gear
sun gear
planetary gear
ring gear
planet carrier / revolving arm
K.6.12.2.1.4.0.0.0_GLEA
Planetary gear transmissions
Ident-Nr.
K.6.12.2.1.4.0.0.0_GLEA
Example: drive: sun gear and ring gear (speed is given)
output: planet carrier (speed is sought)
Determination of gear ratio by
means of Kutzbachs plan
Ident-Nr.
all radii in the Kutzbach plan are operating pitch circle radii
sun gear
planet
wheel
ring gear
radius r
circumferential speed
v = i
planet carrier
sun gear
ring gear
r
H
r
St
r
S
v
H
v
St
v
S
sought: i
S-St
=
n
5
n
5t
v
St
=
v
5
+v
H
2
n
St
=
r
5
n
5
+r
H
n
H
2r
5t
i
St

St
=
i
S

S
+ i
H

H
2
i
S-St
=
2 r
St
n
S
i
S
n
S
+ i
H
n
H
(where = 2f = 2n 6u
[n]=rpm)
planet wheel
K.6.12.2.1.4.0.0.0_GLEA
Transmission ratios for Planetary Gear Trains
Ident-Nr.101_178D000408
1. ring gear fixed, driving
sun wheel large
transmission into low.
2. sun gear fixed, driving
ring gear small
transmission into low
3. planet carrier fixed,
driving sun gear reverse
of sense of rotation with
transmission into low
K.6.12.2.1.4.0.0.0_GLEA
A disc driven by an eccentric disc rolls off a ring performing
double-circle shaped movements, i.e.
it performs cycloidal movements.
In order to avoid sliding during the roll-off, the system must
use form closure.
Principle of a cyclo transmission
Ident-Nr.
system principle
ring
disc
eccentric
drive shaft
K.6.12.2.1.4.0.0.0_GLEA
Cyclo transmissions have
two cycloid discs with an offset of 180 :
in order to achieve compensation of moments of inertia
in order to double the number of pins carrying the load
Section drawing of cyclo transmission
Ident-Nr.
section drawing
rollers
cycloid disc
eccentric cam
drive shaft
drive pin
output shaft
K.6.12.2.1.4.0.0.0_GLEA
Quelle: HD
Principle of a Harmonic Drive Transmission
Ident-Nr.103_127D990202
K.6.12.2.1.5.1.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Design_Indications_and_Interface_Requirements
Gear design is an extremely complex process!
The boundary conditions of utilization and production have
considerable influence!
The objective is always to define the appropriate shape
and properties for the working surface pairs according to
the criteria usefulness (function) and expenses (costs)!
6.12.2.1.5 Design Indications and Interface
Requirements
Ident-Nr.
6.12.2.1.5.1 Introduction
K.6.12.2.1.5.2.0.0_GLEA
Cycloid_as_Tooth_Profile
Cycloids
A cycloid is the path traced out by a point on the
circumference
of a circle that rolls without slipping along a straight line!
Cylinder on plane Cycloid
6.12.2.1.5.2 Cycloid as Tooth Profile
Ident-Nr.
base circle r ->
K.6.12.2.1.5.2.0.0_GLEA
Cylinder on cylinder Epicycloid
Cylinder in cylinder Hypocycloid
Cycloids
Ident-Nr.
here:
vertex on circle around
O with radius r
b
+ 2r
r
r
b
base circle
base circle
r
b
K.6.12.2.1.5.2.0.0_GLEA
Cycloidal gearing
Ident-Nr.
K
1
k
1
E
1
a
C
a
r
l
K
2
driving
wheel 2
wheel 1
driven
r
r1
r
r2
k
2
E
2
r
l
F
1
F
2
K.6.12.2.1.5.2.0.0_GLEA
+ few teeth necessary
+ favorable conditions for meshing and wear
- low contact pressure
- sensitive regarding center distance (variation of speed)
- difficult and expensive fabrication (own hob cutter for every
^ no. of teeth)
- Line of action - no straight line, thus: changing torque
^(vibrations)
Evaluation of cycloidal gearing
Ident-Nr.
Application: hardly used any more,
only for
- clocks
- rotary piston blowers
- pin wheel gearing
K.6.12.2.1.5.2.1.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Design_Indications_and_Interface_Requir
ements Tooth Profiles Intro
6.12.2.1.5.2.1 Introduction
Demands on gearings
accurate and easily producible
favorable tooth geometry regarding strength
pressing and sliding on tooth profile as low as possible
favorable dynamical behaviour (during meshing)
Common tooth characteristics in mechanical engineering
involute toothing
cycloidal gearing
6.12.2.1.5.2 Tooth Profiles
Ident-Nr.
K.6.12.2.1.5.2.3.0_GLEA
Observation of the tooth force:
The following applies:
N
1
= i
i
F
n
i
= i
ii
F
n
ii
= const.
P = F
n
i
i
i

1
= F
n
ii
i
ii

1
if: i
i
= i
ii
, thus
F
n
i
= F
n
ii
v
n
i
= v
n
ii
6.12.2.1.5.2.3 Involute Tooth Profile
Ident-Nr.
v
n
i
v
n
ii
Better: Choose the tooth profile so
that the common normal always has
a constant distance to the centers!
.
i
i
i
ii
0
1
1
uiiving
C
F
n
i
F
n
ii
E
i
E
ii

i
K.6.12.2.1.5.2.3.0_GLEA
unwrapping a string
from a cylinder:
N = i
b
F
n
= const!
Therefore:
normal force on tooth F
n
= const. (no friction)
normal velocity of tooth v
n
= const.
The resulting curve is an involute!
Theoretical model:
Ident-Nr.
Fulfills the condition that
the normal always has
const. distance to center!
Involute!
F
n
F
n
F
n
F
n
F
n
F
n
r
b
K.6.12.2.1.5.2.3.0_GLEA
wheel 1
Involute toothing during meshing
Ident-Nr.
wheel 2 driven
driving
A
F
1
F
2
C
A
2
a
a
l
r
A
1
l
r
a
1
E
K.6.12.2.1.5.2.3.0_GLEA
Rolling body, e.g. ruler
Involute toothing (involute to a circle)
Ident-Nr.
Predominant flank form in technology
3
I
1
2
3
4
0
4
IV
4
III
4
I
2
II
3
II
4
II
3
III
2
I
1
I
n
2
r
b
p
e
p
e
p
e
p
e
N
2
N
1
v
base circle
r
b
=r
p
b

K.6.12.2.1.5.2.3.0_GLEA
normal base pitch:
p
c
=
2r
b
z
Formation of toothed wheel (using a toothed rack)
Ident-Nr.
tooth number: z
base circle diameter: r
b
F - foot = center of curvature in point P
- radius of curvature in point P (changing!)
parts of involute yield tooth profile
addendumcircle
involute
A
1
F
A
2
A
3
A
4
P
K.6.12.2.1.5.2.3.0_GLEA
Evaluation
easy fabrication by tools with straight flanks and one tool
for all tooth numbers
constant pressure angle
the line of action is a straight line
insensitive to variations of center distance
all toothed wheels with the same pitch can be paired
independent of tooth number
risk of cutter interference for small tooth numbers
(weakening of base of gear tooth)
tooth profiles of external gears are convex, therefore high
tooth flank pressure (durability)
Involute toothing
Ident-Nr.
+
+
+
+
+
-
-
K.6.12.2.1.5.2.3.0_GLEA
toothed rack profiles with

straight flanks arise
Involute toothing
Ident-Nr.
D-Tipp:
Involute is uniquely defined by selection of base circle r
b
.
Tooth formation results from additional specification of
pitch, addendum and dedendumcircle
string under limiting angle u
r
b
O
1
r
b

P
e
p
e string length
string
K.6.12.2.1.5.2.3.0_GLEA
basic rack tooth profile acc. DIN 867
Index P: Basic profile. It applies: profile datum line profile center line
Standard tooth sytem
Ident-Nr.
m
c
mating profile
(profile) datumline
lower end of
usable flank
flank angle
p
e
u
p
= 20 u
p
= 20
h
h
f
h
a
m
c
p = m
s
p
= p/2 e
p
= p/2
K.6.12.2.1.5.2.4.0_GLEA
gear pair with
involute flanks
6.12.2.1.5.2.4 Involute Tooth Meshing
Ident-Nr.
common tangent
to base circles
line of action
flank 1
flank 2
base circle 1
base circle 2
2
driving
driven
C
E
O
1
O
2
r
b2
r
w2
r
w1
r
b1
r
b1
K.6.12.2.1.5.2.4.0_GLEA
For involute gear pairs the line of action is always tangent to the base
circles.
The line of action is a straight line.
It is inclined by the pressure angle to the line tangent to the rolling
circles (which passes through pitch point C)
Influence of center distance variations
Involute Tooth Meshing
Ident-Nr.
A variation of center
distance merely changes
the pressure angle
Transmission ratio is
constant, since:
i =
i
w2
i
w1
=
i
b2
i
b1
constant !!
K.6.12.2.1.5.2.4.0_GLEA
Pressure angle for involute toothing:
Pressure angle is constant for tooth pair
Pressure angle can be arbitrarily chosen
Technically: manufactured pressure angle u = 20 (DIN 870)
operating pressure angle uw
results from center distance
Involute Tooth Meshing
Ident-Nr.
10 15 20 30 40
Effect of pressure angle on tooth profile
K.6.12.2.1.5.2.4.0_GLEA
e.g.: for = 20 inv = 0,014904
Involute function
Ident-Nr.
inv = tan -
K.6.12.2.1.5.2.4.0_GLEA
s
y
= 2 i
y

s
2i
+inv -inv
y
with
y
from cos
y
=
r
b
r
y
=
r
r
y
cos
with s and given by radius i
tooth thickness in reference circle
for no clearance between teeth: s = p -l =
2r
Z
-e
with e (space width)
Application e. g. for calculation
of tooth thickness s
y
at radius r
y
Ident-Nr.
K.6.12.2.1.5.2.4.0_GLEA
wheel 1
Ident-Nr.
A
M M
E
K.6.12.2.1.5.2.4.0_GLEA
Inclination angle of flanks of toothed rack = pressure angle
Toothed rack and toothed gear roll off each other
Tooth profile of rack has straight flanks easy fabrication
of tool
Toothed rack as tool for fabrication of gears, independent
of size and thus of tooth number of gear!
Only one tool per module
Summary
Ident-Nr.
K.6.12.2.1.5.2.5.0_GLEA
General_Fundamentals_Design_Indications_and_Interface_Requirements_Involute_Toothing_Fabrication
Since the tooth profiles envelope each other, an existing
toothed gear can be employed as a tool to produce another
toothed gear!
6.12.2.1.5.2.5 Manufacturing of Involute Tooth
Profiles
Ident-Nr.
Special case:
r
b2

r
w2

z
2

CN
2
(flanks are straight)
wheel 2 becomes a toothed rack!
K.6.12.2.1.5.2.5.0_GLEA
Generation of an involute flank by means of
toothed rack
Ident-Nr.
base circle
1
2
3
4
0
r
b
= r
p
b
p
e
p
e
p
e
p
e
4
IV
4
III
4
I
2
II
3
II
4
II
N
2
N
1
v
3
III
2
I
1
I
3
I
K.6.12.2.1.5.2.5.0_GLEA
Generation of an involute flank by means of
toothed rack
Ident-Nr.
p
e
p
e
p
e
p
e
N
1
4
III
4
II
4
I
4
IV
1
2
3
4
0
C
reference circle
base circle
line of action
r geometrical radius
r
b
base circle radius
p
b
base pitch
p
e
normal base pitch
p transverse pitch
r
b
= r cos u
p
e
= p
h
p
e
= p cos u
pressure angle u = 2 reference circle = manufacturing rolling circle
K.6.12.2.1.5.2.5.0_GLEA
Undercut at the root of a gear tooth occurs if addendum circle of the tool
cuts line of action outside of T
1
C !
Effects of undercut:
root of gear tooth is weakened
length of line of action g and profile contact ratio can decrease!
Generation of an undercut (UC) during
manufacturing of involute flank
Ident-Nr.
no undercut
undercut
addendum line of tool
addendum line of tool
C
A
T
1
O
1
line of action
base circle
K.6.12.2.1.5.2.5.0_GLEA
Origin of undercut (involute toothing)
Ident-Nr.
C
undercut
N
1
A
z = 8
E
K.6.12.2.1.5.2.5.0_GLEA
Tooth number below which the entire involute is no longer obtained
as tooth contour, since part of it is cut
away by the tool (undercut).
calculated limit tooth number
Limit tooth number
Ident-Nr.
z
G
= 2 cos
(h
NaP0
-x m
n
)
m
n
sin`
t
wheie h
NaP0
= h
aP0
-
aP0
(1 -sin
n
)
addendum
of rack
height of
tip curvature
envelope curve
helix angle for helical gearing
x profile displacement
p
uP0
radius of the tip curvature of the rack tooth profile
Quelle : Dub1
K.6.12.2.1.5.2.5.0_GLEA
Limit tooth number
Ident-Nr.
Quelle : Dub1
K.6.12.2.1.5.3.0.0_GLEA
General_Fundamentals_Design_Indications_and_Interface_Requirements_Production_Methods_for_Toothed_Gears
Notes about the tools for gear manufacturing:
if tooth flanks of a cylindrical gear are generated by means of a
tooth-rack-like tool and its datum line rolls off on the the pitch
circle of the gear, then a so called x zero gear (with zero
addendum modification) is produced.
m and determine flank form and the tooth depth
additionally, the facewidth is determined by the pitch reference
circle = manufactured pitch circle d=m*z
toothed rack:
straight flank generates involute
tip curvature of tool generates the root fillet. (deviation from
the involute profile)
6.12.2.1.5.3 Manufacturing Processes for Gears
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Gear production, generating processes
Ident-Nr.
cutting wheel
Continuous generating processes
1-gear hobbing, hob grinding
2-hob peeling, shaving,
burnishing
3-shaping
oscillating shaping motion
continuous feed
Quelle: Niemann, Winter
K.6.12.2.1.5.3.0.0_GLEA
Fine machining of gearing by COROWING (Kapp)
Ident-Nr.
Tool steel ring with CBN (cubical boron nitride) coating
K.6.12.2.1.5.3.0.0_GLEA
Hob grinding of compressor shaft
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Measuring Gears
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Steps
rough machining
fine machining
loading, unloading
Machining Steps
Ident-Nr.
integrated gear manufacturing center
K.6.12.2.1.5.3.0.0_GLEA
full shape
Plunge grinding
Ident-Nr.
continuously rolling
profile-grinding
hob grinding with
grinding wheel
K.6.12.2.1.5.3.0.0_GLEA
Gear tooth grinding
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Generative planing
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Generative planing
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Generative planing
Ident-Nr.
K.6.12.2.1.5.3.0.0_GLEA
Gear production, generating methods
Ident-Nr.
4
5
6
Z
1
Generating process with indexing
4-generative planing
6-hob grinding with indexing
(BHS / Hfler, Niles)
5- hob grinding with
indexing (Maag)
continuous feed
K.6.12.2.1.5.3.0.0_GLEA
1 and 2 form cutting processes with indexing
3 and 4 full form cutting processes
Gear production, form cutting processes
Ident-Nr.
1
3
4
2
Z
1
1-side-milling
form grinding
2-end-milling
4-broaching, punching,
cold drawing
3-broaching, punching,
cold drawing
continuous feed
K.6.12.2.1.5.3.0.0_GLEA
spatial forming
Gear production
Ident-Nr.
Casting
injection moulding
extrusion
drop-forging
(bevel gears)
Z
1
K.6.12.2.1.5.3.0.0_GLEA
12 steps DIN 3960
3962
3963
Quality classification for toothed wheels
Ident-Nr.
1 maximum, in practice hardly achievable
2,3 master gears
finish-grinded
4-6 turbine transmissions (circumferential speed v > 50 m/s)
5-9 passenger car transmissions, ship transmissions,
machine tools, shaved
7-12 materials handling engineering, textile machines,
milled
8-12 consumer goods etc.,
cast, punched, moulded
K.6.12.2.1.5.4.0.0_GLEA
General_Fundamentals_Design_Indications_and_Interface_Requirements_Transverse_Contact_Radio
6.12.2.1.5.4 Transverse Contact Ratio
Transverse contact ratio for a spur gear
Ident-Nr.
f
1
b
1
w
1
l
r
l
f
2
b
2
w
2
a
2
a
1
a
a
r
A
C
E
N
2
F
1
F
2
N
1
wheel 1
wheel 2
driving
driven
Meshing relationships
for involute toothing
A beginning of meshing
E end of meshing
angle of action l:
is the travel from start to
end of meshing (contact)
on the pitch circle
length of the line of action
g
u
: distance AE
Intersection points of addendum circles with the line N
1
N
2
determine the
beginning and the end of the line of action (in general).
K.6.12.2.1.5.4.0.0_GLEA
u
is the ratio of the length of the line of action to the normal
base pitch p
c
Transverse contact ratio
Ident-Nr.
u
=
g
u
p
c
=
g
u
pcos
p = pitch
pitch on manufacturing rolling circle
p = m =
u
z
Example:
u
= 2 always 2 teeth of a gear in contact to another
u
= 1 always 1 tooth " " "
u
= 1,S 50% of time 2 teeth " " "
K.6.12.2.1.5.4.0.0_GLEA
u
always > 1
u
: 1,11,251,5
Guideline
Ident-Nr.
essential for silent running!
K.6.12.2.1.5.5.0.0_GLEA
General_Fundamentals_Design_Indications_and_Interface_Requirements_Addendum_Modification_PV
(Also called: profile modification, correction of offset)
Generation:
The tool reference profile line is backed off the pitch circle
(here: =reference circle) by an amount xm (PV = + xm, positive)
or moved towards it (PV = - xm, negative)
and rolled off the unchanged reference circle afterwards.
6.12.2.1.5.5 Addendum Modification PV
Ident-Nr.
xm
C
toothed rack
tooth with addendum modification
x = + 1,0
datum line of rack
r = reference circle
tooth without addendum
modification
K.6.12.2.1.5.5.0.0_GLEA
Addendum Modification
Ident-Nr.
driving wheel 1
z
1
=18
20 - involute zero gears
O
2
O
1
scale 5:1
m =3,5
driven wheel 2
z
2
=20
m =3,5
=20
p
p
e g
=20
2/z
1
r
b1
A
0
A
C
E
N
2
r
b2
=20
E
0
p
e

k

Sp
inv
Sp
inv
k
inv
2
p
s
F
s
N
1
a
s

K.6.12.2.1.5.5.0.0_GLEA
Addendum modification on involute toothing
Ident-Nr.
v=u
0
C
p
p/2
1,2 m
m
h
1
r
b1
h
f1
r
f1
O
1
wheel 1 (machined part)
toothed rack (tool)
p
p/2
m
1,2 m
v=u
0
wheel 2 (machined part)
r
2
r
b2
r
f2
a
2
h
f2
h
a2
C
O
2
pitch line
=datum line
z
1
=8
m=2,5
z
2
=13
m=2,5
r
1
r
a1
scale
m=2,5
toothed rack (tool)
undercut
a.)
b.)
Generation of wheel 1 and wheel 2
(with addendum modification)
small tooth number
K.6.12.2.1.5.5.0.0_GLEA
datum line
pitch line
pitch line
r
a1
r
1
r
b1
r
f1
h
f1
h
a1
r
a2
r
2
r
b2
r
f2
h
f2
h
a2
C
p
p/2
p/2
p
C
m
1,2m
x
2
m
v=u
0
v=u
0
m
1,2m
x
i
m
O
2
O
1
Generation of wheel 1 and wheel 2
(with addendum modification)
small tooth number
Ident-Nr.
c.) d.)
K.6.12.2.1.5.5.0.0_GLEA
Ident-Nr.
r
a1
r
1 r
b1
r
f1
r
a2
r
2
r
f2
r
b2
=
r
2
.
cos
0
1
0
2
x
2
.
m
x
1
.
m
x
s
.
m
y
s
.
m
0
2
0
1
r
1
r
v1

v
v

r
b2
=
r
2
.
cos
r
b1
=
r
1
.
cos
r
v2
r
2
e.)
f.)
wheel 1 and wheel 2 in meshing
distance a=u
1
u
2
=i
1
+i
2
+m(x
1
+x
2
)
common reference profile
but backlash too large
wheel 1 and wheel 2 in meshing
no backlash
distance a reduced to a=i
1
+i
2
+my
required head shortage mk=m(x-y)
K.6.12.2.1.5.5.0.0_GLEA
Ident-Nr.
wheel 2 driven
wheel 1 driving
20- involute - zero gear pair
drawn for m=20 mm
wheels made with a
standard 20- toothed rack
z
2
=25 x
2
=0
z
1
=7 x
1
=0
a.)
A
E
1 81 , 0
cos p
E A
since possible t no

K.6.12.2.1.5.5.0.0_GLEA
Ident-Nr.
20- involute V-zero gear pair
drawn as above
A
E
14 , 1
cos p
E A
ratio contact transverse

z
2
=25 x
2
=-0,5
z
1
=7 x
1
=0,5
b.)
O
1
O
2
K.6.12.2.1.5.5.0.0_GLEA
Ident-Nr.
z
2
=25 x
2
=0,5
O
2
O
1
A
E
drawn as above
scale
m =20
20 - involute V-gear pair
c.)
z
1
=7 x
1
=0,5
' 52 26 20 2 , 1
cos p
AE
w

K.6.12.2.1.5.5.0.0_GLEA
Invariants for addendum modification:
manufacturing pitch line
manufacturing pitch point C
manufacturing pressure angle
base circle
Addendum modification
Ident-Nr.
addendum modification coefficient x = addendum
modification with respect to the modulus
x > u positive addendum modification
x = u zero addendum modification
x < u negative addendum modification
K.6.12.2.1.5.5.0.0_GLEA
Addendum modification what for?
improvement of root-strength of teeth (positive addendum
modification prevention of undercut)
reduction of hertzian pressure on tooth flanks (radii of
curvature of flanks become larger for positive addendum
modification)
improvement of sliding speed
(efficiency p)
realisation of a specified center distance
Addendum modification
Ident-Nr.
K.6.12.2.1.5.5.0.0_GLEA
a) Zero gear pair
Types of transmissions
Ident-Nr.
x
1
= x
2
= u
a
d
=
m (z
1
+ z
2
)
2
(center distance =
sum of refernce radii)
reference circles = pitch circles
b) V-zero gear pair
(x
1
+ x
2
) = u
a = a
d
=
m (z
1
+ z
2
)
2
reference circles = pitch circles
(example: AEG-gearing
x
1
= -x
2
= 0,5)
Objective: reinforcement of the pinion's tooth root at
the expense of the mating gear wheel.
tooth load equal
teeth of pinion
mesh more often
undercut critical!
Note:
hence V zero-
F
n
K.6.12.2.1.5.5.0.0_GLEA
manufaturing pitch circles (=reference circles)
have no "contact" anymore
during operation new pitch circles and pitch
point C (i = const.! also called operating pitch
circles)
center distance
a = a
d
+ m(x
1
+x
2
)
pressure angle operating pressure angle
Ident-Nr.
c) V gear pair x
1
+x
2
= u
o
w
= o
coso
w
=
o
d
o
cos o
t
K.6.12.2.1.5.5.0.0_GLEA
reference circles apart
center distance
pressure angle
path of contact
transverse contact ratio
Ident-Nr.
reference circles intersect
center distance
pressure angle
path of contact
reduction of tooth flank
pressure
adaptation of center distance
adaptation of center distance
noise
V-plus gear pair
V-minus gear pair
(x
1
+x
2
) > u (x
1
+x
2
) < u
Tooth formation often critical!
K.6.12.2.1.5.5.0.0_GLEA
Ident-Nr.
60 10
0
-0,5
0,5
1
X
7
range of usable
gearings
tooth number
Guidelines from DIN 3992
DIN 3994
DIN 3995
useless
x
1
+x
2
= u,7 1,S
x
1
u,S
x
2
u,S
K.6.12.2.1.6.1.0.0_GLEA
General_Fundamental_Tooth_Gear_Selection_Procedure
simplified
gearing
calculation
6.12.2.1.6.1 Selection - Procedure
Ident-Nr.
DIN 3990
previous
dimensioning
pinion volume
main dimensions
load carrying
capacity
calculation
K.6.12.2.1.6.1.0.0_GLEA
Approximated gearing calculation
Ident-Nr.
K.6.12.2.1.6.1.0.0_GLEA
Division of gear pairs
Ident-Nr.
gear with one stage i to 8 (extreme to 18)
gear with two stages i
gcs
to 45 (extreme to 60)
gear with three stages i
gcs
to 200 (extreme to 300)
For spur gear and bevel gear units (not for worm gears) applies:
i
1
= u,7 i
gcs
0,7
i
1
= u,SS i
gcs
0,55
i
2
= i
gcs
0,32
K.6.12.2.1.6.1.0.0_GLEA
Definition of the nominal load value
Ident-Nr.
Transmittable periph. force F
t
depends on
operating pitch circle diameter d
w1
and width b of the pinion
The defined load value is
B =
F
t
u
w1
b
required pinion volume:
B =
2 N
1
b J
w1
2
or
(b u
w1
2
)
crI
=
2 N
1
B
zuI
K.6.12.2.1.6.1.0.0_GLEA
Hardened gears in gear units for planes, vehicles,
machine tools etc.
Ident-Nr.
Hardened and tempered gears in large gear units
for rolling mills, turbines etc.
Non-tempered gears for subordinate purposes
B
zuI
= 1
N
mm
2
B
zuI
= u,6
N
mm
2
B
zuI
= 4 6
N
mm
2
(caibonizeu)
B
zuI
= 2 S
N
mm
2
nitiiueu
Selection of the material
K.6.12.2.1.6.1.0.0_GLEA
Ref. values for the width factor
Ident-Nr.
surface-hardened spur gears
tempered, unhardened spur gears
bevel gears
maximal permissible values
with rigid restraint at both ends
with cantilever bearing at one side
b
d
w1
b
u
w1
= u,1 u,S +
i
2u
b
u
w1
= u,2 u,8 +
i
1u
b
u
w1
= u,1 u,S +
i
1u

i
i` + 1
b
u
w1
max
= 1,2
b
u
w1
max
= u,7S
K.6.12.2.1.6.1.0.0_GLEA
surface-hardened spur gears
Ident-Nr.
tempered, unhardened spur gears
Ref. values for the no. of teeth z
1
In the case of addendum modification, helical gearing, and bevel
z
1
gearing, z
1
is sometimes chosen essentially smaller
u = circumferential speed in
with
= pitch circle diameter in mm
m
s
u
w1
z
1
= 14 +
u
S
+
J
w1
4u
z
1
= 16 +
u
S
+
J
w1
2u
K.6.12.2.1.6.1.0.0_GLEA
with cleanly cast gearing
Ident-Nr.
with cut gearing, bearing on steel
construction, or flying pinion
with cleanly cut gearing, proper bearing in
gear boxes
with accurately cut gearing, exactly parallel
rigid bearing
with accurately cut gearing, exactly parallel
rigid bearing and
m
n
mn

b
1u
Minimum standard module m
n
mtn
m
n
mn

b
1S
m
n
mn

b
2S
m
n
mn

b
Su
m
n
mn

b
Su
b
u
w1
1
K.6.12.2.1.6.1.0.0_GLEA
permanent gear
Ident-Nr.
Reference values for the required safety
temporary gear
safety concerning tooth fraction
pitting
seizure
safety concerning tooth fraction
pitting
seizure
S
B
= 1,8 4,u
S
u
= 1,S 2,S
S
P
= S,u S,u
S
B
= 1,S 2,u
S
u
= u,4 1,u
S
P
= S,u S,u
K.6.12.2.1.6.1.0.0_GLEA
(also applicable when e.g.
a pinion has contact with
several gears)
Ident-Nr.
B =
F
t
b u
w1
u
w1
eI
=
F
t
b
u
w1
B
zuI
N
1
= F
t
u
w1
2
B
zuI
=
2 N
1
b u
w1
2
B
zuI
u
w1
eI
=
2 N
1
b
u
w1
B
zuI
3
with
follows
N
1
u
w1
F
t
b
b
J
w1
t
: permissible nominal load value
: torque to be transmitted at the pinion
: pitch circle diameter of pinion
: peripheral force at pitch circle
for 1 tooth contact
: tooth width
: width factor of pinion
K.6.12.2.1.6.1.0.0_GLEA
Connection between load value and Hertz equation
Ident-Nr.
from Hertz equation of the same materials
follows with
follows with
and thus
H
= z
M

F
t
2 b
H
` = z
M
`
F
t
2 b
N
1
= F
t
u
w1
2
and = u
w1
u
w1
` b = Z
M
`
N
1
H
2
u
w1
` b =
2 N
1
B
zuI
B
zuI
=
2
Z
M
2
H
`
B
zuI
=
H
`
K.6.12.2.1.6.2.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Selection_Criteria_for_Transmissions
6.12.2.1.6.2 Selection Criteria mechanical transmissions using form closure
6.12.2.1.6 Selection
Ident-Nr.
Evaluation:
no slip
power up to = 85000 kW (1979: = 50000 kW)
maximum speed: n = 150000 min
-1
high efficiency for spur gear transmissions:
= 98 - 99,5 % per stage
compare: belt = 95 %
hydrostatical transmissions = 70 - 90 %
hydrodynamical transmissions = 70 - 90 %
large transmission ratios
i: 1...5000 for conventional transmissions
small transmissions i up to 1x1u
6
!
++
+
+
+++
++
K.6.12.2.1.6.2.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Selection_Criteria_for_Transmissions
Evaluation:
certain designs low efficiency:
worm gear: 30 - 96 %
hypoid gear: 85 - 96 %
noise
vibrations due to meshing
not continuously variable ratio
power density lower than hydrostatical transmissions
Selection
Ident-Nr.
-
-
--
-
-
K.6.12.2.1.6.3.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Application_Limits_and_Damages
Calculation of gearing:
standardized worldwide
much empiricism, some theory
Standard: DIN 3990
Capacity limit determined by 5 principal damages:
tooth breakage (forced rupture / endurance failure)
Pitting
gray stippiness (micro-pitting)
gear scuffing (hot seizing / cold seizing)
abrasion wear
6.12.2.1.6.3 Application Limits and Damages
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Parameters (essential):
Operating conditions (kind of load, forces, circumferential speed,
temperature)
Choice of material
Geometry of gearing
Accuracy of manufacture
Surface treatment
Surface finish
Lubricant
Surface hardening
Application Limits and Damages
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Main load-bearing capacity limits of toothed
wheels
Ident-Nr.
Damage curves
define load capacity
limits (limit torque)
of toothed wheels
1 wear limit
2 tooth breakage
limit
3 seizing limit (hot
seizing)
4 pitting limit
5 micro-pitting limit
K.6.12.2.1.6.3.0.0_GLEA
Main Load-Bearing Capacity Limits
Ident-Nr.K.6.12.2.1.6.3 101_820 E 980729
tempering steel case hardening steel
circumferential speed v
t
in m/s
0,3 1 10 m/s 50 0,3 1 10 m/s 50
l
i
m
i
t
i
n
g

t
o
r
q
u
e

M
l
i
m
i
t
l
i
m
i
t
i
n
g

t
o
r
q
u
e

M
l
i
m
i
t
tooth breakage limit
pitting limit
micro-pitting limit
micro-pitting limit
range without damage
range without damage
flank
breakage
K.6.12.2.1.6.3.0.0_GLEA
Tooth breakage
Damage appearance:
breaking off of tooth parts or of entire teeth.
Term:
tooth root breakage
Origin of damage:
root fillet on side of tensile stress
Type of damage:
forced rupture due to temporary overloading, shock load
(e.g. blockage)
vibration fatigue failure (endurance failure) after longer running time
above endurance strength at tooth root region
Tooth damages and causes
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Tooth Breakage I
Ident-Nr.K.6 101_237 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Tooth Breakage II
Ident-Nr.K.6 101_238 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Cause: bending stress of tooth by tooth normal force
Attention: point of the force introduction changes during tooth
movement
Actions to be taken:
constructive overload
protection
design for tooth strength
shape of the tooth rooth
Tooth damages
Ident-Nr.
F
bn
force intoduction
origin of fracture
e.g. root fillet
surface-hardening
shot-peening
tip relief (profile correction)
crowning (longitudinal correction)
Therewith, the tooth
ends are relieved!
K.6.12.2.1.6.3.0.0_GLEA
(material: 17 CrNiMo 6 E)
here, two fragments lie on the fracture surface -
a driven bevel pinion of a water turbine transmission
Flank Breakage
Ident-Nr.K.6.12.2.1.6.3 101_828 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Fracture Surface on Bevel Pinion
Ident-Nr.K.6.12.2.1.6.3 101_829 E 980729
K.6.12.2.1.6.3.0.0_GLEA
material: 31 CrMoV 9,
gas nitrided
Flank Breakage on a Driven gear of an
Auxiliary Gas Turbine Transmission
Ident-Nr.K.6.12.2.1.6.3 101_826 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Crack propagation for Flank Breakage
Ident-Nr.K.6.12.2.1.6.3 101_844 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Combined-Cycle Power Plants
with Transmission
Ident-Nr.K.6.12.2.2.7 101_817 E 000407
Multi-shaft plants
industrial gas turbine (GT)
steam turbine (ST)
two generators (Gen)
Single-shaft plants
industrial gas turbine (GT)
steam turbine (ST)
one generator (Gen)
SSS-coupling
GT Gen ST GT Gen HP GT Gen
Gen
ST
boiler
SSS
MP, (LP)
transmission e.g. between
gas turbine and generator
steam turbine and generator
HP and MP/LP steam turbine
K.6.12.2.1.6.3.0.0_GLEA
power ...100 MW designed
...150 MW (up to 220 MW) planned
rotational speed drive: ...720 min-1 (bis 10 000 min-1)
output: 1500, 1800, 3000, 3600 min-1
transmission ratio 1,2 ... 2
circumferential speed ... 180 m/s
Characteristic Values of High
Power Turbo Transmissions
Ident-Nr.K.6.12.2.2.7 101_818 E 000407
K.6.12.2.1.6.3.0.0_GLEA
Classical dual-shaft transmission
Dual-shaft transmission
with single helical gearing
Distribution transmission
Distribution transmission
Locked-Train-transmission
Various Types of Turbo Transmissions
(Comparison for i=1,2)
Ident-Nr.K.6.12.2.2.7 101_822 E 000407
K.6.12.2.1.6.3.0.0_GLEA
Life Factors for the Tooth Root Strength
According to ISO 6336-5
Ident-Nr.K.6.12.2.1.6.3 101_821 E 980729
L
i
f
e

f
a
c
t
o
r
load cycle number
optimal conditions:
material, pro-
duction, experience
Standardized damage line, deformation or
incipient crack limit
K.6.12.2.1.6.3.0.0_GLEA
Countermeasures for loss
reduction:
limit lubrication and cooling to the
actually needed lubricant quantity
separate oil mist from rotors with the
help of special built-in components,
Richtbleche etc.
optimize gear profile
aerodynamically (tip curvature, tip
clearance)
evacuation of the air in the
transmission housing in order to
reduce ventilation losses (reduction
of density of oil-air-mixture)
bearing concept optimize in
particular geometry and lubricant
supply
use synthetic lubricants
Proportional Gear Losses of High Performance
Turbo Transmissions and Countermeasures
Ident-Nr.K.6.12.2.2.5 101_824 E 000407
bearings, seals
and suchlike: about 50%
ventilation, splashing and
crushing of lubricant:
about 40%
tooth friction:
about 10%
K.6.12.2.1.6.3.0.0_GLEA
Example for the Effect of
Measures for Loss Reduction
Ident-Nr.K.6.12.2.2.5 101_825 E 000407
bearing total gearing
gear efficiency
e
f
f
i
c
i
e
n
c
y

[
%
]
g
e
a
r

l
o
s
s
e
s

[
k
W
]
reduction of gear losses by 50%
thereof
- bearing losses
by about 25%
- gearing losses
(ventilation, pulse,
squeezing and friction)
by about 68%
1200
1000
800
600
400
200
0
100
99,6
99,2
98,8
98,4
98,0
HET transmissions, 70 MW, 5434 / 3000 min
-1
conventional transmission, 70 MW, 5434 / 3000 min
-1
190 593
350 471
540 1064
99,2% 98,5%
K.6.12.2.1.6.3.0.0_GLEA
Surface of Vibration Fatigue Failure and
Position of Primary Incipient Crack (PR)
Ident-Nr.K.6.12.2.1.6.3 101_830 E 000407
K.6.12.2.1.6.3.0.0_GLEA
Surface of Vibration Fatigue Failure and
Position of Primary Incipient Crack (PR)
Ident-Nr.K.6.12.2.1.6.3 101_831 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Flank Breakage of a Pinion of a 30 MW Steam
Turbine Transmission
Ident-Nr.K.6.12.2.1.6.3 101_832 E 000407
material: 17CrNiMo 6 E
K.6.12.2.1.6.3.0.0_GLEA
Flank Breakage of a 75 MW Gas Turbine
Transmission of a Combined-Cycle Power Plant
(Quillshaft Construction)
Ident-Nr.K.6.12.2.1.6.3 101_833 E 000407
cf. 101_834
cf. 101_835
K.6.12.2.1.6.3.0.0_GLEA
Ident-Nr.K.6.12.2.1.6.3 101_834 E 000407
K.6.12.2.1.6.3.0.0_GLEA
Ident-Nr.K.6.12.2.1.6.3 101_835 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Normal Section with Starting Position of the
Primary Crack (PR)
Ident-Nr.K.6.12.2.1.6.3 101_827 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Starting Position of the Primary Crack (PR),
Several Crack Branches (BS) and of the Crack
Deflektion (BU)
Ident-Nr.K.6.12.2.1.6.3 101_836 E 980729
K.6.12.2.1.6.3.0.0_GLEA
One Polished Section out of Four (Unetched)
Ident-Nr.K.6.12.2.1.6.3 101_837 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Radial Cracking Starting from a Local
Separation
Ident-Nr.K.6.12.2.1.6.3 101_838 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Radial Cracking Starting from a Local
Separation
Ident-Nr.K.6.12.2.1.6.3 101_839 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Residual Stresses after Cooling in the
Surrounding of an Al2O3 Inclusion
Ident-Nr.K.6.12.2.1.6.3 101_840 E 000407
0 0,2 0,4 0,6 0,8 1,0 mm
distance from center of the inclusion
MPa
1200
1000
800
600
400
200
0
-200
-400
-600
-800
-1000
s
t
r
e
s
s

r
K.6.12.2.1.6.3.0.0_GLEA
Pressed-in Spheroids in a
Plastically Deformed Zone
Ident-Nr.K.6.12.2.1.6.3 101_842 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Starting Position of Primary Crack (PR) in a
Normal Section
Ident-Nr.K.6.12.2.1.6.3 101_843 E 980729
K.6.12.2.1.6.3.0.0_GLEA
Equivalent and Principal Shear Stresses of
a Gas Turbine Transmission pH= 870MPa
Ident-Nr.K.6.12.2.1.6.3 101_845 E 000408
K.6.12.2.1.6.3.0.0_GLEA
Pitting formation
Damage appearance:
pores and surface abrasion (crumbling) on tooth flanks (pittings)
Origin of damage:
mostly below rolling circle
Type of damage:
fatigue of material under continuous stressing
Cause:
shear stresses near flank surface and surface cracks
due to slip under high contact pressure.
Ident-Nr.
high Hertzian stress
at contact area!
K.6.12.2.1.6.3.0.0_GLEA
gray stippiness and pitting formation while lubricating with
mineral oil and instrument transformer oil
Pittings, Case-Hardened Gearing
Ident-Nr.K.6 101_231 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Pittings on Tempered Gearing
Ident-Nr.K.6 101_232 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Influences
Hertzian stress
surface hardness
surface finish
flank geometry deviations
constructive boundary conditions
sliding on flank
oil viscocity
oil additives
oil quality
Oil temperature
Pitting formation
Ident-Nr.
oils of higher viscosity
dimensioning for higher flank
load capacity
low flank roughness
case hardening
K.6.12.2.1.6.3.0.0_GLEA
Ident-Nr.
Gray stippiness, micro-pitting
Damage appearance:
numerous microscopically small breakouts optical impression gray
spots
Origin of damage:
tooth flank surfaces being in contact
Type of damage:
disruption of material on the surface
Cause:
low lubricating films lead to locally very high stress
improvement of lubrication conditions
> krit 0,7, i.e. lubricating film thickness sufficiently large
oil additives for boundary layer in the case of "mixed lubrication
K.6.12.2.1.6.3.0.0_GLEA
Examples for Micro-Pitting on Tooth Flanks
Ident-Nr.K.6 101_233 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Gear scuffing, hot seizing
Damage appearance: two types
scores in sliding direction of tooth flanks in varying quantity
scoring
dim surface damages due to scuffing as fine scratches, coherent
areas or large scuffing zones seizure
Origin of damage:
tooth flank, local destruction of chemical protective film during mixed
lubrication
Type of damage:
local welding with consecutive ripping off of material during rolling
and sliding
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Scores and Scuffing on Pinion Flank
Ident-Nr.K.6 101_230 E 980727
scores
scuffing
K.6.12.2.1.6.3.0.0_GLEA
Cause:
Lubricating film is penetrated due to too high stress or too high
temperature. Thereby the EHD film as well as the local chemical
protective layer (build by additives) are destroyed. Scoring typical for
circumferential speed < 30 m/s for oils w/o additives seizure typical
for circumferential speed > 30 m/s
use a smaller module
relief of tip and root
nitrifying
low surface roughness (run-in!)
lubricants with EP-additives very efficient !
Scores and Scuffing on Pinion Flank
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Wear caused by cold seizing
Damage appearance:
scoring with large amount of material removal
Origin of damage:
tooth flank
Type of damage:
wear due to direct contact of metallic surfaces with relative movement
Cause:
for low circumferential speeds < 5 m/s and coarse gearing quality mixed
lubrication in large parts
better gearing accuracy
high viscous lubricants
better quality of flank surfaces
Ident-Nr.
K.6.12.2.1.6.3.0.0_GLEA
Wear
Ident-Nr.K.6 101_235 E 980727
K.6.12.2.1.6.3.0.0_GLEA
Wear, abrasion wear
Damage appearance:
large areas of surface abrasion of tooth flank material, especially: tip,
root
Origin of damage:
tooth flank, often near tip or root
Type of damage:
qpure abrasion wear
Cause:
no separating lubricating layers due to low circumferential speeds (< 0,5
m/s), hence full metallic contact
lubricant with high viscosity and solid lubricant additives (MoS2)
surface-hardening, nitrifying
same hardness for pinion and gear wheel
Ident-Nr.
K.6.12.2.1.8.1.0.0_GLEA
General_Fundamentals-Tooth_Gear_Mechanisms_Dimensioning_Introduction
Principle of calculation of the load carrying capacity
6.12.2.1.8 Dimensioning
Ident-Nr.
standard DIN 3990
is applied generally, but often with company-specific
supplements!
principle of calculation:
verify wether a transmission has sufficient safety against all
discussed damage limits for a given life time.
K.6.12.2.1.8.1.0.0_GLEA
General_Fundamentals-Tooth_Gear_Mechanisms_Dimensioning_Introduction
Fundamental idea of the calculation of the load carrying capacity
1) calculation is based on nominal circumferential load on a tooth
of perfect geometry, infinite rigidity, for medium lubrication
conditions.
2) for that, mechanical strength properties are determined on
standardized test stands with standardized reference test wheels
under standardized test conditions
3) the effect of the differing boundary conditions of the real
application are taken into account by influence factors.
Dimensioning
Ident-Nr.
Realisation: very simplified calculation method with
extensive tables and diagrams for the determination
of the influence factors.
K.6.12.2.1.8.2.0.0_GLEA
General_Fundamentals_Tooth_Gear_Mechanisms_Dimensioning_Tooth_Breakage_and_Tooth_Load_Capacity_for_Spur_Gearing
Bending stress
the point of application of the flank normal force moves along flank
critical case: addendum contact
6.12.2.1.8.2 Tooth breakage and Tooth Strength for
Spur Gears
Ident-Nr.
for calculation:
shift F
n
into
the tooth centre
C
EL
r
'
n
F
t
F
r
F
'
n
F
'
F
(changing!!)
'
t
F
'
n
F
'
r
F
w
point of contact
'
E
K.6.12.2.1.8.2.0.0_GLEA
Special case: point of contact = pitch point
Calculation of forces
Ident-Nr.
F
t
=
M
t
r
given! F
n
i
=
F
t
cos
w
= F
n
F
t
i
= F
n
cos
F
|
=
F
t
cos
F
|
cos
w
F
r
i
=
F
t
sin
F
|
cos
w
F
t
i
= F
t
=
N
t
i
since
F
i
=
w
K.6.12.2.1.8.2.0.0_GLEA
Stresses in the tooth
Ident-Nr.
K.6.12.2.1.8.2.0.0_GLEA
compressive
stress:
Ident-Nr.
bending:
shear:
equivalent stress
section modulus:
(Maximum Shear
Strain Energy
theory)
(Max. Shear Stress Theory)
D
=
F
r
i
A
F
A
F
= s
F
b
F
B
=
F
t
i
h
F
W
W =
b
F
s
F
`
6
m
=
F
t
i
A
F
V
=
B
-
D
2
+S
0

m
2
V
=
B
-
D
2
+4
0

m
2
0
- Bachs correction factor
with
0
= 2,S
K.6.12.2.1.8.2.0.0_GLEA
Approach:
D
and
m
need not be considered
Ident-Nr.
thus:
tooth root stress
F
=
B
=
F
t
i
h
F
W
=
F
t
cos
F
i
h
F
6
cos
w
b
F
s
F
`
=
F
t
b
F
m
n

cos
F
i
h
F
6 m
n
cos
w
s
F
`
multiplied with
m
n
m
n
therewith:
F
=
F
t
b m
n
Y
F
The tooth is considered as a transverse
beam and is therefore dimensioned at
the fixed end .
= Y
F
tooth formation factor
K.6.12.2.1.8.2.0.0_GLEA
All further influences are taken into account by
influence factors according to DIN 3990 :
Ident-Nr.
F
t
Nominal circumferential load at reference circle
b Width of tooth face
m
n
Real pitch module
Pu
Form factor DIN 3990/ISO 6336, part 3, page 17, 23
Su
Stress correction factor - DIN 3990/ISO 6336, part 3, page 40, 41
s
Contact ratio factor - DIN 3990/ISO 6336, part 3, page 49, 50
[
Helix angle factor - DIN 3990/ISO 6336, part 3, page 50, 51
K
A
Application factor - DIN 3990, part1, page 25, annex A, page 144
K
v
Dynamic factor - DIN 3990, part 1, page 26, 44, 51
K
P[
Longitudinal load distribution factor (root str.) - DIN 3990, part 1, page 53, 54
K
Pu
Transverse load distribution factor (root str.) - DIN 3990, part 1, page 117, 129
F
=
F
t
b m
n
Y
Fa
Y
Sa
Y
s
Y
K
A
K
V
K
F
K
Fu
K.6.12.2.1.8.2.0.0_GLEA
For the verification of resistance the tooth root stress
is compared to tooth root resistance.
Verification of resistance against tooth break
Ident-Nr.
where
F,IIm
Tooth endurance limit - DIN 3990, part 5, page 10, 17
Y
ST
Stress correction factor - DIN 3990, part 3, page 49
Y
NT
Life factor - DIN 3990, part 3, page 52, 53
Y
8,rcIT
Relative notch sensitivity factor - DIN 3990, part 3, page 55, 63
Y
X
Size factor (tooth root) - DIN 3990, part 3, page 73, 74
S
F
=

FG
FG
permissible tooth root
stress according to DIN 3990
FG
=
F,IIm
Y
ST
Y
NT
Y
8,rcIT
Y
X
K.6.12.2.1.8.2.0.0_GLEA
Calculation with
Reference value for safety against tooth break SF
Ident-Nr.
a) maximum torque against fatigue strength
b) nominal torque x
application factor
c) b) + high reliability
S
Fmtn
= 0,7 ... 1,0 (presses, shearing machines)
S
Fmtn
= 1,3 ... 1,5 (standard case, industrial
transmission)
S
Fmtn
= 1,6 ... 3,0 (flight transmission, ship trans-
mission, turbo transmission)
K.6.7.1.4.3.0.0.0_GLDA
Lagerungen_und_Fhrungen_Bauformen_Einfhrung
Idea:
Determination of the Hertzian stress in the pressure area of
the tooth flanks and comparission with permissible values!
6.12.2.1.8.3 Pitting and Load Carrying Capacity of
the Tooth Flanks
Ident-Nr.
Fundamental principle
Hertzian theory
Contact of two cylinders
under load
b
2
2a
p
max
F
K.6.7.1.4.3.0.0.0_GLDA
where
p
max
maximum Hertzian stress
F force
a half pressure area width
b pressure area length
poisson's ratio (steel = 0,3)
E equivalent modulus
equivalent curvature radius
Pitting and Load Carrying Capacity of the Tooth
Flanks
Ident-Nr.
p
max
=
2 F
a b
a
2
=
8 F 1 - `
E b
= 2
E
1
E
2
E
1
+ E
2
1
=
1
1
+
1
2
K.6.7.1.4.3.0.0.0_GLDA
p
max
2
=
4 F`
` a` b`
Flanks
Ident-Nr.
p
max
2
=
4 F` E b
28 F 1 -
2
` b`
=
F E
2 b 1 -
2
with:
and substitution follows:
for steel:
p
max
2
= u,17S
F E
b
K.6.7.1.4.3.0.0.0_GLDA
Gearing
Flanks
Ident-Nr.
1) Curvature radii
1
= i
w1
sin
w
2
= i
w2
sin
w
The following is required:
O
2
O
1
w
.
line of action
.
C

1
2
K.6.7.1.4.3.0.0.0_GLDA
The following applies to the pitch point:
Flanks
Ident-Nr.
with:
it follows for the example:
1
= i
w1
sin
w
2
= i
w2
sin
w
=

1

2
1
+
2
=
i
w1
i
w2
sin`
w
(i
w1
+i
w2
) sin
w
u = tooth numbei iatio
=
z
gcar
z
pInIon
> 1
u =
z
2
z
1
=
i
w1
i
w2
i
w2
= u i
w1
wheie i
w1
= i
1

cos
cos
w
=
u
u +1
i
w1
sin
w
K.6.7.1.4.3.0.0.0_GLDA
2) Force F in the contact, spur gear
Flanks
Ident-Nr.
Hertzian stress at tooth flank contact
it follows with
z
M
material factor
for = 0,3 (steel) same material
F = F
N
=
F
t
cos
w
H
=
E
(1 - `)
F
t
(u + 1)
2 i
1
cos
w

cos
cos
w
sin
w
u b
H
= z
M

F
t
(u + 1)
2 i
1
cos sin
w
u b
=
z
M
z
M
= u,SS E

H
= z
M

F
n
2 b
K.6.7.1.4.3.0.0.0_GLDA
Calculation according to DIN 3990:
Consideration of boundary conditions is carried out by influencial factors:
Flanks
Ident-Nr.
H
= Z
BD
Z
H
Z
E
Z
s
Z

F
t
(u + 1)
u
1
b u
K
A
K
V
K
H
K
Hu
F
t
Nominal circumferential load at reference circle
b Width of tooth face
u
1
Reference diameter of pinion
u Gear ratio z
2
/z
1
; |z
2
/z
1
| 1
Z
BD
Single mesh factors Z
B
, Z
D
- DIN 3390,part 2, page 19
Z
H
Zone factor - DIN 3990, part 2, page 19
Z
E
Elasticity factor according to DIN 3990, part 2, page 24
Z
s
Contact ratio factor - DIN 3990, part 2, page 26
Z
Helix angle factor - DIN 3990, part 2, page 28

K
A
Application factor - DIN 3990, part 1, page 25
K
V
Dynamic factor - DIN 3990, part 1, page 26
K
H
Longitudinal load distribution factor (face str.) - DIN 3990, part 1, page 53
K
Hu
Transverse load distribution factor (face str.) - DIN 3990, part 1, page 117
K.6.7.1.4.3.0.0.0_GLDA
This calculated Hertzian stress is compared to a permissible
Hertzian stress, the pitting limit strength
Flanks
Ident-Nr.
HG
=
H,IIm
Z
NT
Z
L
Z
R
Z
V
Z
W
Z
X
H,IIm
Pitting resistance - DIN 3990, part 5, page 9
Z
NT
Life factor (face) - DIN 3990, part 2, page 29
Z
L
Lubrication factor - DIN 3990, part 2, page 35
Z
R
Roughness factor - DIN 3990, part 2, page 39
Z
V
Velocity factor - DIN 3990, part 2, page 14
Z
W
Material pairing factor - DIN 3990, part 2, page 45
Z
X
Size factor (face) - DIN 3990, part 2, page 1
K.6.7.1.4.3.0.0.0_GLDA
Safety against pitting
Flanks
Ident-Nr.
S
H
=
o
Hu
o
H
Reference values:
Calculation with
a) maximum torque against fatigue strength
S
Hm|n
= 0,5 ... 0,7
b) nominal torque x application factor
S
Hm|n
= 1,0 ... 1,2
c) b) + high reliability
S
Hm|n
= 1,3 ... 1,6
K.6.12.2.2.1.0.0.0_GLEA
General_Fundamentals_Cylindrical_Gears
6.12.2.2 Cylindrical Gears
6.12.2.2.1 General Fundamentals
Ident-Nr.
K.6.12.2.2.1.0.0.0_GLEA
Ident-Nr.
b
s
e
p
d
u
a
u
I
left flank
right flank
gearing
dedendum flank
addendum flank
s: tooth thickness
e: spacewidth
p: pitch
d
a
: addendum circle
d: reference circle
d
f
: dedendum circle
h
f
: dedendum
h: depth of teeth
h
a
: addendum
b: width of tooth
face
tooth number: z
gear ratio: u =
z
2
z
1
pitch: P =
d
z
= n
K.6.12.2.2.1.0.0.0_GLEA
reference diameter:
modulus ( scale quantity ):
center distance:
tip diameter:
addendum:
Introduction
Ident-Nr.
u = m z
m =
P
a =
u
1
+ u
2
2
a =
1
2
u
1
+ u
2
=
m
2
(z
1
+ z
2
)
u
a
= u + 2 h
a
h
a
h
a
= m
values determined in DIN 780
m = ...1,...1,25...1,5...
Preferred numbers!
normal:
K.6.12.2.2.1.0.0.0_GLEA
root diameter:
dedendum:
depth of teeth:
common depth of teeth:
Kopfspiel:
tooth thickness:
spacewidth in reference circle:
Introduction
Ident-Nr.
u
I
= u - 2h
I
h
I
h
I
= 1,1 - 1,S m
h = h
I
+ h
a
h
w
= h
a1
+ h
a2
c
c
1
= h
2
- h
w
c
2
= h
1
- h
w
s
e
normal: 0,10,3 x m
normal:
K.6.12.2.2.1.3.0.0_GLEA
Cylinder_Gears_Mechanisms_Characteristic_Features_and_Classification
6.12.2.2 Cyclinder Gears
6.12.2.2.1.3 Characteristic Features and Classification
Ident-Nr.
K.6.12.2.2.1.3.0.0_GLEA
Cylinder_Gears_Mechanisms_Characteristic_Features_and_Classification
Necessary case depth for cylinder gears
Ident-Nr.K.6.12.2.2.1.3101_1081E050429
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Modul
2,5
2,0
1,5
1,0
0,5
C
a
s
e

d
e
p
t
h
Cylinder Gear
Material:
16MnCr
Surface layer
hardness:
61 3 HRC
E
x
a
m
p
l
e
:

M
o
d
u
l

=
1
0
Largest hardening
depth = 2 mm
Minimum hardening
depth = 1,5 mm
K.6.12.2.2.1.4.2.0_GLEA
Cylindrical_Gears_Types_Tooth_Profiles_of_Cylindrical_Gears
6.12.2.2.1.4.2 Tooth Profiles of Cylindrical Gears
6.12.2.2 Cylindrical Gear Mechanisms
6.12.2.2.1.4 Designs
Ident-Nr.
Arrangement of teeth for cylindrical gears
a) spur gear, b) cluster gear,
c) helical gear, d) herringbone gearing (double helical gear),
e) circarc gear (round-flank toothing)
a)
b) c)
d) e)
K.6.12.2.2.1.4.3.0_GLEA
Cylindrical_Gears_Spur_Gears_with_Involute_Toothing
so far: infinitely thin wheel
now: wheels of finite width
b
6.12.2.2.1.4.3 Spur Toothed Wheels with Involute
Toothing
Ident-Nr.
The flank is generated
by the line A
1
A
2
on a
surface of a cylinder
which is unwinded.
The line A
1
A
2
is parallel
to the axis of the
cylinder. All points of the
line describe an involute
on the plane
perpendicular to the
cylinder axis
(transverse section).
Generation of an involute flankon spur toothed gear
A
2
r
b
A
1
tooth traces (straight lines)
plane involutes
base cylinder
K.6.12.2.2.1.4.3.0_GLEA
Cylindrical_Gears_Spur_Gears_with_Involute_Toothing
wheel a = wheel 1
driving
Tooth forces on spur toothed wheels
Ident-Nr.
wheel 1
driving
wheel 2 driven
wheel b = wheel 2
driven
driving wheel 1
tangential force:
normal force:
radial force:
driven wheel 2
tangential force:
normal force:
radial force:
F
t1
=
2 N
1
u
w1
=
N
t
i
w1
F
N1
=
F
t1
cos
w
F
r1
= F
t1
tan
w
F
t2
= F
t1
F
N2
=
F
t2
cos
w
F
r2
= F
t2
tan
w
Quelle:
Decker
K.6.12.2.2.1.4.4.0_GLEA
Cylindrical_Gears_Helical_Gears_with_Involute_Toothing
The flank is generated
by the line A
1
A
2
on a
surface of a cylinder
which is unwinded.
The line A
1
A
2
is a
straight line on the
unwound surface,
which is skewed to the
axis of the cylinder.
On the cylinder, it
forms a helix. All points
of the line describe an
involute on the plane
perpendicular to the
cylinder axis
(transverse section).
6.12.2.2.1.4.4 Helical Gears with Involute Toothing
Ident-Nr.
B
2
A
2
r
b
B
1
A
1
tooth traces (helical lines)
plane involutes
base cylinder
K.6.12.2.2.1.4.4.0_GLEA
Helical gearing
helix angle
transverse section t
exact involute
decisive for transverse
contact ratio
normal sectionn
definition basic profile
maximum number of teeth
profile modification
calculation of strength
Helical gearing
Ident-Nr.
Quelle:
Habehauer,
Bodenstein
K.6.12.2.2.1.4.4.0_GLEA
transverse pitch:
Fundamental relations between transverse and
normal section
Ident-Nr.
transverse pressure angle:
reference diameter:
transverse module:
p
t
=
p
n
cos
m
t
=
m
n
cos
u
t
= m
t
z =
m
n
cos
z
tan
t
=
tan
n
cos
K.6.12.2.2.1.4.4.0_GLEA
Definition
Equivalent spur gearing
Ident-Nr.
Basic profile defined in normal section
same tools for spur and helical gearing
Equivalent spur gearing in normal section
section yields ellipse
laige axis: a =
u
t
2
cos
small axis: b =
u
t
2
curvature radius of an ellipse in general
=
a`
b
equivalent circle
through pitch point C:
i
n
=
u
t
2
cos`
u
n
=
u
t
cos`
K.6.12.2.2.1.4.4.0_GLEA
Notice
Equivalent spur gearing
Ident-Nr.
With equivalent circle J
n
, all equations of the spur gearing can be
applied to the helical gearing as well.
equivalent
tooth number:
z
n
=
u
n
m
n
=
u
t
m
n
cos`
=
z
cos
also called: "virtual number of teeth"
K.6.12.2.2.1.4.4.0_GLEA
Profile contact ratio for helical gear wheels
Ident-Nr.
p
t
b
overlap ratio
total contact ratio
u
=
g
u
p
c
p
c
= p
t
cos
t
gcs
=
u
+
=
oveileap length
tiansveise pitch
=
b tan
p
t
degree of
overlapping
b tan
K.6.12.2.2.1.4.4.0_GLEA
driving wheel 1
tangential force:
axial force:
radial force:
normal force:
Tooth forces for helical gear wheels
Ident-Nr.
driven wheel 2
tangential force:
axial force:
radial force:
normal force:
F
t1
=
2 N
1
u
w1
F
a1
= F
t1
tan
w
F
r1
= F
t1
tan
wt
F
N1
=
F
t1
cos
wt
cos
F
t2
= F
t1
F
a2
= F
a1
F
r2
= F
r1
F
N1
= F
N2
Quelle : Decker
K.6.12.2.2.1.4.4.0_GLEA
consider axial forces on bearings
axial forces limit the
helix angle up to about 30
poss.: double helical gearing
shafts with two gears: balance forces
Helical gearing
Ident-Nr.
D-Tip:
K.6.12.2.2.1.7.2.0_GLEA
Cylindrical_Gears_Applications_Manual_Car_Transmissions_with_Layshafts
Passenger Car with Drive Assemblies
6.12.2.2.1.7.2 Passenger Car Manual Transmission
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
Power Train
Ident-Nr.K.7.3 101_052E 980706
differential
primary shaft
clutch system
wheel
motor
transmission
axle drive shaft
K.6.12.2.2.1.7.2.0_GLEA
gear
reverse
Source: Fahrzeuggetriebe (Lechner, Naunheimer)
5 Gear Passenger Car Manual Transmission ZF S 5-31
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
6 speed gearbox (2007 AUDI TT)
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
Manual Transmission Operation
Ident-Nr.K.7.4 111_016E 990809
K.6.12.2.2.1.7.2.0_GLEA
source: http://www.howstuffworks.com/transmission.htm
Manual Transmission Operation
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
Source: Diehl
Passenger Car Transmission with Selector Forks
and Bronze Synchro Rings
Ident-Nr.K.6.12 104_959E 000717
K.6.12.2.2.1.7.2.0_GLEA
Vehicle transmission
Ident-Nr.
5 R 1 2
3 4
idlers
shifting forks with
synchronization
layshaft
main shaft
K.6.12.2.2.1.7.2.0_GLEA
Source:
Fahrzeuggetriebe
(Lechner,
Naunheimer)
Piece parts of 5-gear passenger car manual
transmission ZF S 5-31
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
1 selector shaft, 2-selector sleeve, 3-catch pin,
5 to 7-shifting forks, 8-lock, 9-swivel
Arrangement of shifting elements in a transmission
Ident-Nr.
Source:
Fahrzeuggetriebe
(Lechner,
Naunheimer)
gear selection
gear alley selection
K.6.12.2.2.1.7.2.0_GLEA
1 gear shift
2 ball joint
3 shift finger
4 sliding selector shaft
5 locking device
6 selector fork
7 gearshift sleeve
8 synchronization
9 idler
Direct gear-shifting of 5-gear-transmission with
three sliding selector shafts
Ident-Nr.
select shift
K.6.12.2.2.1.7.2.0_GLEA
internal gear shift elements:
sliding selector shafts, shifting forks,
synchronizations, shifting claws
external gear shift elements :
selector lever, four-joint-transmission,
syncro-systems, tackle lines
very large variety,
hence only fundamental principles here
Gear shift elements
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
a) Sliding wheel
b) Claw circuit
c) Pin circuit
d) Synchronisation
without locking
device
Interior constituent in car transmissions
Ident-Nr.K.6.12.2.1 101_1183D020528
Source: Lechner
K.6.12.2.2.1.7.2.0_GLEA
e) Synchronisation
without locking device
f) Servo-locking device
g) hydr. operated clutch
for transmissions
h) hydr. operated brake for
planetary transmission
Interior constituent in car transmissions
Ident-Nr.K.6.12.2.1 101_1184E 020528
Source: Lechner
K.6.12.2.2.1.7.2.0_GLEA
improves gearshift comfort and safety
(passenger car 100%, truck >60%)
adjusts circumferential speeds of the elements to be
joined in short time (0,1-0,3s) and with small forces
often critical component
not necessary if
small increment < 1,15 or
small masses to be synchronized (e.g. motor bikes)
Synchronizations
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
adjustment of speed by force closure with
appropriate working surface pairs (cone) in
connected status after synchronisation
torque transmission by form closure via
appropriate working surface pairs
Synchronization - Principle
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
1 idler running on needle
roller bearings
2 intermediate ring with spline
profile and friction cone
3 synchro ring with counter
cone and locking serration
4 synchro hub with internal
spline profile for form
closure with gear shaft and
external spline profile for
the gearshift sleeve
5 gearshift sleeve with
Internal spline profile and
circular groove
6 transmission shaft
One-cone synchronization (ZF-B)
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
Gear Shifting - Synchronisation
Ident-Nr.K.6.3.9.6.1 111_008E 990804
K.6.12.2.2.1.7.2.0_GLEA
Source: Diehl
Survey of Synchro Ring with 3-D-
Coordinate - Measuring Machine
Ident-Nr.K.5.3.4.6 104_960E 000717
K.6.12.2.2.1.7.2.0_GLEA
One-cone synchronization,
System Borg-Warner
Ident-Nr.
1- idler gear running on needle roller bearings
2- intermediate ring with spline
3- synchro ring
4- synchro hub with internal spline
5- coil spring
6- ball pin
7- pressure pad
8- gearshift sleeve
K.6.12.2.2.1.7.2.0_GLEA
2- intermediate ring with spline
3- synchro ring
4- synchro hub with internal
gearing
5- coil spring
6- ball pin
7- pressure pad
8- gearshift sleeve
Operation of synchronization
Ident-Nr.
K.6.12.2.2.1.7.2.0_GLEA
specify tooth number and modulus for the pinions of all
gearpairs
calculate stresses (
and p
) considering the different

operating times
verify that wheels have the intended gear ratio (deviations
might occur due to the identical center distance)
calculate bending and torsion stress of the shaft and limit its
elastic deflection
dimensioning of bearings
calculation of mechanical and thermal load of synchro rings
Dimensioning of transmissions with layshafts
Ident-Nr.
K.6.12.2.2.1.7.3.0_GLEA
Cylindrical_Gears_Applications_Cylindrical_Gears_with_Flangemounted_Motor
6.12.2.2.1.7.3 Cylindrical Gear Transmission with
Flange-Mounted Motor
Ident-Nr.
K.6.12.2.2.1.7.3.0_GLEA
Components of the Transmission
Ident-Nr.
K.6.12.2.2.1.7.3.0_GLEA
Assembly
Ident-Nr.
K.6.12.2.2.1.7.3.0_GLEA
Transmission without Motor
Ident-Nr.
K.6.12.2.2.1.7.4.0_GLEA
Cylindrical_Gears_Applications_Flatbed_Turning_Machine
6.12.2.2.1.7.4 Flat-Bed Turning Machine
Ident-Nr.
feed
transmission
headstock
tool
holder
compound carriage
tailstock
longitudinal carriage
Quelle: Werkzeugmaschinen Maschinenarten und Anwendungsbereiche (M. Weck)
K.6.12.2.2.1.7.4.0_GLEA
Cylindrical_Gears_Applications_Flatbed_Turning_Machine
Transmission of Flat-Bed Turning Machine
Ident-Nr.
multi-step reduction gear
compound carriage
lead screw
feed shaft
feed transmission
longitudinal carriage
Quelle: Werkzeugmaschinen Maschinenarten und Anwendungsbereiche (M. Weck)
K.6.12.2.2.1.7.5.0_GLEA
Cylindrical_Gear_Applications_Gear_Shaping_Machine
6.12.2.2.1.7.5 Gear Shaping Machine (Gear
Generator)
Ident-Nr.
K.6.12.2.2.1.7.5.0_GLEA
Cylindrical_Gear_Applications_Gear_Shaping_Machine
Schematic View of the Gear Generator
Ident-Nr.
K.6.12.2.2.1.7.6.0_GLEA
Cylindrical_Gears_Applications_Turbo_Transmission
n
= 44000 U/min
6.12.2.2.1.7.5 Turbo Spur Gear Transmission
Ident-Nr.K.6.12.2.1.7101_1776E041217
K.6.12.2.2.1.7.6.0_GLEA
Quelle: Allianz Report -Bildnachweis: BHS Cincinnati Getriebetechnik
Turbo Transmission with Torsion Shafts
Ident-Nr.K.6.12.2.1.7101_1776E041217
K.6.12.2.2.1.7.6.0_GLEA
Typical 75-MW turbo transmission with double helical gearing
to connect a gas turbine to a generator
Turbo Transmission
Ident-Nr.K.6.12.2.1.7101_1776E041217
K.6.12.2.2.1.7.6.0_GLEA
Double Helical Gearing
Ident-Nr.K.6.12.2.1.7101_1776E041217
K.6.12.2.2.1.7.7.0_GLEA
Cylindrical_Gears_Applications_Car_Doubleclutch_Transmission
Transmission systems in cars
Ident-Nr.
automated
gearbox
CVT
AT
MT
ECM
DSG / PSG
Source: ZF-Sachs, LuK, AutoMagazin24
K.6.12.2.2.1.7.7.0_GLEA
Dual Clutch Gearbox VW
Direct Shift Gearbox DSG
Ident-Nr.K.6.9.3.7 101_1617D031117
Source: ATZ 11/2003
K.6.12.2.2.1.7.7.0_GLEA
DSG- Force flow
Ident-Nr.K.6.9.3 101_1618D031117
Source: ATZ 11/2003
M

K.6.12.2.2.1.7.7.0_GLEA
DSG- Main cut
Ident-Nr.K.6.9.3 101_1619D031117
Source: ATZ 11/2003
Oil pump
Mechatronics
Reverse gear shaft
Spring-damper-element
Dual Clutch
Output shaft 2
Drive shaft 1
Drive shaft 2
Output shaft 1
Axle drive
with parking break gear
K.6.12.2.2.1.7.7.0_GLEA
Dual Clutch
Ident-Nr.K.6.9.3 101_1620D031117
Source: ATZ 11/2003
Sealing ring
Piston
External disc
carrier
Inner disc carrier
Input collar
Carrier plate
Main collar
K.6.12.2.2.1.7.7.0_GLEA
Gearshift actuator
Ident-Nr.K.6.9.3 101_1621D031117
Source: ATZ 11/2003
Magnet
Travel sensor
Piston
Gear positioner
Cylinder
Gear positioner
Ball lining
Localisation
K.6.12.2.2.1.7.7.0_GLEA
Oil system
Ident-Nr.K.6.9.3 101_1622D031117
Source: ATZ 11/2003
Mechatronics
Oil pump
Suctionfilter
Shower
Pressure filter
Oil cooler
Dual Clutch
Cylinder
Gear positioner
Gearbox oil system
Gearbox oil pump structure
K.6.12.2.2.1.7.7.0_GLEA
Mechatronics-module
Ident-Nr.K.6.9.3 101_1623D031117
Source: ATZ 11/2003
Control valve
Gear positioner
Clutch-modulators
K1/K2
Hydraulic module
Vehicle-sided plugs
Hybrid
U-connector to the electrohydraulic
control unit
Electronic control unit with
Sensorcluster
K.6.12.2.2.1.7.7.0_GLEA
Regulation system
Ident-Nr.K.6.9.3 101_1624D031117
Source: ATZ 11/2003
K.6.12.2.2.1.7.7.0_GLEA
User interface
Ident-Nr.K.6.9.3 101_1625D031117
Source: ATZ 11/2003
K.6.12.2.2.1.7.7.0_GLEA
Performance data
Ident-Nr.K.6.9.3 101_1626D031117
Source: ATZ 11/2003
Acceleration
maximal
Velocity
Consumption
V
e
l
o
c
i
t
y
Automatic
Gearbox
Manual
Gearbox
to to
C
o
n
s
u
m
p
t
i
o
n
K.6.12.2.2.1.7.7.0_GLEA
Summary
Ident-Nr.K.6.9.3 101_1627D031117
Driving
Performance
Fuel
Consumption
Driving
Comfort
Driving dynamics
Driving fun
Source: ATZ 11/2003
K.6.12.2.3.1.1.0.0_GLEA
Bevel_Gears_Introductions
6.12.2.3 Bevel Gears
6.12.2.3.1 General Fundamentals
Ident-Nr.
K.6.12.2.3.1.1.0.0_GLEA
deflection of energy flow (mostly 90) if axes
intersect in one point.
arrangement:
Ident-Nr.
K.6.12.2.3.1.1.0.0_GLEA
Bevel Gear Mechanisms
Ident-Nr.
Attention, cone apexes
must be positioned precisely !
precise manufacturing
design of bearing arrangement
axial forces
D-Tip =
K.6.12.2.3.1.4.1.0_GLEA
Bevel_Gears_Types_and_Properties_Introduction
6.12.2.3 Bevel Gears
Ident-Nr.
K.6.12.2.3.1.4.2.0_GLEA
Bevel_Gears_Tooth_Profiles_of_Bevel_Gears
6.12.2.3.1.4.1 Tooth ProfilesTraces of Bevel Gears
Ident-Nr.
Tooth shapes for bevel gears (on the unrolled cylinder generated surface)
a-straight bevel gear, b- helical bevel gear, c-spiral gear,
d-palloid gear (involute tooth trace), e-circarc gear (round-flank toothing)
K.6.12.2.3.1.4.2.0_GLEA
Bevel_Gears_Tooth_Profiles_of_Bevel_Gears
spur gearing
Examples for tooth traces
Ident-Nr.
cyclo-palloid-
spiral gearing
K.6.12.2.3.1.4.3.0_GLEA
Straight_Toothed_Bevel_Gears
gear ratio:
6.12.2.3.1.4.3 Straight Toothed Bevel Gears
Ident-Nr.
u =
d
e2
d
e1
shaft angle (angle enclosed by the
axles of the bevel gear pair):
= 6
1
+ 6
2
K.6.12.2.3.1.4.3.0_GLEA
u
ac
external tip diameter
u
c
external reference
diameter
u
Ic
external root diameter
u
m
mean reference
diameter
u
aI
internal root diameter
b face width
z tooth number
t
b
locating distance
t
H
auxiliary plane distance
t
E
tip diameter distance
Ident-Nr.
alternative names:
external outside
internal inside
K.6.12.2.3.1.4.3.0_GLEA
gear ratio:
Ident-Nr.
partial shaft angle:
tip diameter :
ext. reference diameter:
root diameter:
pitch:
cone distance:
external modulus:
mean modulus:
internal modulus:
i =

drIvIng
drIvcn
=
n
drIvIng
n
drIvcn
1
= aictan
sin
u + cos
;

2
= aictan
sin
1
u
+ cos
u = z m
u
a
= u + 2 h
a
cos
u
I
= u - 2 h
I
cos
p = m
R =
u
2 sin
m
c
=
u
c
z
m
m
= m
c
1 -
u,S b
R
c
m
I
= m
c
1 -
b
R
c
K.6.12.2.3.1.4.3.0_GLEA
addendum angle:
dedendumangle:
tip angle:
root angle:
Ident-Nr.
tan
a
=
h
a
R
tan
I
=
h
I
R
a
= +
a
I
= -
I
bevel gears deflect the energy flow if the axes
intersect in one point
pitch cone angles must intersect in exactly one point,
otherwise the following will occur:
uneven load distribution or jamming
increased wear and noises
D-Tip =
K.6.12.2.3.1.4.3.0_GLEA
driving wheel 1
tangential force:
axial force:
radial force:
Tooth loads on spur toothed bevel gears
Ident-Nr.
driven wheel 2
tangential force:
axial force:
radial force:
F
t1
=
2 N
1
u
w1
F
a1
= F
t1
tan sin
1
F
r1
= F
t1
tan cos
1
F
a2
= F
t2
tan sin
2
F
r2
= F
t2
tan cos
2
F
t2
= F
t1
K.6.12.2.3.1.7.0.0_GLEA
Bevel_Gears_Applications
Ident-Nr.
K.6.12.2.3.1.7.0.0_GLEA
Partial cut Two-Stage Spiral Bevel Gear
Transmission
Ident-Nr.
K.6.12.2.3.1.7.0.0_GLEA
Differential Gear Hummer H3
Ident-Nr.
Quelle: General Motors
K.6.12.2.4.1.4.1.0_GLEA
Worm_Gears_Types_and_Properties_Introduction
6.12.2.4 Worm Gears
Ident-Nr.
K.6.12.2.4.1.4.2.0_GLEA
Worm_Gears_Types_of_Worm_Gears
6.12.2.4.1.4.2 Types of Worm Gears
a - cylindrical worm gear (cylinder worm globoid worm
wheel)
b - contrate worm gear (enveloping worm and spur gear),
c and d double enveloping worm gear pair (enveloping
worm globoid worm wheel)
6.12.2.4 Worm Gear Mechanisms
Ident-Nr.
K.6.12.2.4.1.4.2.0_GLEA
Design requirements:
manufacturing precision surface
mating material (hardened, ground,
wormagainst phosphor- or Al- multi-alloy bronze)
rigid bearing arrangement and accurate assembly
best lubrication (hypoid oil)
sufficient heat dissipation
Worm gear pair
Ident-Nr.
K.6.12.2.4.1.4.2.0_GLEA
Cylindrical Worm Gear
Ident-Nr.
K.6.12.2.4.1.4.3.0_GLEA
Worm_Gears_Measurements_of_Cylindrical_Worm
gear ratio: u =
z
2
z
1
z
1
: tooth number of worm
z
2
: tooth number of worm gear
common tooth numbers of the worm for
different transmission ratios:
6.12.2.4.1.4.3 Dimensions of the Cylindrical Worm
Ident-Nr.
i= 5...10 1015 1530 >30
z
1
4 3 2 1
K.6.12.2.4.1.4.3.0_GLEA
diametral quotient
of worm:
q =
d
m1
m
Axial, normal and transverse section on cylindrical
worm
Ident-Nr.
describes the
worm shape,
especially its section
modulus against
deflection
axial section
transverse section
normal
section
K.6.12.2.4.1.4.3.0_GLEA
center distance: a =
d
m1
+d
2
2
tip diameter: u
a1
= u
m1
+2 h
a1
root diameter: u
I1
= u
m1
-2 h
I1
tip diameter: u
a2
= u
2
+2 h
a2
root diameter: u
I2
= u
2
-2 h
I2
pitch angle: tan
m
=
mz
1
d
m1
=
z
1
q
normal pitch: p
n
= p cos
m
normal pressure angle: tan
n
= tan cos
m
Calculations on cylindrical worm
Ident-Nr.
K.6.12.2.4.1.4.3.0_GLEA
: effective friction angle
n
: normal pressure angle
Tooth loads on cylindrical worm
Ident-Nr.
D-Tip:
The high axial loads must be
considered during the
dimensioning of the bearings.
cog
K.6.12.2.4.1.4.3.0_GLEA
worm (gear 1) drives worm wheel (gear 2)
efficiency: =
P
2
P
1
=
F
t2v
2
F
t1
v
1
F
t1
= F
1
sin
m
+
F
t2
= F
2
cos
m
+
v
2
= v
1
tan
m
=
tan y
m
tan(y
m
+8)
forces on worm wheel:
tangential force: F
t2
=
P
2
v
2
axial force: F
a2
= F
t2
tan(
m
+ )
radial force: F
r2
= F
t2

cos ptan u
n
cos(y
m
+p)
Forces on cyclindrical worm
Ident-Nr.
from equilibrium of forces, it
follows:
F
1
= F
2
> u
forces on worm:
tangential force: F
t1
= F
a2
axial force: F
a1
= F
t2
radial force: F
r1
= F
r2
K.6.12.2.4.1.4.3.0_GLEA
worm wheel (gear 2) drives worm (gear 1)
(friction forces change their direction of effect by 180!)
efficiency: p =
P
1
P
2
=
tan(y
m
-p)
tan y
m
for y
m
p it follows, p u => self - locking
Self - locking
Ident-Nr.
D-Tip:
Self-locking can be useful for the design:
desired in order to avoid uncontrolled reverse movements after
switching off the drive.
K.6.12.2.4.1.7.0.0_GLEA
Worm_Gears_Applications
6.12.2.4.1.7 Applications Examples
Ident-Nr.
K.6.12.2.4.1.7.0.0_GLEA
Applications Examples
Ident-Nr.
K.6.12.2.4.1.7.0.0_GLEA
Integrated Coupling Actuator
Ident-Nr.
master cylinder
forcing lever
equalizer
spring
bolt
servo-motor
driving worm
worm wheel
worm wheel
shaft
integratedmaster controller
displacement
sensor
K.6.12.2.5.1.1.0.0_GLEA
Planetary_Gear_Mechanisms_Introduction
Planetary gear systems differ from the transmissions
dealt with so far by the following:
additional gear wheels, the axes of which rotate around a
central axis
high power density
symmetrical design
good efficiency
torque division possible (summation or differential gear)
6.12.2.5 Planetary Gear Mechanisms
Ident-Nr.
K.6.12.2.5.1.1.0.0_GLEA
Planetary_Gear_Mechanisms_Introduction
Introduction
Ident-Nr.
K.6.12.2.5.1.4.1.0_GLEA
Planetary_Gears_Types_and_Properties_Introduction
Ident-Nr.
K.6.7.1.4.3.0.0.0_GLDA
6.12.2.5.1.4.2 Planetary Gears
Ident-Nr.
Planetary Gear
sun gear
planetary
gear
ring gear
planet carrier / revolving arm
K.6.7.1.4.3.0.0.0_GLDA
planet gear
Planetary gear set
Ident-Nr.
sun gear
ring gear
planet carrier
n
H
n
St
n
S
K.6.7.1.4.3.0.0.0_GLDA
Example: drive: sun gear and ring gear (speed is given)
output: planet carrier (speed is sought)
Determination of gear ratio by
means of Kutzbachs plan
Ident-Nr.
all radii in the Kutzbach plan are operating pitch circle radii
sun gear
planet
wheel
ring gear
planet carrier
sun gear
ring gear
planet wheel
radius r
v = i
r
H
r
St
r
S
v
H
v
St
v
S
sought: i
S-St
=
n
5
n
5t
v
St
=
v
5
+v
H
2
n
St
=
r
5
n
5
+r
H
n
H
2r
5t
i
St

St
=
i
S

S
+ i
H

H
2
i
S-St
=
2 r
St
n
S
i
S
n
S
+ i
H
n
H
(where = 2f = 2n 6u
[n]=rpm)
K.6.7.1.4.3.0.0.0_GLDA
Without torque division (i. e. one element fixed), 7 different transmissions are possible with a
single-support planetary gear set.
2 reverse
5 forward (one stage for blocked
transmission)
Example 1:
drive: sun gear (speed given, v
S
)
output: planet carrier (speed sought, v
St
)
fixed: ring gear (v
H
= 0)
i =
n
5
n
5t
= 1 +
Z
H
Z
5
Example 2:
drive: sun gear (given: v
S
)
output: ring gear (sought: v
H
)
fixed: planet carrier (v
St
= 0)
i =
n
5
n
H
= -
Z
H
Z
5
Single-support planetary gear set
Ident-Nr.
v
St
v
S
v
H
v
S
v
v
r
r
K.6.7.1.4.3.0.0.0_GLDA
Example 3:
drive: planet carrier (given: v
St
)
output: ring gear (sought: v
H
)
fixed: sun gear (v
S
= 0)
i =
n
5t
n
H
=
Z
H
Z
5
+Z
H
Since the interchange of drive shaft and output shaft is too complicated,
multiple-carrier planetary gears (e. g. Simpson- or Ravigneaux-planetary
gears) are employed in vehicle transmissions.
Ident-Nr.
v
H
v
St
v
r
K.6.7.1.4.3.0.0.0_GLDA
v
S
=
S
i
S
v
H
=
H
i
H
v
St
= v
H
+
v
S
-v
H
2
=
v
S
+v
H
2
Definition:
stationary/fixed-axis gear ratio*: planet carrier is fixed!
stationary gear ratio of sun gear
(planet carrier standing still)
stationary gear ratio of ring gear
(planet carrier standing still)
transmission ratio sun gear/p.c.
(ring gear standing still)
Ident-Nr.
* compare with:
6.12.2.1.3. "Stationary
transmission"=fixed-axis
gear transmission
i
O,S
=

S
H
= -
i
H
i
S
= -
Z
H
Z
S
i
O,H
=

H
S
=
1
i
O,S
i
S,St
=

S
St
= 1 -i
O,S
K.6.7.1.4.3.0.0.0_GLDA
angular speeds:
ring gear fixed
Equilibrium of forces of the planet gear
Ident-Nr.
F
SP
force from sun gear on planet gear
F
HP
force from ring gear on planet gear
r
S
F
SP
F
St
F
HP
F
HP
= -
N
H
i
H
F
SP
= -
N
S
i
S
N
H
N
S
=
i
H
i
S
=
Z
H
Z
S
sun gear:
S
= tan
S
=
v
5
r
5
planet carrier:
St
= tan
St
=
v
5
r
5
=
v
5t
r
5
+r
P
=
m
5
1-I
O,5
ring gear:
H
= u
K.6.7.1.4.3.0.0.0_GLDA
sun gear: F
SP
= -
M
5
r
5
ring gear: F
HP
= -
M
H
r
H
planet carrier: F
St
= -2F
SP
N
ST
= F
ST
i
S
+i
P
Forces and torques: circumferential forces
calculated from the equilibrium
Ident-Nr.
F
HP
F
SP
F
St
M ( instantaneous
center of rotation if ring
gear is standing still)
K.6.7.1.4.3.0.0.0_GLDA
M
5
r
5
=
M
H
r
H
;
M
5t
r
5
+r
P
= -
2M
5
r
5
sun gear: N
S
= N
H
r
5
r
H
= -
1
2
r
5
r
5
+r
P
N
St
ring gear: N
H
=
r
H
r
5
N
S
= -
1
2
r
H
r
5
+r
P
N
St
planet carrier: N
St
= -2
r
5
+r
P
r
5
N
S
Torques
Ident-Nr.
K.6.12.2.5.1.4.2.1_GLEA
Planetary_Gear_Animation_Kutzbachplan
Animation Kutzbachs Plan
Ident-Nr.
K.6.12.2.5.1.6.2.0_GLEA
Planetary_Gear_Mechanisms_Selection_Criteria
smallest transmission ratio
limit: bearing size of planet gears
largest transmission ratio
limit: minimum distance of planet
gears
6.12.2.5.1.6 Selection
6.12.2.5.1.6.2 Selection Criteria
Ident-Nr.
planet carrier
minimum 3 m
K.6.12.2.5.1.6.2.0_GLEA
Planetary_Gear_Mechanisms_Selection_Criteria
Transmission ratios for
Planetary Gear Trains
Ident-Nr.K.6.12.2.5 101_178E 000408
1. ring gear fixed, driving
sun wheel
large transmission into
low.
2. sun gear fixed, driving
ring gear
small transmission into
low
3. planet carrier fixed,
driving sun gear
reverse of sense of rotation
with transmission into low
K.6.12.2.5.1.7.0.0_GLEA
Planetary_Gear_Mechanisms_Applications
Ident-Nr.
1 planet gears
1
output output
Source: FAG
2
2 sun gears
3
3 rotating housing
(carrier)
Planetary
gear train
using bevel
gears
Final drive of a
passenger car
K.6.12.2.5.1.7.0.0_GLEA
Planetary gear train with bevel gears
Ident-Nr.
Planetary gear train with bevel gears
ring gear
differential cage
right
axle shaft
left
axle shaft
differential
bevel gears
driving bevel gear
K.6.12.2.5.1.7.0.0_GLEA
Transmissions Differential Gear
Ident-Nr. K.7.4 111_013E 990809
K.6.12.2.5.1.7.0.0_GLEA
Planetary Gear Train
Ident-Nr. K.6.12.2.5101_620E 980706
gear case
sun gear of 1
st
stage
( toothed shaft or pinion )
sun gear of 2
nd
stage
ring gear for 1
st
and 2
nd
stage
planet gears of 1
st
and 2
nd
stage
slow shaft
bearing of slow
shaft (2 ball bearings)
gear cover
fast shaft
bearing of fast shaft
(needle roller bearing)
planet gears of 2
nd
stage
planet carrier of 1
st
stage
planet gears of 1
st
stage
K.6.12.2.5.1.7.0.0_GLEA
1: output bearing
2: housing
3: Circular Spline
Harmonic Drive Transmission
Ident-Nr. K.6.12.2.5.7103_126E 990203
4: Wave Generator
5: Flexspline
Quelle: Harmonic Drive
K.6.12.2.5.1.7.0.0_GLEA
Quelle: HD
Ident-Nr. K.6.12.2.5.7103_127E 990202
K.6.12.2.5.1.7.0.0_GLEA
Ident-Nr. K.6.12.2.5.7111_183E 050524
K.6.12.2.5.1.7.0.0_GLEA
Quelle: Kreuzer
Cyclo Transmission
Ident-Nr. K.8.11.3.4103_145E 990209
K.6.12.2.5.1.7.0.0_GLEA
A disc driven by an eccentric disc rolls off a ring performing
double-circle shaped movements, i.e.
it performs cycloidal movements.
In order to avoid sliding during the roll-off, the system must
use form closure.
Principle of a cyclo transmission
Ident-Nr.
system principle
ring
disc
eccentric
drive shaft
K.6.12.2.5.1.7.0.0_GLEA
As the eccentric camrotates, it rolls the cycloid discs around
the internal circumference of the stationary ring gear. The
resulting action is similar to that of a wheel rolling around the
inside of a ring. As the wheel (cycloid disc) travels in a
clockwise path around the ring (ring gear housing), the wheel
itself turns slowly on its own axis in a counter-clockwise
direction.
Key plan of cyclo transmission
Ident-Nr.
system principle
rollers
cycloid disc
rolling element
eccentric cam
drive shaft
drive pins of
ring gear
output shaft
K.6.12.2.5.1.7.0.0_GLEA
Cyclo transmissions have two cycloid discs with an offset of
180:
in order to achieve compensation of moments of inertia
in order to double the number of pins carrying the load
Section drawing of cyclo transmission
Ident-Nr.
section drawing
rollers
cycloid disc
eccentric cam
drive shaft
drive pin
output shaft
K.6.12.3.1.1.0.0.0_GLEA
Chain_Drive_Transmissions_Introduction
6.12.3.1 General Fundamentals
6.12.3 Chain Drive Transmissions
Ident-Nr.
K.6.12.3.1.2.0.0.0_GLEA
Chain_Drive_Tranmssions_Basic_Functions_and_Principles
Usually form closure is used for the power transmission
Special case: CVT* chain drives (here: force closure)
6.12.3 Chain Drives
Ident-Nr.
K.6.12.3.1.2.0.0.0_GLEA
Chain_Drive_Tranmssions_Basic_Functions_and_Principles
Evaluation
Ident-Nr.
no slip
multiple inputs
large center distances are possible
lowstresses on shafts and bearings since preloading forces are low
easy to assemble
can be used in hot environments as well (life time )
wear in joints leads to larger chain pitch
changes of chain length have to be compensated (e.g. idlers)
unsuitable for periodic reversion of sense of rotation (idle time due to
sag)
chain vibrations occur at strong periodic shock-type loads and at high
circumferential speeds
+
+
+
+
+
+
-
-
-
-
K.6.12.3.1.3.0.0.0_GLEA
Chain_Drive_Transmisions_Types_and_Properties
roller chains
movable rollers protect sprocket
from wear, sliding motions take
place between bushing and rollers.
inverted tooth chains (silent
chains)
On every pin, plates are beaded
side by side, where every plate
belongs to the next chain link.
Ident-Nr.
roller chain
DIN 8187
pin bushing
roller
toothed chain, non-standardized
center guide link
K.6.12.3.1.3.0.0.0_GLEA
Chains
Ident-Nr.
simple roller chain double roller chain triple roller chain
plate shape
straight or curved
l
o
c
k
i
n
g
s
i
d
e
l
o
c
k
i
n
g
s
i
d
e
l
o
c
k
i
n
g
s
i
d
e
Quelle: Decker
K.6.12.3.1.3.0.0.0_GLEA
Chains
Ident-Nr.
a) bushingchain b) detachable link chain
e) roller chain f) rotarychain
c) Galle chain, draw-benchchain d) bushdrivingchain
h) invertedtoothedchain
g) leaf chain
center guide link
Quelle: Decker
K.6.12.3.1.3.0.0.0_GLEA
Roller Chain
Ident-Nr.
K.6.12.3.1.3.0.0.0_GLEA
Simple Roller Chain (DIN 8187)
Ident-Nr.K.6.12.3 109_001E 990204
K.6.12.3.1.3.0.0.0_GLEA
Drive- and load-type
specific factors:
Factors influencing the life time of chains
Ident-Nr.
Chain specific factors:
Drive specific parameters:
- joint motions
- drive arrangements
- adjustment/guidance
- lubrication
Static parameters:
- tensile chain force
- centrifugal force
Dynamical parameters:
- shock-type loads
- polygon effect
- running-in stresses
- load cycle/frequency
- pulsating stress
Dimensioning:
- single parts
- complete setup
Materials:
- type
- quality
- heat treatment
- surface treatment
Processing:
- parts production
- assembly precision
- initial greasing during
manufacture
breaking strength
wear resistance
fatigue strength
K.6.12.3.1.3.0.0.0_GLEA
A chain runs between two conical pulley pairs. The pulleys
can be shifted in the axial direction, so the groove widens
on the drive shaft and simultaneously narrows on the
output shaft, and vice versa. Thus, raceway radii and the
transmission ratio change continuously.
Continuously Variable Transmission Chain Drives
Ident-Nr.
K.6.12.3.1.3.0.0.0_GLEA
Principle of a CVT Transmission
Ident-Nr.
engine torque
torque converter and
start-up clutch
transmission
dynamical wheel
torque
wheel
chain
driven
pulley
motor
driving
pulley
friction coefficient
Quelle: LuK
K.6.12.3.1.5.0.0.0_GLEA
Chain_Drive_Transmissions_Design_Indications
Evaluation of various chain gear arrangements
6.12.3.1.5 Design Indications and Interface
Requirements
Ident-Nr.
unfavorable
favorable
very unfavorable
support wheels
K.6.12.3.1.7.0.0.0_GLEA
Chain_Drive_Transmissions_Applications
CVT chain drive
6.12.3.1.7 Applications (Examples)
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
CVT chain drive
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
CVT chain drive
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
CVT chain drive
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
CVT Chain Drive
Ident-Nr. K.7.4.3.3 101_899E 001801
K.6.12.3.1.7.0.0.0_GLEA
CVT for 250 Nm (LuK)
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
Uneven Plate Load Distribution
Ident-Nr.
Uneven load distribution on the plates of a CVT chain
Quelle: LuK
K.6.12.3.1.7.0.0.0_GLEA
Quelle: Chevrolet
Chain Transmission
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
Quelle: Mercury
Chain Transmission
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
Quelle: LuK
Construction and Components of the LuK-
P.I.V-CVT-Chain
Ident-Nr. K.6.12.3.4106_093E 990111
K.6.12.3.1.7.0.0.0_GLEA
Multiple Chain Drive
Ident-Nr.
K.6.12.3.1.7.0.0.0_GLEA
Quelle: all4magazines 24.6.2003
Cone-ring Transmission
Continously Variable Transmission
Ident-Nr.K.6.12.5.1.7 101_1478E 030624
K.6.12.3.1.7.0.0.0_GLEA
Quelle: HCVT
High torque CVT
Ident-Nr. K.6.12.4.1.7101_1851D060413
K.6.12.3.1.7.0.0.0_GLEA
High torque CVT
Ident-Nr. K.6.12.4.1.7101_1849D060413
K.6.12.3.1.7.0.0.0_GLEA
Quelle: HCVT
High torque CVT
Ident-Nr. K.6.12.4.1.7101_1852D060413
K.6.12.3.1.7.0.0.0_GLEA
High torque CVT
Ident-Nr. K.6.12.4.1.7101_1850D060413
Quelle: HCVT
K.6.12.4.1.1.0.0.0_GLEA
Belt_Drives_Introduction
IPEK Institute of Product Engineering
www.kit.edu
K.6.12.4.1.1.0.0.0_GLEA
Belt_Drives_Introduction
6.12.4 Belt Drive Transmissions
6.12.4.1 General Fundamentals
Ident-Nr.
K.6.12.4.1.2.0.0.0_GLEA
Belt_Drive_Transmission_Basic_Functions_and_Principles
6.12.4.1.2 Basic Function and Principles
6.12.4 Belt Drives
Ident-Nr.
Form closure:
toothed belt
Force closure:
flat belt
V-belt
round belt
K.6.12.4.1.2.0.0.0_GLEA
Belt_Drive_Transmission_Basic_Functions_and_Principles
silent operation due to force closure
easy to assemble, relatively low accuracy required
large center distances become bridgeable
no lubrication, minimum maintenance
lightweight
multiple drives
large space requirements
high shaft stresses (1,2 - 2,5 times circumferential load) due to preload
friction coefficient and belt stretch dependent on ambient conditions (e.g.
dust, dirt, oil, temperature and humidity)
applicable only in limited temperature ranges
running noise of toothed belts
Evaluation
Ident-Nr.
+
+
+
+
+
+
-
-
-
-
-
K.6.12.4.1.4.0.0.0_GLEA
Belt_Drive_Transmission_Types_and_Properties
V-belt
Ident-Nr.
Quelle: Habehauer, Bodenstein
K.6.12.4.1.4.0.0.0_GLEA
V-belts
V-belt pulley for narrow V-belts
Ident-Nr.
Quelle: Habehauer, Bodenstein
K.6.12.4.1.4.0.0.0_GLEA
Toothed belts
Ident-Nr.
The neoprene tooth:
K.6.12.4.1.4.0.0.0_GLEA
Toothed belts
Ident-Nr.
The glass fiber tensile body
K.6.12.4.1.7.0.0.0_GLEA
Belt_Drive_Transmissions_Applications
Stone crusher (power input 800kW, crush performance 1000t/h)
Ident-Nr. K.6.12.4.1.4101_1784E 050127
K.6.12.4.1.7.0.0.0_GLEA
Textile machine
Ident-Nr. K.6.12.4.1.4101_1784E 050127
K.6.12.4.1.7.0.0.0_GLEA
Quelle: Sonderheft Antriebstechnik fluid
Double Drive Belt (Grinding Machine)
Ident-Nr. K.6.12.4.1.4101_1784E 050127
K.6.12.4.1.7.0.0.0_GLEA
CVT- belt drive dry
Ident-Nr. K.6.12.4.1.4101_1784E 050127
K.6.12.4.1.8.0.0.0_GLEA
Belt_Drive_Transmissions_Dimensioning
6.12.4.1.8 Dimensioning Force- and friction
situation for belt drives
Ident-Nr.
stop c
pulley a
a) b) c)
belt b
F
N
F
F
1
F
2
F
i
F
i
F
i
F
N
F
i
F
i
F
i
F
N
/2

/2
K.6.12.4.1.8.0.0.0_GLEA
F
I
= F
N

F
N
= F
I
2
+ F
I
+F
I

2
= F
I
+F
I
2
= F
I

F
I
F
I
=
Integration yields:
ln
F
1
F
2
=
Eytelweins formula:
F
1
F
2

Equilibrium of forces on an infinitely small belt
element (for small angles )
Ident-Nr.
K.6.12.4.1.8.0.0.0_GLEA
Loads on running driving belt
Ident-Nr.
Quelle: Decker
K.6.12.7.1.0.0.0.0_GLEA
Electric_Transmissions_Introduction
Electric Transmissions
Connecting Link between the two axles is an electric field
Electric Transmissions make it possible to realize a
continously variable transmission
6.12.7 Electric transmissions
Ident-Nr.
driving
machine
driven
machine
E - Motor
Inverter
Generator
K.6.12.7.2.0.0.0.0_GLEA
Electric_Transmissions_Basic_Funktions_and_Principels
6.12.7.1.2 basic funktions and principles
Ident-Nr.
Electric transmissions
Electric transmissions are buildt up out of:
A generator
An electric motor
LSS electric field
Mechanical
power
Mechanical
power
Generator Motor
K.6.12.7.3.0.0.0.0_GLEA
Electric_Transmissions_Applications
6.12.7.2 Applications
Ident-Nr.
EPG- elektric planetary gear
Drive trainToyota Prius
K.6.12.7.4.0.0.0.0_GLEA
Electric_Transmissions_Applications_EPG
6.12.7.2.2 EPG - Electric planetary gear
Ident-Nr.K.6.12.2.5.1.4.2 101_1865 D 060516
Quelle: Antriebstechnik Special II/2001
Revolution for the drive train??
K.6.12.7.4.0.0.0.0_GLEA
new abrasion free, electrical CVT
Electric planetary gear
Ident-Nr.
Quelle: Ingelheim Consult
K.6.12.7.4.0.0.0.0_GLEA
Both electric machines are connected to each other. Under
disregard of the electric losses the following terms count:
Power P
a
= P
b
N
a

a
= N
b

b
Ident-Nr.
K.6.12.7.4.0.0.0.0_GLEA
One of the two machines is transformed into a machine with
external rotor. This doesnt have effects on the basic function.
N
a

a
= N
b

b
;
a
= -
b
;
N
a
= -
N
b

Ident-Nr.
K.6.12.7.4.0.0.0.0_GLEA
Parts of the windings are connected non-rotatably and fitted
to a shaft. That construction is equal a planetary gear with a
planet carrier which stands still. Therefore the rotation speed
equation of a planetary gear applies.
b
=

a
-u
b
-u
=

a
-
s
b
-
s
= -;
N
a
N
b
= -
1

Ident-Nr.
K.6.12.7.4.0.0.0.0_GLEA
Axle b is now hold constant, the planet carrier can move =
EPG electric planetary gear
a
-
s
b
-
s
=

a
-
s
u -
s
= -

s
=

a
1 +
N
s
= 1 + N
a
Ident-Nr.
K.6.12.7.4.0.0.0.0_GLEA
Advantage:
Wear- and maintenance-free
Oil free (dry-running)
Torsionally flexible and vibration-reducing
Torque limitation realisable (overload protection)
can be installed independent of position
High rotation speed possible
High torque possible
Ident-Nr.
K.6.12.7.5.0.0.0.0_GLEA
Electric_Transmissions_Applications_Toyota_Hybrid
6.12.7.2.3 Toyota hybrid drive
6.12.7.2 applications
Ident-Nr.
Electric CVT in the hybrid drive
K.6.12.7.5.0.0.0.0_GLEA
Drive line off Hybrid vehicles
Ident-Nr.
Drive-
shaft
Motor power
gasoline
combustion-
engine
Breaks
transmission
selector lever
accelerator pedal
air conditioning
Vehicle
speed
Motor power
electric
recuperation
Electric-
motor
Battery
Generator
K.6.12.7.5.0.0.0.0_GLEA
Toyota P112 Hybrid-Transaxle
Seriell-parallel Hybridsystem
Ident-Nr.
Oil Pump E- Motor
Planetary gear
Sun
wheel
Planet
wheel
annulus
Chain gear drive
Generator
Differential gear
Silent chain
drive
Gear wheel
cascade
Gear wheel
cascade
Driving gear
Driven gear
K.6.12.7.5.0.0.0.0_GLEA
Ident-Nr.
Quelle: Toyota Motor Corp.
K.6.12.7.5.0.0.0.0_GLEA
Ident-Nr.
Power split planetarygear
Sun wheel 30 Zhne
Planet wheel 23 Zhne
annulus 78 Zhne
Motor speed reduction planetary gear
Sun wheel 23 Zhne
Planet wheel 18 Zhne
annulus 57 Zhne
Intermidiate drive
Final drive
Oil pump
Transmission damper
Combustion engine
Motor-Generator 1
Motor-Generator 2
Differential
gear
Power split
planetary gear
Speed reduction
planetary gear
K.6.12.7.5.0.0.0.0_GLEA
Ident-Nr.
Intermidiate drive
Final drive
Oil Pump
Transmission
Damper
Motor Generator 1
Motor Generator 2
Differential
gear
Power split planetary
gear
Motor speed reduction
planetary gear
K.6.12.8.1.1.0.0.0_GLEA
Hydraulic_Gears_Introduction
Hydraulic Gears
link between shafts is a liquid
distinction between power transmission by momentum- or pressure
forces hydrodynamic and hydrostatic gear, respectively
hydraulic gears make a variable conversion of speed and torque
possible (major advantage for the construction of cars and building
machinery who make use of hydraulic gears)
6.12.8 Hydraulic Gear Mechanisms
Ident-Nr.
K.6.12.8.1.2.1.0.0_GLEA
Hydraulic_Transmissions_Basic_Functions_and_Principles
6.12.8.1.2.1 Basic Functions
a) Hydrodynamic gears (coupling) (Fttinger speed
transformer, Fttinger torque converter)
utilization of momentum forces of a liquid
i. e. hydrodynamic forces ( as in Fttinger coupling) for motion transfer
Hydrodynamic gears consist of:
one pump
one turbine
at least one guide wheel
Ident-Nr.
K.6.12.8.1.2.1.0.0_GLEA
a
Hydrodynamic gear
(Fttinger speed transformer)
Ident-Nr.
Quelle: Lechna, Naunheimer
pump
drive
fluid
turbine
guide
wheel
power
take-off
K.6.12.8.1.2.1.0.0_GLEA
transmission by momentum of oil flow i. e. hydrodynamic
forces
hydrodynamic couplings:
main parts: - pump impeller
- turbine wheel
cannot convert torque, since torque cannot be supported in
housing
Principle of hydrodynamic coupling
Ident-Nr.
K.6.12.8.1.2.1.0.0_GLEA
b) Hydrostatic coupling
Ident-Nr.
Hydrostatic couplings consist of:
one hydro pump
one hydro motor
Quelle: Nieman
hydrostatic vane gear:
a- drive (pump)
b- output (motor)
altering the volume flow
by changing the eccentricity ea (and eb)
K.6.12.8.1.4.1.0.0_GLEA
Hydraulic_Transmissions_Types_General_Fundamentals
6.12.8.1.4.1 General Fundamentals
Fundamentals
hydrodynamic couplings:
main parts:
pump impeller
turbine wheel
cannot convert torque, since torque cannot be supported in
housing
hydrodynamic torque converter: at least one guide wheel
working medium: ATF- oil (Automatic Transmission Fluid)
flow passes successively through pump, turbine and guide
wheel
Ident-Nr.
K.6.12.8.1.4.2.0.0_GLEA
Hydraulic_Transmissions_Types_Hydrostatic_Transmissions
Hydraulic pumps and hydraulic motors are realized as:
a) rotary machines
(rotating piston machines) :
6.12.8.1.4.2 Hydrostatic Gear Mechanisms
Ident-Nr.
deliver hydraulic fluid with
uniform rotation in cells whose
volumes are altered cyclically
due to the design of the limiting
walls or penetrating of a tooth.
(e. g. geared- and wing pumps)
K.6.12.8.1.4.2.0.0_GLEA
Hydraulic_Transmissions_Types_Hydrostatic_Transmissions
b) Machines displacing strokes
(shear piston engines):
Hydrostatic Gear Mechanisms
Ident-Nr.
deliver hydraulic fluid by cyclical
altering of the cell volume, by
means of pistons moving in
longitudinal direction (e. g. in-line
piston pumps and axial piston
pumps).
K.6.12.8.1.4.3.0.0_GLEA
Hydraulic_Transmissions_Types_and_Properties_Hydrodynamic_Coupling_and
Introduction:
Principle is the use of dynamic flow processes
of fluids.
First of all:
Hydrodynamic Coupling
6.12.8.1.4.3 Hydrodynamic Transmissions
Ident-Nr.
K.6.12.8.1.4.3.0.0_GLEA
Hydrodynamic Coupling
Ident-Nr.
Quelle: W. Bohl Strmungsmaschinen 1
K.6.12.8.1.4.3.0.0_GLEA
n
pump
> n
turbInc
for the clutch torque the following
applies:
N
coupIIng
= N
Input
= N
output
Function
Ident-Nr.
hydrodynamic coupling
1 turbine wheel, 2 pump impeller
motor feeds energy into pump impeller
flow in radial and tangential direction
energy transfer to turbine wheel so long as:
Quelle: Bosch
K.6.12.8.1.4.3.0.0_GLEA
Hydrodynamic converter (Fttinger torque converter)
6.12.8.1.4.3 Hydrodynamic Gear Mechanisms
Ident-Nr.
pump turbine cover & damper
guide wheel
size:
weight:
K.6.12.8.1.4.3.0.0_GLEA
Function:
Hydrodynamic Gear Mechanisms
Ident-Nr.
P pump impeller (index E)
T turbine wheel (index A)
L guide wheel (index L)
D diameter
As the hydrodynamic clutch
but with fixed guide wheel
deflecting the flow. The guide
wheel torque is supported in
the housing.
for the converter torque the following
applies:
N
output
= N
Input
_ N
guIdc whccI
M
guide wheel
is a function of the free
flow direction and of the blading
curvature.
K.6.12.8.1.4.3.0.0_GLEA
Guide wheel not rigid anymore
but connected to the housing
via a free-wheeling.
for the converter torque
the following applies:
For M
guide wheel
< 0 the guide wheel runs freely with the flow.
The following applies: M
output
= M
input
=> For M
vane wheel
= 0 on the Trilok converter runs in clutch mode
Trilok converter (clutch converter)
Ident-Nr.
So long as M
output
> M
input
and
M
guide wheel
> 0 the free-wheeling
fixes the guide wheel on the
housing.
=> operation as ordinary converter
Hydrodynamic converter
1 drive, 2 turbine, 3 pump, 4 guide
wheel, 5 free-wheeling, 6 output
Quelle: Bosch
K.6.12.8.1.4.3.0.0_GLEA
Converter testing
Ident-Nr.K.6.9.1.8 111_182E 050520
K.6.12.8.1.4.3.0.0_GLEA
ABP- Automatikgetriebe 6HP19
Ident-Nr.K.6.12.8.1.7 111_184 D
050620
K.6.12.8.1.7.1.0.0_GLEA
Applications_Introduction
6.12.8.1.7 Applications
Ident-Nr.
K.6.12.8.1.7.2.0.0_GLEA
Hydraulic_Transmissions_Applications_Schematic_Diagram_of_Screwtype_Compressor
6.12.8.1.7.2 Schematic diagram of a screw-type
compressor
Ident-Nr.
1- drive shaft
3- master piston
4- slave piston
2- back gear
Quelle: FAG, 1976-1
K.6.12.8.1.7.2.0.0_GLEA
Applications (Examples)
Ident-Nr.
K.6.12.8.1.7.2.0.0_GLEA
Ident-Nr.
filling
transport
K.6.12.8.1.7.2.0.0_GLEA
Ident-Nr.
compression
compression
K.6.12.8.1.7.2.0.0_GLEA
Ident-Nr.
output
K.6.12.8.1.7.2.0.0_GLEA
Ident-Nr.
K.6.12.8.1.7.3.0.0_GLEA
Hydraulic_Transmissions_Applications_Automatic_Gear_as_Planetary_Gear
Quelle: LuK
6.12.8.1.7.3 Automatic Gear as Planetary Gear
Ident-Nr.
weight:
length:
K.6.12.8.1.7.3.0.0_GLEA
Hydraulic_Transmissions_Applications_Automatic_Gear_as_Planetary_Gear
7-Gear Automatic Transmission
Ident-Nr.
Foto: DaimlerChrysler AG
K.6.12.8.1.7.4.0.0_GLEA
Hydraulic_Transmissions_Applications_Retarder
Function:
Cooling of stator is
required!
6.12.8.1.7.4 Retarder
Ident-Nr.
The rotor of the hydro-
Dynamical converter
converts the mechan-
ical energy into kinetic
energy of a liquid.
At the stator, this kinet-
ic energy is then converted
into heat.
Quelle: Bosch
16-speed group gear with integrated retarder for trucks (ZF-16 S 220 Ecosplit).
1 drive shaft, 2 shift interface, 3 main shaft, 4 selector shaft and fork, 5 planetary
wheelset, 6 output, 7 layshaft, 8 integrated hydrodynamic retarder.
A split set, B main set, C region set
speed speed speed speed speed speed speed speed speed
L slow, S fast
Transmissions for speeds (optional) input
torque
K.6.12.8.1.8.0.0.0_GLEA
Hydraulic_Transmissions_Dimensioning
a) Components of a
hydrodynamic converter
1 pump impeller
2 turbine wheel
3 guide wheel
4 hollow shaft for guide wheel
support in housing
5 housing fixed
6 hollow shaft of pump impeller
for driving the gear oil pump
7 wall cover connected to pump
impeller
8 guide wheel free-wheeling
9 turbine shaft
(transmission input)
b) flow course
6.12.8.1.8 Dimensioning
Ident-Nr.
On operation at the optimal point, i. e. fluid undergoes no losses due
to impact and it impinges on the blades tangentially, the torque balance
for converters applies: M
T
+M
P
+ M
L
=
(1)
K.6.12.8.1.8.0.0.0_GLEA
Flow circulation in
converter with flow
velocities on zero
impact flow
Dimensioning
Ident-Nr.
Single torques calculated according to Eulers equation:
Difference of angular momentum
between blade inlet and -outlet
Angular momentum as product of radius r times
circumferential component cu of absolute velocity c
M = Q p r
u

2
r
u
= r
a
u,a
- r
e
u,e

3
volume flow
density
K.6.12.8.1.8.0.0.0_GLEA
Since closed system and mass flow rate = const
=> balance of angular momentum follows with equilibrium of torque:
With power of one wheel:
=> power balance follows from the fact that the guide wheel is fixed:
Power losses PV are made up of: - friction losses
- losses due to impact
- ventilation losses
- gap losses
the efficiency results in:
Dimensioning
Ident-Nr.
i c
u
= u
P = P
P
+P
T
+P
V

(4)

P = N
w
i
=
P
T
P
P
=
N
T

T
N
P

P
=
5 whcrc
=
N
T
N
P
; =

T
P
K.6.12.8.1.8.0.0.0_GLEA
Hydrodyn. couplings only contain a turbine wheel and a pump impeller,
guide wheel is dropped response torque cannot be absorbed
no conversion of torque only speed is converted
On speed differences, torque can be transferred
between turbine wheel and pump impeller
Speed difference is denoted by slip
Hydrodynamic couplings and their characteristics
Ident-Nr.
- differing centrifugal forces lead to pressure differences
- thus circulation of working medium
interchange of momentum between both wheels is possible
S =

P
-
T
P
= 1 -
P
= 1 -
(15)
K.6.12.8.1.8.0.0.0_GLEA
In the range of very small slip torque towards 0 air friction
N
IrIc
cannot be neglected compared to transferred torque
efficiency for very small S (equivalent to 1)
decreases steeply towards 0
On usual residual slip for hydrodyn. couplings (and converters)
of S = 2....4%, this range is not reached in operation
By substitution of (15) in (5) it follows
Ident-Nr.
=
N
T

T
N
P

P
=
N
T

T
(N
T
+N
IrIc
)
P
=
N
T
N
T
+N
IrIc
1 -S
(16)
K.6.12.8.1.8.0.0.0_GLEA
The figures show the characteristics of a hydrodynamic coupling,
on the left hand side for n
PV
= const, on the right hand side the dimensionless
representation (allows for comparison of different couplings)
Ident-Nr.
Course of as function of S = 1- can be influenced by
constructive design of the blade surface and the fill factor
Application : truck coupling
turbine speed n
T
speed ratio v
e
f
f
i
c
i
e
n
c
y

q
,

f
i
g
u
r
e

o
f

m
e
r
i
t

I
e
f
f
i
c
i
e
n
c
y

q
,

t
o
r
q
u
e

M
K.6.12.8.1.8.0.0.0_GLEA
Converter can absorb response torque by fixed guide wheel and can
convert input torque
efficiency for = 0,7....0.8 (depending on converter)
more favorable than for clutch
N
T
plotted versus speed difference decreases linearly to first order
from starting torque (with
a
) towards N
T
= 0 (in the vicinity of = 1)
parabola-shaped course of drive power P
T
=
T
. N
T
(for constant input power) and of efficiency =P
T
/ P
P
Hydrodynamic converters and their characteristics
Ident-Nr.
K.6.12.8.1.8.0.0.0_GLEA
A starting point (standstill point), turbine is standing still,
starting conversion amounts to
a
= N
F,A
/N
P,A
Hydrodynamic converters and their characteristics
Ident-Nr.
M optimal point (design point) with = max
K coupling point (N
P
=N
T
, N
L
= 0)
D through point, turbine is unloaded N
T
=0
turbine speed n
T
speed ratio v
e
f
f
i
c
i
e
n
c
y

q
,

t
o
r
q
u
e

M
e
f
f
i
c
i
e
n
c
y

q
,

f
i
g
u
r
e

o
f

m
e
r
i
t

I
t
o
r
q
u
e
c
o
n
v
e
r
s
i
o
n

K.6.12.8.1.8.0.0.0_GLEA
a) single-stage (guide wheel located in front of pump, single-stage turbine,
motor steadily loaded ( = const))
Control of converter characteristics
Ident-Nr.
b) three-stage with speed reduction (most favorable for passenger cars,
, n multiple-stage turbine for good efficiency)
c) three-stage without speed reduction (for multiple-stage turbine: with guide
wheel located in front of pump increase of ( again = const))
d) effect of speed reduction
turbine speed hT
(output speed)
major speed reduction
minor speed reduction
no speed difference, I(v)=const.
p
u
m
p

s
p
e
e
d

P
(
m
o
t
o
r

s
p
e
e
d
)
K.6.12.8.1.8.0.0.0_GLEA
Single-stage 2-phase converter (Trilok (research association)- converter),
used exclusively in passenger cars (with centripetal flow through turbine)
The Trilok converter
Ident-Nr.
Combines advantages of hydrodyn. couplings and converters in order
to avoid the declined branch of the converter efficiency parabola
Function:
converter operates up to coupling point at N
T
=0 (phase 1), thereafter guide
wheel releases from housing via the free-wheeling
free creep no response torque (phase 2)
for couplings straight line of origin of efficiency rating
turbine speed n
T
speed ratio v
e
f
f
i
c
i
e
n
c
y

q
,

t
o
r
q
u
e

M
e
f
f
i
c
i
e
n
c
y

q
,

f
i
g
u
r
e

o
f

m
e
r
i
t

I
t
o
r
q
u
e
c
o
n
v
e
r
s
i
o
n
conversion range
coupling range
K.6.12.8.1.8.0.0.0_GLEA
Dimensioning of converters
Additional information
Ident-Nr.
Auxiliary means: - hydraulic model laws
- experimentally determined characteristic values
Assumption:
geometric similarity (same length scale for all fluids relevant components)
e. g. m =
B
B
M

(6)
original profile diameter
profile diameter of model
Kinematic similarity (corresponding velocities of original and model must have
the same ratio
similarity of velocity triangles)
c
c
M
=

M
=
u
u
M

(7)
K.6.12.8.1.8.0.0.0_GLEA
With circumferential speed u =
D
2
, the velocity scale becomes:
Ident-Nr.
For angular momentum scale with (8) comes:
The volume flow Q (from continuity equation Q=A c) is proportional to the
product m
V
(8) m(6)
m
V
=
u
u
M
=
B
M
B
M
= m

M

(8)
m
anguIar momcntum
=
(ic
u
)
(ic
u
)
M
= m`

M

(9)
m
Q
=
Q
Q
M
= m
V
m` =
B
M
B
M

(10)
K.6.12.8.1.8.0.0.0_GLEA
For the power, the following applies with (2):
Ident-Nr.
Substitution for (8), (9), (10) in (11)
P = N = Q i c
u

(11)
P
P
M
=
B
5
M

M
B
5
M
oi P~
3
B
5

(12)
K.6.12.8.1.8.0.0.0_GLEA
With proportionality factor the similarity law follows:
Ident-Nr.
For the torque it follows with M=P/
is a function of and is denoted as figure of merit.
It can be used for comparison of different converters.
The density of AFT oils is = 800-900 kg/m
N
N
M
=
` B
5
M
`
M
B
5
M
anu N
P
~
2
B
5
, iespectively
(13)
N
P
=
P
` B
5
K.6.12.8.1.8.0.0.0_GLEA
On hydrodynamic torque converters without speed reduction
the torque absorption is independent of n
T
, according to (14) it results
in a parable as characteristic curve
Interaction motor - hydrodynamic converter
Ident-Nr.
converter 3 with decreasing = () with speed reduction in characteristic diagram
for torque operational range for =0 und =1
operational range
a) char. diagram for torque, b) max. power absorption, c) efficiency
converter 1,2 at I = unst D
1
=
M
N
Ipm
M
`
5
; D
2
=
M
max
Ipm
max
`
5
D
1
< D
2

(17)
pump speed
turbine speed
turbine speed
full load
e
f
f
i
c
i
e
n
c
y
m
a
x
.

p
o
w
e
r
a
b
s
o
r
p
t
i
o
n
p
u
m
p

t
o
r
q
u
e
K.6.12.8.1.8.0.0.0_GLEA
Converter shown above as Trilok- type.
Ident-Nr.
a) converter 3 with speed reduction, as 2- phase converter
in K (coupling point
K
=0,75) guide wheel releases by free-wheeling
converter operates as coupling
b) maximum input in Trilok- carrying out
c) efficiency rating Trilok- converter
pump speed turbine speed
turbine speed
e
f
f
i
c
i
e
n
c
y
m
a
x
.

p
o
w
e
r
a
b
s
o
r
p
t
i
o
n
p
u
m
p

t
o
r
q
u
e
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