Que1.

A nine speed gear box is to connected to a motor running at 720 rpm through a
belt drive. The gear box is to have a minimum speed of 1.5 rpm and a maximum speed
500 rpm. Using standard spindle speeds,
a). Draw the structure and speed diagram for the arrangement.
b). Draw the gear box layout
c). Determine the number of teeth on each gear of the gear bo
Ans.1 the standard pulley diameters are based on R20 series with a diameter starting 80 mm.
Z=9
1
1
= 3 3

The design would be for a 2 stage, 9 speed gear box.

NM

= 720 rpm

N1 =

N Min

NM

N max = 500 rpm

N max 500
=
N min 31.5

NM

= 31.5 rpm

= 15.873

=R N z1 =15.873 91
= 1.41(R20/3 series)
The nine standard spindle speeds on the output shaft can be calculated as under:
N 1=31.5
N 2=N 1 = 44.4 45
N 3=N 2 = 63.45 63

N 4 =N 3 = 88.88

90

N 5=N 4 = 126.9 125

N 6=N 5 = 176.3 180
N 7=N 6 = 253.8 250
N 8=N 7 = 352.2 335
N 9=N 8 = 500.6 500

Fig. structure diagram

i g= 8
For this structure diagram the maximum value of

ig

occurs in stage 2.

i g=6 =1.416 = 7.86 < 8

This value is less than 8, and hence the structure diagram is suitable. The speed diagram such
same has been shown in fig.

Fig. speed diagram

From the above speed diagram, it can be speed that in the last stage, the speed reduction for
the gear pair would be from 125rpm to 31.5rpm (gear ratio 3.97 which is less than 6).
It is given that a belt drive is used to connect the motor with the input shaft of the gear box.
N M =720 rpm,
The motor speed was
whearas the input shaft speed from the speed
diagram is
DM

N M =500 rpm

. Thus, if the pulley connected to the motor has a diameter

and that connected to the input shaft I of the gear box has a diameter

pulley dia. Ratio,

D I N M 720
=
=
=1.44
D M N I 500

D1

, then the

D I =1.44 D M
The pulleys are in R20 series starting with a minimum dia. Of 80mm. Hence standard sized
pulleys would be found by first determining the GP ratio.
P =2010 = 1.125
Standard Pulley diameters would be = 80 mm
80 1.125 = 90mm
90 1.125 = 100mm
100 1.125 = 112mm
112 1.125 = 125mm
125 1.125 = 140mm
140 1.125 = 160mm
160 1.125 = 180mm
180 1.125 = 200mm
Assuming a minimum pulley diameter

DM

, the input shaft pulley diameter should be

calculated till the desired standard pulley is available. The procedure as shown
D M D I =1.44 D M
80

115.2

90

129.6

100

144

112

161.28

125

180

This the pulley diameter on the would be 125 mm and that on the input shaft of the gear box
will be 180 mm. This would ensure that the input shaft speed would be 500 rpm.
The gear box layout would be as shown in fig.

Fig. Gear box Layout

The gear ratio can then be calculated as under:
'

Z a N a 500
= =
=2.78
Z a N 'a 180
Z 'b N b 500
= =
=2.00
Z b N 'b 250
'

Z c N c 500
= =
=4.00
Z c N 'c 125
The largest gear ratio in this case would be for gears c and c. Hence the number of teeth is
these gears should be determined. The pinion in this case would be gear. Let the number of
with on gear c be Zc.

'

Z c =4 Z c
Z 'b =2 Z b
Z 'a =2.78 Z a
Z a + Z 'a=Z b +Z 'b =Z c +Z 'c =Z c + 4 Z c = 5 Z c
'

Z a + Z a=5 Z c
Z a +2.78 Z a=5 Z c
3.78 Z a=5 Z c
Z a =1.323 Z c
'

Z a + Z a=5 Z c
Z b +2 Zb =5 Z c
3 Z b=5 Z c
Z b =1.667 Z c

Que2. A three stage gear box with twelve speeds is to be designed based on R10 series
with a minimum spindle speed of 63 rpm. The electric motor is connected to the gear
box through a belt driver and runs at 1440 rpm and transmits power of 6 kW. Using
standard spindle speed,
a). Draw the structure and speed diagram for the arrangement.
b). Determine the ratio of the belt pulley diameters.
c). Draw the gear box layout
d). Determine the number of teeth on each gear of the gear box
Ans.2
Given Data
Z 12 , R10

series

N min = 63rpm

N m = 1440 rpm , P = 6KN

Here z = 12 = 2 2 3
Design is a based on the 3 stage, 12 speed Gearbox
N,

N min

= 63rpm

10
And = 10=1.2589

N 1=63
N 2=N 1 = 79.31 86
N 3=N 2 = 99.84 100
N 4 =N 3 = 115.83 120
N 5=N 4 = 158.62 160
N 6=N 5 = 201.4 200
N 7=N 6 = 251.7 250
N 8=N 7 = 314.7 315
N 9=N 8 = 396.55 400
N 10=N 9 = 503.56 500
N 11=N 10 = 629.45 630
N 12=N 10 = 793.110 800
The structure diagram
Z = 2 (1) 2(2) 3(4)
Z = 2 (1) 2(6) 3(2)
Z = 2 (3) 3(1) 2(1)
Z = 2 (6) 3(1) 2(3)
Z = 3 (2) 2(6) 2(1)
Z = 3 (6) 2(2) 2(1)

For selection

x 1< x 2 < x 3

so here we get the 1st Z = 2 (1) 2(2) 3(4) and structure diagram

and speed dia. As shown in fig.

The radius of belt pulley diameter
D i=Dai . of pully
D em =Dia. of electric motor pulley
ni=Input speed
new =Electric motion speed
ni= n 6 n7= 250 250=223.66

D i n ew 1440
= =
=6.439
D m ni 223.6
No. of teeth on gears
Kinematic pulley of gear box

For 1st stage

Z1 i 200
=
=0.8945
Z 10 223.6
Z 10=1.118211
Z2 i
250
=
=1.118
220 223.6
Z 2 i=1.18220
Z 10=nzi Z 2i =Z 20
If

Z 1 i=18 Z20=1.118 18=20

Z 1 i=18 Z10=20
Z 2 i=20 Z 20=18
For 2nd stage
Z 3 i 400
=
=1.6
Z 30 250
Z 3 i=1.6230
Z3 i 160
=
=0.64
240 256
Z 4 i=1.15624
Z5 i 250
=
=1
250 250

Now
Z 5 i=250

Z 3 i +230+ Z 4 i +250=Z 5 i+ 250

1.6230 + 230 =
2.6

Z 4 i+1.56241=22 Si

Z 30=2.56 Z 4 i=72 S i

Z 30=0.48 Z 4 i=0.762 Si
If

Z 30=18
Z 4 i=18.36
Z si=23.68

Z 30=19

If

Z 9 i=19.38=19
Z si=25
So

Z si + Z 30=2 Z si
Z 3 i +19=

2 25

Z 3 i=31
Z 4 i+ Z 40=2 Z si
19+Z 40 =

2 25

Z 40 =31
Z 3 i=31

Z si=25

Z 30=19

Z 50=25

Z 4 i=19

Z 40 =31

For 4th stage

Z 6 i 200
=
=0.5
Z 60 400
Z 60=2 Z6 i
Z 7 i 800
=
=2
270 400
Z 7 i=2270

Take
if

Z 6 i=270Z60 =Z 7 i

Z 6 i=18
Z 60=18 2=36

And

Z 7 i=36Z 70=18

Z 6 i=18 Z 60=36
Z 7 i=36 Z 70=18