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MECHANICS OF MACHINES – DDA 3043


POWER TRANSMISSION SYSTEM: GEAR SYSTEM

1.1 Introduction to Gear System

Mechanical power transmission between shafts can be done in several ways. In most
engineering practice, major power transmission used is gear system, belt drive, chain or rope
drive. However, among these, gear system is the most efficient. The efficiency can go up to 98%.
Gear system is efficient because it can perform high consistency of connection to produce high
speed and load transfer with minimal noise of operation.
It is analogical with belt drive system because belt drive is a flexible, easy to install way
of power transmission mode. However, belt drive’s efficiency depends on the distance between
the driver and driven pulley. The efficiency can be affected by belt drive slip, centrifugal effect
and creep factor. Gears are used in many machines such as metal cutting machine tools,
automobiles, hoists, rolling mill and so on.

1.2 Types of Gear System

The function of gear is to transmit mechanical power from one shaft to another shaft with
a certain speed ratio. Gear system parts include at least a set of gear that consist of Driver Gear
and Driven Gear. Driver Gear is the gear that actuates power while Driven Gear is the gear that
receives the power. A series of gear set is called Gear Train. Gear can be classified according to
the relative position of the axes of mating gears.

a) Parallel Axes Shaft


The shaft axes between driver and driven gear is parallel to each other. Example of this type of
gear is Spur Gears and Helical Gears.
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Spur Gear Double Helical Gear

b) Intersecting Axes Shaft


The shaft axes between driver and driven gear is perpendicular to each other. Example of gear is
bevel gears.

Bevel Gear

c) Perpendicular Axes haft


The shaft axes between driver and driven gear are perpendicular to each other and do not
intersect to each other. Example of gear is “Worm Gear” and “Rack and Pinion Gear”.
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Worm Gear Rack and Pinion Gear

1.3 Relationship between Pitch Diameter and Pitch Circle

Some of the important terminology of gear system is:


Pitch Circle : An imaginary circle which by pure rolling action, would produce the same
motion as the toothed gear wheel.
Circular Pitch : The distance measured along the circumference of the pitch circle from a point
on one tooth to the corresponding point on the adjacent tooth.
Addendum Circle : Circle that limits the top of the teeth.
Tooth Thickness : The width of the tooth measured along the pitch circle
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For both gear to mate efficiently, the pitch circle of both gear must be the same. Thus;

p = πD1 = πD2
N1 N2

D2
Thus = N2
D1 N1

Where D1 = Diameter of driver gear


D2 = Diameter of driven gear
N 1 = Number of teeth of driver gear
N 2 = Number of teeth of driven gear

1.4 Gear Ratio


Consider a gear set below;

Driven gear
Driver gear

When two gear mate efficiently at point A, the velocity, v of both gear are the same. Thus;

v = v1 = v 2 with v = wD 2

w1
Then from w1 D1 = w2 D2 will produce = D2
2 2 w2 D1

Where w1 = speed of driver gear


w2 =speed of driven gear
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Gear ratio n is defined as ratio of speed of driven gear with the speed of driver gear.
w2 D1 N 1 α 2
n= = = =
w1 D2 N 2 α 1

Where α 1 = angular acceleration of driver gear


α 2 =angular acceleration of driven gear

1.5 Gear Train

Combination of gear wheels by means of which motion is transmitted from one shaft to
another shaft is called Gear Train. In simple gear train, each shaft carries one gear only. Some
gear trains consist of three gear that is driver gear, idler gear and driven gear. In Compound Gear
Train, each shaft carries two wheels, except the first and the last.

Simple gear train Compound gear train

The idler gear doesn’t affect the Gear Ratio of a gear system, but only affect the rotation
of the driven gear. When the gear train is complex (consist of many gear sets), it is important for
the designer to identify the rotation of the driver and the final driven gear respectively. However,
there is a simple formula to determine the rotation of each successive gear in a gear train.
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“For an ODD number of mating gears, the rotation of Driven gear is the SAME as Driver Gear.”
“For an EVEN number of mating gears, the rotation of Driven gear is REVERSE of Driver
Gear.”

Another classification of gear train is called Reverted Gear Train and Epicyclic Gear Train.

1.6 Gear Efficiency

Gear efficiency is defined as the ratio of Output Power from Driven Gear to the Input
Power from Driver Gear. Gear efficiency measures how efficient a gear system is to transmit
power. High value of gear efficiency reflects a more efficient gear system. Power loss in a gear
system may come from sources like friction, slip, backlash and so on.
From Power, P = Tω , then

P2 T2ω 2 T2
Gear Efficiency, η G ,1−2 = = = n
P1 T1ω1 T1

Where P1 = Input power from driver gear


P2 = Output power from driven gear
n = Gear ratio

If theη G ≠ 1.0 , thus the torque at driver gear T1 is;


nT2
T1 =
η G ,1− 2

1.7 Power Transmission in a Gear Train System

In a gear train system, power loss normally happen in the bearing and gear due to friction
and loading imposed on it and also power loss in overcoming shaft inertia. Consider a gear train

consists of two sets of gear reducing arrangement. A motor is attached to the system with I m is
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the moment of inertia of motor shaft, I T is moment of inertia of middle shaft and I G is the
moment of inertia of hoist which acts as the load of the system. Gear ratio and gear efficiency of

gear set 1-2 is n1 / 2 andη G1 / 2 , between gear set 3-4 is n3 / 4 and η G 3 / 4 respectively. Let;
Tm = Torque of motor

TG = Torque of hoist

T X = Friction torque at bearing X

Draw free body diagram and using Newton Second Law, ∑ T = Iα

Hoist

Assume clockwise direction as positive value.


For (A)
Tm − T1 = I mα m ……………………………… (1)

For (B)
T2 − T3 = I T α T ………………………………. (2)
Since there is gear mating between gear 1 and 2, thus, must include in the analysis its own gear
ratio and gear efficiency, and relate it to the inertia of middle shaft, I T .
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T2
Previously,η G1 / 2 = n1 / 2 , thus it follows that
T1

η G1 / 2T1
T2 = ……………………………….………. (3)
n1 / 2

For (C)
T4 − T X − TG = I Gα G ……………………………….. (4)

T3η G 3 / 4
also T4 = ………………………………………..(5)
n3 / 4

Using power, P = Tω , power transfer to each gear component is;


a) Power transfer by the motor
Pm = Tmω m

b) Power at gear 1
P1 = T1ω m = ( Tm − I mα m )ω m

c) Power at gear 2
P2 = P1η G1 / 2

d) Power at gear 3
P3 = T3ωT = ( T2 − I T α T )ωT

e) Power at gear 4
P4 = P3η G 3 / 4

f) Power at hoist
PG = TG ω G = ( T4 − T X − I Gα G )ω G

g) Overall power transfer efficiency, η O


PG
ηO =
Pm

Thus if friction torque, T X effect is neglected,


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PG  PT   PG 
This concludes that η O = =  ×  = η G1 / 2 × η G 3 / 4
Pm  Pm   Pm 
TG
Also; η O = n1 / 2 n3 / 4
Tm

1.8 Equivalent Moment of Inertia, I equiv


Consider a simple gear system as below Figure. In order for the driver gear A to start
rotate, it must have enough torque to overcome its own inertia, I A first, and then another
additional torque to start accelerate the driver gear B. However, to relate torque with the gear
parameter, inertia term will be taken into account. For a simple gear system, the solution is
straightforward, but when it comes to complex gear train design, it is useful to simplify / group
together all inertia term in the system into a single compact inertia expression. The inertia term
of each moving gear parts will be referred to a single part in the system, normally at motor side.

IA
IB

Driven gear Driver gear

1. Torque at B to overcome I B
TB = I B α B
ωB αB
Refer α B to gear A side. Use gear ratio, n = ωA = α A

Thus, TB = I B nα A
2. Gear efficiency is related to power and thus torque of the mating gears, thus
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PB TB n
ηG = =
PA TA

3. Therefore, torque at A, to accelerate I B

TB n ( I B α B ) ( I nα ) n I n 2α A
TA = = n= B A = B
ηG ηG ηG ηG

4. Therefore total torque at A to accelerate I A and I B is


TTOTAL = I Aα A + T A

 I Bn2 
TTOTAL = I A + α A , Or in general form, TTOTAL = I equivα A (referred to motor side)
 ηG 

 I Bn2 
Thus I equiv =  I A + 
 ηG 

The derivation of I equiv of this simple gear system can be extended to a double set of gear

reducing problem as in section 1.7. By neglecting the friction torque effect, T X , thus,

I T (n1 / 2 ) 2 I G (n1 / 2 ) 2 (n3 / 4 ) 2


I equiv = Im + +
η G ,1 / 2 (η G ,1 / 2 )(η G ,3 / 4 )

1.9 Gear Train Applications (Solved Problem)

Example 1
A motor is accelerating a 250 kg load with acceleration of 1.2 m/s2 through a gear system as
shown below. The rope that carries the load are encircled on a hoist with diameter 1.2m.Gear for
the hoist’s shaft has 200 teeth, gear for motor shaft has 20 teeth. Gear efficiency is 90%. Mass
and radius of gyration of each shaft is as below;
Mass (kg) Radius of gyration (mm)
Motor shaft 250 100
Hoist shaft 1100 500
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Calculate the torque of the motor needed to bring up the load with acceleration 1.2 m/s 2. Neglect
friction effect.

Dia = 1.2 m

Hoist

Solution
Total torque at motor to bring up load
Ttotal = TM 1 + TM 2

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).


TM 2 =Torque to accelerate the load through gear system

a) Consider for TM 1

IG n2
From I equiv = I M +
ηG

Thus I M = Motor shaft inertia

I M = mr 2 = 250( 0.1) = 2.5 kgm2


2

I G = Hoist shaft inertia

I G = 1100( 0.5) = 275 kgm2


2

N1 20
Gear ratio, n = = = 0.1
N 2 200

 275( 0.1) 2 
Put into I equiv = 2.5 +   = 5.55 kgm2
 0 . 9 
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Acceleration of hoist, aG = α G rG
1.2
Thus α G = = 2 rad/s
0.6
αG 2
From the gear ratio, angular acceleration of motor, α m = = = 20 rad/s
n 0.1
Now torque due to equivalent inertia, TM 1 = I equivα m

TM 1 = 5.55(20) = 111.1 Nm.

b) Consider for TM 2

TG From Newton 2nd Law, ∑ F = ma


Hoist F − 250 g = 250a
r
F = 250( g + a ) = 250( 9.81 + 1.2 )
F = 2752.5 N
a F
Then, torque at hoist
TG = Fr = 2752.5( 0.6) = 1651.5 Nm
250 kg
But due to gear efficiency (since the hoist shaft is connected to
the gear system), torque to accelerate the load,
250g TG n1 / 2 1651.5( 0.1)
TM 2 = = = 183.5 Nm
η G ,1 / 2 0.9

Then total torque referred to motor side is;


Ttotal = TM 1 + TM 2
Ttotal = 111.1 + 183.5

Ttotal = 294.6 Nm

Example 2
Figure below shows a motor used to accelerate a hoist through two sets of gear reducing
system. Moment of inertia for the motor shaft is 5 kgm2, middle shaft is 40 kgm2 and hoist shaft
is 500 kgm2. Gear ratio for gear set 1 and 2 is 1/3.5 while for gear set 3 and 4 is 1/ 4.5. Gear
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efficiency for both gear set is 90%. By neglecting the friction effect, find the total torque
required by the motor to accelerate the load of 6 tones at acceleration of 0.4 m/s2.

Hoist

Diameter = 1.2 m m

Solution

Given that I M =5 kgm2, I T = 40 kgm2, I G =500 kgm2, n1 / 2 = 13.5 , n3 / 4 = 1 4.5 , η G = 0.9

Neglect friction effect.


Total torque required for the motor is
Ttotal = TM 1 + TM 2

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).


TM 2 =Torque to accelerate the load through gear system

a) Consider for TM 1

Recall that TM 1 = I equivα m , but for two set of gear system with friction effect is neglected,

I T (n1 / 2 ) 2 I G (n1 / 2 ) 2 (n3 / 4 ) 2


I equiv = I m + +
η G ,1 / 2 (η G ,1 / 2 )(η G ,3 / 4 )

40( 1 ) 2 500( 1 ) 2 ( 1 ) 2
I equiv = 5 + 3.5 + 3.5 4.5 = 11.116 Nm
0.9 (0.9)(0.9)
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From question, given that, aG = 0.4 m/s2, thus;


aG 0.4
αG = =
rG 0.6

α G = 0.6667 rad/s2

αG αG αT 1 1 1
From gear ratio, = × = × =
α m α T α m 4.5 3.5 15.75

Thus, α m = 15.75α G
α m = 15.75( 0.6667 ) = 10.5 rad/s2

Thus, Tm1 = I equivα m = 11.116(10.5)

TM 1 = 116.72 Nm.

b) Consider for TM 2

From Newton 2nd Law, ∑ F = ma


Hoist
4500 − F1 = 4500a
a
F1 = 4500( g − a ) = 4500( 9.41) = 42345 N
a F1 F2
F2 − 6000 g = 6000a
F2 = 6000( a + g ) = 61260 N
6000 kg
4500 kg Resultant torque at hoist
FR = F2 − F1 = 18.915 kN
6000g Thus torque at hoist
4500g
TG = FR rG = 18.915( 0.6 ) = 11.349 kN

It is known that TG referred to motor side will be denoted as TM 2 and is related by


TG n1 / 2 n3 / 4
TM 2 =
η G ,1 / 2η G ,3 / 4

TM 2 =
11.349 1 ( 1 )(
3.5 4.5 = 889.6 Nm
)
0.9( 0.9)
Thus total torque at motor required is
Ttotal = TM 1 + TM 2
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Ttotal = 116.72 + 889.6

Ttotal = 1006.32 Nm.

Example 3

Hoist Dia = 0.9 m

Figure above shows a motor accelerating a hoist with diameter 0.9m, through two sets of
gear reducing system. Gear ratio for gear 1 and 2 is 1/3.5 while for gear 3 and 4 is 1/ 4.5.
Moment of inertia for the motor shaft is 5 kgm2, middle shaft is 20 kgm2 and hoist shaft is 100
kgm2. The rope that is encircled on the hoist must be capable to lift up a load of 5 tones that is
sliding on a 1 in 50 slope. Friction on the slope is 1000N and the total torque at motor required to
raise the load is 1500N. Use gear efficiency of 90% for both gear set.
If there is friction torque effect on the middle shaft, T X = 150 Nm and at hoist shaft is

T y = 800 Nm. Calculate the acceleration of the load at the above condition.

Solution
For the overall gear ratio,
1 1 1
n0 = n1 / 2 n3 / 4 = × =
3.5 4.5 15.75
Total torque required by motor to raise load
Ttotal = TM 1 + TM 2 + TM 3

Where TM 1 = Torque to overcome equivalent inertia (refer to motor side).


TM 2 =Torque to accelerate the load through gear system
TM 3 = Total torque to overcome friction effect.
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a) Consider for TM 1

Previously, TM 1 = I equivα m
For double set of gear reducing system,
I T (n1 / 2 ) 2 I G (n1 / 2 ) 2 (n3 / 4 ) 2
I equiv = I m + +
η G ,1 / 2 (η G ,1 / 2 )(η G ,3 / 4 )

20( 1 ) 2 100( 1 ) 2 ( 1 ) 2
I equiv = 5 + 3.5 + 3.5 4.5 = 7.312 kgm2
0.9 (0.9)(0.9)
From a = αr , thus
a a
αG = =
rG 0.45

αG 1
Also from gear ratio, = , thus
α m 15.75

 a 
α m = 15.75α G = 15.75  = 35a
 0.45 
Thus TM 1 = 7.312( 35a )
TM 1 = 255.92a Nm

b) Consider for TM 2
From ∑ F = ma,
F1 − FR − mg sin θ = ma
F1 F1 = 5000a + 1000 + 5000( 9.81) 1 ( 50)
F1 = ( 5000a + 9.81) N
FR 5000g
Mg sinθ
Thus, torque to accelerate hoist
θ
TG = F1 r = ( 5000a + 9.81)( 0.45)

TG = 2250a + 891.45 Nm
F1 Use gear efficiency to relate TG with TM 2
TG n1 / 2 n3 / 4
r TM 2 =
η G ,1 / 2η G ,3 / 4
hoist
TM 2 = (176.4a + 69.876 ) Nm
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c) Consider for TM 3

Friction effect can be grouped together to form TM 3 where;


T X n1 / 2 TY n1 / 2 n3 / 4
TM 3 = +
η G ,1 / 2 η G ,1 / 2η G ,3 / 4

 1   1  1 
150  800  
 3.5   3.5  4.5  Nm
TM 3 = + 2
= 110.33
0.9 0.9

From Ttotal = TM 1 + TM 2 + TM 3
1500 = ( 255.92a ) + (176.4a + 69.876 ) + 110.33
Thus a = 3.1 m/s2

2.0 Vehicle Dynamics

Wheel
v
wr
D/2 R

FT
Surface

For a moving vehicle, some of the forces acting on it are;


• Friction due to the vehicle’s body (aerodynamic friction), R
• Forces due to friction from the engine to the wheel such as friction in bearing, shaft,

clutch and gears, R INT .

• Forces due the acceleration of the vehicle, which is called tractive force, FT considering
no slip between the wheel and the road surface.
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We can estimate the speed of the moving vehicle by considering the speed of the wheel itself.
D
Vehicle speed, v = wr  
2

Example 1 (Solved Problem)

Total mass for a two wheeled motorcycle including passenger is 190 kg. The engine produce
torque of 25 Nm at speed of 1800 RPM. Moment of inertia for each wheel is 1.4 kgm2 while for
other rotating parts in the engine is considered as 0.15 kgm2. The wheel’s effective diameter is
610 mm. If the motorcycle is moving on a road with a speed 23 km/hr at second gear, find
(i) Gear ratio for the second gear
(ii) Acceleration at speed 23 km/hr
Assume wind friction is 200 N and gear efficiency is 90%.

Solution
Given that m =190 kg, Ttotal =25 Nm at N =1800 PM, I R =1.4 kgm2, I int =0.15 kgm2, D =610
mm,
If v =23 km/hr at 2nd gear, with R =200 N, η G =90%.

1st Step – Draw Free Body Diagram

Iint
IR
Engine

Wheel
Gear system
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2nd Step
Total torque at engine, Ttotal
Ttotal = TM 1 + TM 2

Where TM 1 = Torque due to equivalent inertia of rotating parts in the engine.(referred to engine
side).
TM 2 = Torque to accelerate the wheel.

3rd Step
Convert all measurement to SI standard.

2πN 2π (1800 )
Engine speed, wint = = = 188.5 rad/s
60 60
23(1000 )
Wheel speed, v = 23km / hr = = 6.3889 m/s
3600

4th Step– Determine TM 1


In order to find gear ratio for second gear,

w
n= R =
(6.3889 0.305) = 1 (Where wR = v ( D 2 ) )
wint 188.5 9

Thus gear ratio for second gear is n = 19 ( )


Equivalent moment of inertia is
I Rn2
I equiv = I int +
ηG

( 2 × 1.4) ( 19 )
2
2
I equiv = 0.15 + = 0.1884 kgm
0.9
In order to find α int , use α R and gear ratio

α R = a ( D 2)
20

α int
α
= R =
(a 0.305) = 29.508a
( 19 )
2
rad/s
n

Thus, TM 1 = I equivα int = 0.1884( 29.508a )

TM 1 = 5.559a Nm.

5th Step – Determine TM 2

From ∑ F = ma,
a FT = R + ma
R
FT = 200 + 190a
m=190 kg
Total torque at wheel,
FT
TR = FT r = ( 200 + 190a ) 0.305
TR = 61 + 57.95a

Refer TR to motor side using gear efficiency

TM 2 = =
( )
TR n ( 61 + 57.95a ) 9
1
ηG 0.9

TM 2 = (7.35 + 7.154a ) Nm

Thus, total torque at engine


Ttotal = ( 5.559a ) + ( 7.35 + 7.154a )

The acceleration at that speed is


By solving the equation for the total torque above, thus
a = 1.374 m/s2

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