‫كلية تكنولوجيا الصناعة والطاقة‬

Higher Diploma in Mechatronics Technology (Y2)

Mechatronics Program
Mechatronics
q System
Dr.Sherif Al Hosary
Lec. 3 February 2024
‫‪Outline‬‬
‫كلية تكنولوجيا الصناعة والطاقة‬
 Gear Drive System
A gearbox is a device for converting the speed of a shaft from one speed to another.
In the process, the torque is changed.

For example a winch in which a motor with high speed and low torque is geared
down to turn the drum at a low speed with a larger torque. Or a marine engine may
also use a reduction gearbox to reduce the speed of the engine to that of the
propeller.

This function can be done with a belt-drive system but gears have advantages over
these systems.
 Types of Gears

Rack & Pinion

Spur Gear

Epicyclic Gear

Worm Gear
Bevel Gear
 Basic Gearbox Theory

A key parameter is the gearbox ratio, GR

 Torque & Efficiency
The power, P [W], transmitted by a torque, T [Nm], applied to a shaft rotating at N [rpm[
is given by:

In an ideal gearbox, the output power = the input power

i.e. if the speed is reduced, the torque is increased and vice versa.

In a real gearbox, power is lost through friction and so the power output is related to
the power input through the gearbox efficiency:
 Clamping Torque
Because the torque in and torque out are
different, a gearbox has to be clamped in order
to stop the gearbox from rotating.

The total torque must add up to zero, hence:

If we use the convention that anti-clockwise torque is positive and clockwise

torque is negative, then we can determine the holding torque.

Note: the direction of rotation of the output shaft depends on the design of the
gearbox.
 Example 1
A gearbox has an input speed of 1500 rpm clockwise and an output speed of 300 rpm
anticlockwise. The input power is 20 kW and the efficiency of transmission is 70%.
Determine the following:

a. The gear ratio

b. The input torque
c. The output power
d. The output torque
e. The holding torque
 Example 1 – cont.
A gearbox has an input speed of 1500 rpm clockwise and an output speed of 300 rpm
anticlockwise. The input power is 20 kW and the efficiency of transmission is 70%.
Determine the following:

a. The gear ratio

b. The input torque
c. The output power
d. The output torque
e. The holding torque
 Example 1 – cont.
A gearbox has an input speed of 1500 rpm clockwise and an output speed of 300 rpm
anticlockwise. The input power is 20 kW and the efficiency of transmission is 70%.
Determine the following:

a. The gear ratio

b. The input torque
c. The output power
d. The output torque
e. The holding torque
 Simple Gear Train
The meshing of two gears may be idealized as two smooth discs with their edges touching
and no slip between them.

This idealized diameter is called the Pitch Circle Diameter (PCD) of the gear.

The direction of rotation is reversed from one gear to another. The only function of the
idler is to change the direction of rotation. This has no effect on the gear ratio. The teeth
on the gears must all be the same size so if gear A advances one tooth, so do B and C.
 Simple Gear Analysis
If we use D for the pitch circle diameter, t for the number of teeth, then we define the
modem, m as such:

Which has to be the same for all meshing gears, otherwise they won’t mesh.

Which can be rewritten as:

Now if ω is the angular velocity, and v is the tangential velocity, which

has to be the same for all meshing gears, otherwise they would be slipping.

And the gearbox ratio becomes:

Example 2
A simple gear train has 3 gears. Gear A is the input and has 50 teeth. Gear C is the
output and has 150 teeth. Gear A rotates at 1500 rpm anticlockwise. Calculate the
gear ratio and the output speed.

The input torque on A is 12 Nm and the efficiency of transmission is 75%. Calculate

the output power and holding torque.
 Compound Gears
Compound gears are simply a chain of simple gear trains with the input of the second
being the output of the first.

Gear A is the input of the compound gear train shown in the figure, while gear D is the
output of the gear train.

Gear B is the output of the first pair and gear C (which is locked on the same shaft as that
of B and revolves at the same speed) is the input of the second pair.

The velocity of each tooth on A and B are the

same since they are meshing with each other.
Likewise for gears C and D:
 Analysis of Compound Gear

Notice that since gears B and C are locked to the same shaft,
 Example 3
Calculate the gear ratio for the compound chain show. If the input gear rotates clockwise,
in which direction does the output gear rotate?
Gear #Teeth
A 20
B 100
C 40
D 100
E 10
F 100

There are 3 chains, each reverses the

direction of rotation. So if A is
clockwise, B and C rotate anticlockwise.
Hence D and E rotate clockwise, and
therefore the output gear F rotates
anticlockwise.
 Epicyclic Gears
Epicyclic means one gear revolving upon and around another. The design involves
planet and sun gears as one orbits the other like a planet around the sun.

This design produces larger gear

ratios in a small space and are used
on a wide range of applications from
marine gearboxes to electric
screwdrivers.
 Basic Arrangement
Suppose gear C is fixed while the arm A is
allowed to rotate about the axis through the
center of C.

Gear B meshes with gear C and revolves

around it when the arm A is rotated. At the
same time, B revolves around its own axis!
 Basic Arrangement
Suppose the arm is held stationary and
gear C is rotated once.

Gear B meshes with gear C and so when

C spins once, B spins about its own
center and the number of revolutions it
makes is the ratio tC/tB.

B will rotate by this number for every

complete revolution of C.

Now consider that C is unable to rotate and the arm A is revolved once. Gear B will
revolve tC/tB+1 because of the orbit.
 Another Arrangement
The arm is the input and gear D is the output. Gear C is a fixed internal gear
and is normally part of the outer casing of the gear box. There are normally four
planet gears and the arm takes the form of a cage carrying the shafts of the
planet gears. Note that the planet gear and internal gear both rotate in the
same direction.
 A Third Arrangement
The arm is the input and gear C is the output. In this case the sun gear D is
fixed and the internal gear C is made into the output.
 A Fourth Arrangement
In this design a compound gear C and D is introduced. Gear B is fixed and gears C rotate
upon it and around it. Gears C are rigidly attached to gears D and they all rotate at the
same speed. Gears D mesh with the output gear E.
 Example 4
A simple epicyclic gear has a fixed sun gear with 100 teeth and a planet gear with 50
teeth. If the arm is revolved once, how many times does the planet gear revolve?
C is fixed, and the arm rotates once. This
causes gear B to rotate by ?? times about
itself while at the same time revolving once
around gear C.

To know how many times gear B rotates

about itself. Consider that C rotates once,
while the arm A is made stationary. Gear B
meshes with gear C and so when C spins
once, B spins about its own center and the
number of revolutions it makes is the ratio
tC/tB = 100/50.

Hence gear B will rotate about its axis by tC/tB (= 100/50) while simultaneously revolving
once (= 1) around gear C.

B will rotates 100/50 +1 = 3 times for every revolution of the arm A.

 Example 5
An epicyclic gear box has a fixed sun gear D and the internal gear C is the output with
300 teeth. The planet gears B have 3- teeth. The input is the arm/cage A. Calculate the
number of teeth on the sun gear and the ratio of the gear box.

Now, PCD of gear C must equal that of D +

those of gears B.

DC = DD + 2 DB

But remember that for meshing gears, the

model D/t must be the same. Hence:

mtC = mtD + 2 mtB

tC = tD + 2 tB

So gear D has 300 – 60 = 240 teeth.

 Example 5 – cont.
An epicyclic gear box has a fixed sun gear D and the internal gear C is the output with
300 teeth. The planet gears B have 3- teeth. The input is the arm/cage A. Calculate the
number of teeth on the sun gear and the ratio of the gear box.
D is fixed. A is the input, so when A rotates, planet
gears B rotate about themselves by ?? times while
simultaneously revolves around D.

Because gears B and C are meshing, then C will tD/tB

revolve as well by ?? times around itself .

tB/tC

Considering that when A rotates once, the planet gears B

will revolve once about D, so planet gears B make tD / tB + 1
= 240/30 + 1 = 9 revolutions per revolution of A.

Similarly gear C will make tB/tC + 1 = 240/300 + 1 = 1.8

revolutions per revolution of A.
 ‫كلية تكنولوجيا الصناعة والطاقة‬
Gear drive Belt drive
Requires less space compared to belt drive. Requires more space compared to gear drive.

Low friction loss compared to belt drive, therefore higher High friction loss compared to gear drive, therefore lower
transmission and more efficiency. transmission and less efficiency.

Requires less maintenance, but maintenance cost is Requires high inspection and maintenance, but
relatively dearer and cumbersome. maintenance cost is relatively cheaper and convenient.

Much greater life expectancy than belt drives. Low life expectancy than gear drives.

Complicated equipment design, as tolerances are very Easy, flexible equipment design, as tolerances are not
much important. important.
No isolation from shock and vibration between driver and Isolation from shock and vibration between driver and
driven system. driven system.

Requires regular lubrication. Requires relatively less or no lubrication.

Noisy in operation. Very quiet in operation.

 ‫كلية تكنولوجيا الصناعة والطاقة‬

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