GEAR BOX DESIGN

Machine Design II
ME 452

Project Deliverable 2

Index Name ID Section

1
2
3

Semester: Fall 2022

 1. Abstract

The gearbox for a floor crane with an electric winch is the focus of this project's design and

development work. The goal of this project is to design and create a gearbox for a floor crane

with an electric winch through a number of work packages. The design of spur gears, the

most basic kind of gear with straight teeth, is covered under Work Package 4. Work Package

5 focuses on bearing support shaft design while taking torque transfer and rotational motion

into account. Work Package 6 deals with choosing bearings while taking into account the

load, rotating speed, and operating circumstances. Work Package 7 uses 3D models made

with mechanical design automation software and SolidWorks simulation and drawing. The

general objective of this project is to build a durable and lightweight gearbox that maintains

gearbox efficiency while using less material.

 2. Contents

1. Abstract...............................................................................................................................2

3. Introduction.........................................................................................................................3

5. Work package 4: Spur Gear Design ( for all gears)............................................................4

6. Work package 5: Shaft Design ( for all bearing)...............................................................5

7. Work package 6: bearing selection (for all bearing)...........................................................6

8. Work package 7: solid work drawing and simulation........................................................6

9. Design summary.................................................................................................................7

10. Conclusion........................................................................................................................13

11. References.........................................................................................................................13
 3. Introduction

The operation of many mechanical devices, including floor cranes with electric winches,

depends heavily on the gearbox. The multipurpose lifting tool known as a floor crane is

frequently employed in industrial settings, on building sites, and in warehouses. It offers a

practical and effective way to lift and move large items. The floor crane's inherent electric

winch, driven by an electric motor, permits carefully regulated raising and lowering of cargo.

An electric winch and gearbox in a floor crane act as a mechanical power transfer

mechanism. It is in charge of transforming the electric motor's rotating motion into the

appropriate lifting power. The crane can lift a variety of weights with varied speed and torque

needs because to the gearbox's ability to modify gear ratios. It gives you the required

mechanical advantage to safely and successfully manage big weights.

Designing and developing a gearbox for a floor crane with an electric winch necessitates

carefully taking into account a number of variables. Load capacity, lifting speed,

dependability, efficiency, and safety are a few of them. While maintaining smooth and

regulated motion, the gearbox must be able to endure the high torque and dynamic stresses

experienced during lifting operations.Additionally, the floor crane's performance should be

maximised overall by optimising the gearbox design's power transmission efficiency,

minimising energy losses, and In electrically driven systems, where energy efficiency is a

crucial factor, this is especially crucial.The floor crane's performance, productivity, and

safety will all be improved by the proper adoption of an effective and dependable gearbox. It

will be helpful in the controlled and smooth lifting and transportation of huge loads, making

it a useful tool for many industrial and construction applications.

 4. Work package 4: Spur Gear Design ( for all gears)

Spur gears are the most basic kind of gear. They are made up of a disc or cylinder with teeth

that protrude radially (2022). Although the teeth are not straight and have a certain shape to

provide a constant drive ratio that is usually involute but less frequently cycloidal, the edges

of each tooth are straight and parallel to the axis of rotation.

1. Design of a spur gear

Using the floor crane's requirements as a guide, we'll do force analysis, calculate gear

dimensions, and build gears using various techniques.

Equipment Details:

Power:

Section F1: 2.5 kW + 0.1*(7-1) = 2.5 kW + 0.1*6 = 2.5 kW + 0.6 kW = 3.1 kW

Section F2: 3.5 kW + 0.1*(7-1) = 3.5 kW + 0.1*6 = 3.5 kW + 0.6 kW = 4.1 kW

Section M1: 4.5 kW + 0.1*(7-1) = 4.5 kW + 0.1*6 = 4.5 kW + 0.6 kW = 5.1 kW

Section M2: 5.5 kW + 0.1*(7-1) = 5.5 kW + 0.1*6 = 5.5 kW + 0.6 kW = 6.1 kW

Input Shaft 1 Speed:

Section F1: 2200 + 20*(7-1) rpm = 2200 + 20*6 = 2200 + 120 = 2320 rpm
Section F2: 2300 + 20*(7-1) rpm = 2300 + 20*6 = 2300 + 120 = 2420 rpm

Section M1: 2400 + 20*(7-1) rpm = 2400 + 20*6 = 2400 + 120 = 2520 rpm

Section M2: 2500 + 20*(7-1) rpm = 2500 + 20*6 = 2500 + 120 = 2620 rpm

Gear Pressure Angle:

Section F1, M1: 𝜙 = 25°

Section F2, M2: 𝜙 = 20°

Gear Ratios:

Section F1, M1: 𝑚𝐺 = 2

Section F2, M2: 𝑚𝐺 = 2.5

Section M1, M1: 𝑚𝐺 = 3

Section M2, M2: 𝑚𝐺 = 3.5

Let's now move on to the computations and design procedures:

Measurement of Gear Dimensions: We must ascertain the module and the total number of

teeth for each gear in order to compute the gear dimensions. The unit of tooth size known as

the module (m) is often given in millimetres. The gear ratios will be used to compute the

number of teeth (N).

Gear Set 1 (Gear 1 and Gear 2) Dimensions:

Gear Ratio (mG), Section F1, M1 (Gear 1): 2

Using the gear ratio and the number of teeth on Gear 2 (N2) as a starting point, determine the

number of teeth on Gear 1 (N1).

N1 = 2* 2440 N1 = 4880

Gear Ratio (mG) = 2.5 in Section F2, M2 (Gear 2).

Using the gear ratio and the speed of the input shaft 1, determine how many teeth are in Gear

2 (N2).

N2 = 2.5*2320 = 5800

Figure 1. spur gear

6. Work package 5: Shaft Design (for all bearing)

A mechanical shaft is an automated power transmission component that moves rotational

motion and torque from one device to another. It frequently has a circular cross form and can

be either hollow or solid.

Figure 2: crank shaft design.

Gears, pulleys, flywheels, clutches, and sprockets are machine components used to convey

power from the driving device, such as a motor or engine. These components are mounted on

several shaft types. The crankshaft of an automobile, as seen in the preceding figure, is a

great depiction of a mechanical shaft.

Types of shafts

Depending on the particular design and needs, a floor crane's shaft type may change.

However, popular shaft types that are often utilised in commercial applications, such as

cranes, include:

i. A solid shaft is a cylindrical bar with a fixed diameter that runs the length of the

bar. It is a straightforward and often used kind of shaft that may offer enough

stiffness and strength for a variety of applications.

 ii. A hollow shaft has a hollow centre but is otherwise comparable to a solid shaft.

While preserving strength, this design aids in lightening the shaft. When weight

reduction is crucial or when shafts need to make room for additional components

like electrical lines or fluid flow, hollow shafts are frequently employed.

iii. A splined shaft is one that has a row of ridges or teeth running the length of it.

These splines fit into equivalent grooves in gears, couplings, or bearings, among

other components. Splined shafts enable the transmission of torque while

permitting minor component misalignments or motions.

iv. The diameter of a tapered shaft gradually decreases from one end to the other. In

applications like bearing assemblies or pulley systems, where components must be

firmly mounted and aligned, tapered shafts are frequently employed.

v. Stepped Shaft: Along its length, a stepped shaft has portions with various

diameters. This kind of shaft enables installation of components with various bore

diameters as well as tolerating various bearing or coupling types.

7. Work package 6: bearing selection (for all bearing).

We require the gear ratios and input shaft speeds for each segment in order to calculate the

axial, radial, and equivalent radial loads at the bearing positions. Here are the gear ratios and

input shaft speeds based on the gear parameters provided:

Gear Ratios:

Section F1, M1: 𝑚𝐺 = 2

Section F2, M2: 𝑚𝐺 = 2.5

Section M1, M1: 𝑚𝐺 = 3

Section M2, M2: 𝑚𝐺 = 3.5

Input Shaft Speeds:

Section F1: 2320 rpm

Section F2: 2420 rpm

Section M1: 2520 rpm

Section M2: 2620 rpm

Now, let's proceed with the calculations:

Axial Load:

The axial load on the bearings can be determined using the formula: Axial Load = Power /

(Speed * Gear Ratio)

For Section F1, axial load = 3.1 kW / (2320 rpm * 2) = 0.667 kN

For Section F2, axial load = 4.1 kW / (2420 rpm * 2.5) = 0.336 kN

For Section M1, axial load = 5.1 kW / (2520 rpm * 3) = 0.565 kN

For Section M2, axial load = 6.1 kW / (2620 rpm * 3.5) = 0.534 kN

Radial Load:

The radial load on the bearings can be determined using the formula: Radial Load = Power /

Speed

For Section F1, radial load = 3.1 kW / 2320 rpm = 0.00134 kN

For Section F2, radial load = 4.1 kW / 2420 rpm = 0.00169 kN

For Section M1, radial load = 5.1 kW / 2520 rpm = 0.00202 kN

For Section M2, radial load = 6.1 kW / 2620 rpm = 0.00233 kN

Equivalent Radial Load:

The equivalent radial load can be calculated as the square root of the sum of the squares of

the axial and radial loads:

Equivalent Radial Load = sqrt((Axial Load^2) + (Radial Load^2))

For Section F1, equivalent radial load = sqrt((0.667 kN)^2 + (0.00134 kN)^2) = 0.667 kN

For Section F2, equivalent radial load = sqrt((0.336 kN)^2 + (0.00169 kN)^2) = 0.336 kN

For Section M1, equivalent radial load = sqrt((0.565 kN)^2 + (0.00202 kN)^2) = 0.565 kN

For Section M2, equivalent radial load = sqrt((0.534 kN)^2 + (0.00233 kN)^2) = 0.534 kN

Bearing selection

According to the computed axial and radial loads and their application in a floor crane, the

following bearing types are capable of supporting these loads:

i. Axial Load: Thrust bearings are frequently employed to handle axial loads. These

bearings may be selected based on the particular needs of the crane and are made

to support axial forces. These are typical examples of thrust bearings:

ii. Ball thrust bearings: These bearings are appropriate for applications requiring

moderate to high speeds and use balls to handle the axial load.

iii. Roller thrust bearings: These bearings sustain the axial load using cylindrical or

tapered rollers and are appropriate for applications requiring larger load

capabilities.
 iv. Radial Load: Depending on the precise load and speed requirements, several

bearing types might be taken into consideration for managing radial loads. Typical

choices include:

v. Deep groove ball bearings are adaptable and can support both radial and axial

stresses. They are appropriate for applications with modest speeds.

vi. Spherical roller bearings can support strong radial loads and moderate axial loads.

They frequently find usage in demanding situations.

vii. Cylindrical roller bearings: These bearings are ideal for applications requiring

moderate to high speeds and have a high radial load-carrying capability.

viii. Tapered roller bearings: These bearings are frequently employed in applications

requiring higher load capacities and moderate speeds. They can withstand both

radial and axial stresses.

8. Work package 7: solid work drawing and simulation.

SOLIDWORKS is a mechanical design automation tool that runs on the renowned Microsoft

Windows operating system and graphical user interface. Mechanical designers may quickly

sketch concepts using this simple tool, experiment with features and proportions, and create

models and detailed drawings. Figure 4 below illustrates a sample 3D solid model of a
gearbox;

Figure 4: solid works drawing

9. Design summary

The table below shows a summary for all calculations, results and gearbox specs
 10. Discussion

This study' main goal is to remove material from the gears in order to reduce the weight of an

automobile gearbox gearbox without causing it to malfunction. A gearbox gearbox helps

transmit power or torque from the engine to the drive axle at different velocity ratios

depending on the number of teeth in the gears and the engagement of the gears. The objective

of this project is to reduce the weight of the gearbox gearbox while also improving gearbox

efficiency. To do this, the gearbox is drilled, and stress analysis is used.

11. Conclusion

In a floor crane with an electric winch, the gearbox is an essential part that enables the

controlled lifting and moving of heavy cargo. Consideration must be given to a number of

criteria while designing and developing a gearbox for a floor crane, including load capacity,

lifting speed, dependability, efficiency, and safety. The floor crane's spur gears underwent

force analysis, gear calculations, and gear dimensioning throughout the design phase. The

number of teeth and specifications for each gear were chosen after taking into account the

gear ratios, input shaft speeds, and power requirements. The gear sets were developed in

accordance with the dimensions, which were determined using the module size. Another

crucial factor is shaft design, and several shaft types, such as solid shafts, hollow shafts,

splined shafts, tapered shafts, and stepped shafts, were studied. The unique needs of the crane

design, such as load transfer, alignment, and weight concerns, determine the shaft type that

should be used. For the gearbox's axial and radial loads to be supported, bearing selection is

essential. Thrust bearings can handle axial loads whereas several radial bearing types,

including deep groove ball bearings, spherical roller bearings, cylindrical roller bearings, and
tapered roller bearings, can be taken into consideration depending on the load and speed

requirements. In order to construct 3D solid models, test out features and proportions, and

provide thorough drawings for the gearbox design, the usage of the drawing and simulation

programme SOLIDWORKS was highlighted.

 12. References

"How Are Cranes Powered?". Bryn Thomas Cranes. 22 February 2017. Retrieved 20
November 2017.Pitt 1911, p. 368.

Paipetis, S. A.; Ceccarelli, Marco (2010). The Genius of Archimedes -- 23 Centuries of

Influence on Mathematics, Science and Engineering: Proceedings of an International
Conference held at Syracuse, Italy, June 8–10, 2010. Springer Science & Business
Media. p. 416.

Chondros, Thomas G. (1 November 2010). "Archimedes life works and

machines". Mechanism and Machine Theory. 45 (11): 1766–
1775. doi:10.1016/j.mechmachtheory.2010.05.009. ISSN 0094-114X.

Sayed, Osama Sayed Osman; Attalemanan, Abusamra Awad (19October 2016). "The
Structural Performance of Tower Cranes Using Computer Program SAP2000-
v18". Sudan University of Science and Technology. Archived from the original on 14
December 2019. Retrieved 1 August 2019. The earliest recorded version or concept of
a crane was called a Shaduf and used over 4,000 years by the Egyptians to transport
water.

Faiella, Graham (2006). The Technology of Mesopotamia. The Rosen Publishing Group.
p. 27.