Design of Gear Box

Using PSG Design Data Book

Sample Problem
Design a gearbox to give 9 speed output from a
single input speed. The required speed range is
180 rpm to 1800 rpm.
Given:
n
=9
Nmin = 180 rpm
Nmax = 1800 rpm

Step - 1 Calculation of Step ratio

Nmax
Nmin

n-1

1800
9-1
=
180
= 1.333

Refer PSG Data Book P. No : 7.20 to check

whether, the calculated step ratio is a std. value

Since its not a std. value, Lets find a multiples

of std. value come close to calculated step ratio
1.6
1.25
1.12
1.06

Cannot be used
Cannot be used
1.12 x 1.12 = 1.254
1.06 x 1.06 x 1.06 x 1.06 x 1.06 = 1.338

Multiples of 1.06 gives nearest value of 1.333

As 1.06 is multiplied 4 times we skip 4 speed
Hence std. = 1.06 & R 40 series is selected

Step - 2 Selection of Speeds

100

106

112

118

125

132

140

236

250

265

280

300

315

335

560

600

630

670

710

750

800

1338

1418

1503

1593

1689

1790

1898

150
355
850

160

170

180

190

200

212

224

375

400

425

450

475

500

530

900

950

1000

1060

1123

1191

1262

The speeds are;

180,236,315,425,560,750,1000,1320,1790
Check for deviation

lets calculate the allowable deviation and actual

deviation for the given range of speed.
Allowable deviation = 10 ( - 1) %
= 10 (1.333 - 1) %
= 3.33 %
Actual deviation

= (Nmax actual - Nmax) x

Nmin
Nmax

= (1790 - 1800) x 180

1800
= - 1.0 %

Since the deviation is within the allowable

range we can design for standard speeds.

The selected standard speeds are;

180,236,315,425,560,750,1000,1320,1790

Step - 3 Structural formula & Ray

Diagram
The structural formula for 9 speed gear box is
3 (1) 3 (3)
Stage 1 - Single input is splitted into 3 speeds
Stage 2 - 3 input is splitted into 9 speeds
ie., each input is splitted into 3 speed

1790

Selected speeds are;

1338

180,236,315,425,560,
750,1000,1320,1790

1000
750
560
425
315
236
180
Stage 1

Stage 2

Lets group the final

output speeds into 3,
since the structural
formula is
3 (1) 3 (3)

Lets select the input speed of stage 2. For that the

input speed should satisfy two following conditions.
At Least one output speed should be greater than
input speed. (1 for 3 o/p and 2 for 4 o/p)
The input and output must satisfy the following
ratios
Nmin
Ni/p

0.25

Nmax
Ni/p

1790
1338
1000
750

Stage 2

Lest find input speed for the

lowest output speed set.
For the
first condition,
possible input speeds are 750
& 560.
For the second condition,

560

Nmin

425

Ni/p

315

Nmax

236

Ni/p

180
Stage 1

Stage - 2

180

= 0.32

0.25

= 1.78

660
= 1000
560

The conditions are satisfied

1790
1338
1000
750

Stage 2

Lest find input speed for the

lowest output speed set.
For the
first condition,
possible input speeds are
1338 & 1790
For the second condition,

560

Nmin

425

Ni/p

315

Nmax

236

Ni/p

180
Stage 1

Stage - 1

560

= 0.41

0.25

= 0.74

1338
= 1000
1338

The conditions are satisfied

Step - 4 Kinematic Arrangement

1

5
Shaft - 1 / Input
7

9
11

Shaft - 2 / Intermediate

4
6

Shaft - 3 / Output

10
12

Step - 5 Calculation of number of

number of teeth in gears
Start from the final stage
First find the number of teeth for maximum
speed reduction pair.
Assume the number of teeth in the driver
gear (It should be above 17)
The sum of number of teeth in meshing
gears in a stage is always equal.

Stage - 2 First Pair - Maximum Speed Reduction

Assume number of teeth in driver = 20
z11
z12

N12
N11

20
180
=
z12
560
z12 = 62.2 62

Stage - 2 Second Pair - Minimum Speed Reduction

z7
z8

N8

z7

N7

z8
z7 = 0.76 z8

425
560

Stage - 2 Third Pair - Maximum Speed Increment

z9
z10

N10

z9

N9

z10
z9 = 1.78 z10

1000
560

Stage - 2
z7 + z8 = z9+ z10 = z11+ z12

z11 = 20

z7 + z8 = z9+ z10 = 20 + 62 = 82

z12 = 62

z7 + z8 = 82

z7 = 0.76 z8

0.76 z8 + z8 = 82

z9 = 1.78 z10

z8 = 46.5 46

z7 = 36

z9+ z10 = 82
1.78 z10+ z10 = 82
z10 = 29.49 30

z9 = 52

Stage - 1 First Pair - Maximum Speed Reduction

Assume number of teeth in driver = 20
z5
z6

N6
N5

20
560
=
z6
1338
z6 = 41.8 42

Stage - 1 Second Pair - Minimum Speed Reduction

z1
z2

N2

z1

N1

z2
z1 = 0.56 z2

750
1338

Stage - 1 Third Pair - Maximum Speed Increment

z3
z4

N4

z3

N3

z4
z3 = 0.74 z4

1000
1338

Stage - 1
z1 + z 2 = z 3 + z 4 = z 5 + z 6

z5 = 20

z1 + z2 = z3+ z4 = 20 + 42 = 62

z6 = 42

z3 + z4 = 62

z1 = 0.56 z2

0.74 z4 + z4 = 62

z3 = 0.74 z4

z4 = 35.63 36

z3 = 26

z1 + z2 = 62
0.56 z2 + z2 = 62
z2 = 39.74 40

z1 = 22

Solution
z1 = 22

z7 = 36

z2 = 40

z8 = 46

z3 = 26

z9 = 52

z4 = 36

z10 = 30

z5 = 20

z11 = 20

z6 = 42

z12 = 62