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ACTUATORS &
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CHAPTER 5 : GEAR & PULLEY
(PART II)
LEARNING OUTCOME
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CHAPTER CONTENTS
Gear
Introduction
Types of gears
Spur gears
Helical gears
Bevel gears
Worm gears
Rack and pinion
gears
Example Calculation
Pulley
Introduction
Fixed Pulley
Movable Pulley
Combined Pulley
Pulley Systems
Example Calculations
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GEARS
INTRODUCTION
Gears are a means of changing the rate of rotation
and
can
be
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INTRODUCTION
Another thing gears do is adjust the direction of
rotation.
For instance, in the differential between the rear
wheels of your car, the power is transmitted by a shaft
that runs down the center of the car, and the
differential has to turn that power 90 degrees to apply
it to the wheels.
There are a lot of intricacies in the different types of
gears.
In this topic, we'll learn exactly how the teeth on gears
work, and we'll talk about the different types of gears
we can find in all sorts of mechanical gadgets.
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BASICS
On any gear, the ratio is determined by the distances
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TYPES OF GEARS
1. Spur gears
TYPES OF GEARS
1. Spur gears
Spur gears are used in many devices that we can see all
over, like the electric screwdriver, dancing monster,
oscillating sprinkler, windup alarm clock, washing
machine and clothes dryer. But we won't find many in
the car.
This is because the spur gear can be really loud. Each time
a gear tooth engages a tooth on the other gear, the teeth
collide, and this impact makes a noise. It also increases the
stress on the gear teeth.
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TYPES OF GEARS
2. Helical gears
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TYPES OF GEARS
2. Helical gears
TYPES OF GEARS
2. Helical gears
TYPES OF GEARS
3. Bevel gears
Bevel gears are useful when the direction of a
shaft's rotation needs to be changed. They are
usually mounted on shafts that are 90 degrees
apart, but can be designed to work at other
angles as well.
The teeth on bevel gears can be straight, spiral
or hypoid. Straight bevel gear teeth actually have
the same problem as straight spur gear teeth -- as
each tooth engages, it impacts the corresponding
tooth all at once.
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TYPES OF GEARS
3. Bevel gears
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TYPES OF GEARS
3. Bevel gears
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TYPES OF GEARS
3. Bevel gears
TYPES OF GEARS
4. Worm gears
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TYPES OF GEARS
4. Worm gears
TYPES OF GEARS
4. Rack and Pinion gears
Rack and pinion gears are used to convert
rotation into linear motion.
A perfect example of this is the steering system on
many cars. The steering wheel rotates a gear which
engages the rack. As the gear turns, it slides the
rack either to the right or left, depending on which
way you turn the wheel.
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Output
Stationary
Calculation
Gear Ratio
Sun (S)
Planet
Carrier (C)
Ring (R)
1 + R/S
3.4:1
Planet
Carrier (C)
Ring (R)
Sun (S)
1 / (1 + S/R)
0.71:1
Sun (S)
Ring (R)
Planet Carrier
(C)
-R/S
-2.4:1
Also, locking any two of the three components together will lock
this planetary gear set, but these are the ones that are
relevant to our automatic transmission. You can try
these out in the animation below:
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and
one
reverse
gear
our
section.
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thicker part of the top gear tooth. This pushes the top gear
ahead, so it compensates for the slightly smaller contact
diameter.
As the teeth continue to rotate, the contact point moves
even further away, going outside the pitch diameter but
the profile of the bottom tooth compensates for this
movement. The contact point starts to slide onto the skinny
part of the bottom tooth, subtracting a little bit of velocity
from the top gear to compensate for the increased diameter
of contact.
The end result is that even though the contact point
diameter changes continually, the speed remains the same.
So an involute profile gear tooth produces a constant ratio
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of rotational speed.
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EXAMPLE CALCULATION
Example 1 (Question)
EXAMPLE CALCULATION
Example 1 (Answer)
Work out the Velocity Ratio (Gear Ratio);
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EXAMPLE CALCULATION
Example 2 (Question & Answer)
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EXAMPLE CALCULATION
Example 3 (Question & Answer)
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EXAMPLE CALCULATION
Example 4 (Question)
Below are examples of the way to work out
'revolutions per minute', or RPM as it is usually
called.
In the example below the DRIVER gear is large than
the DRIVEN gear. The general rule is - large to small
gear means 'multiply' the velocity ratio by the rpm
of the first gear. Divide 60 teeth by 30 teeth to find
the velocity ratio. Multiply this number (2) by the
rpm (120). This gives an answer of 240rpm.
If A revolves at 120 revs/min what is B ?
(Remember large gear to small gear increases revs)
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EXAMPLE CALCULATION
Example 4 (Answer)
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EXAMPLE CALCULATION
Example 5 (Question)
In the example below the DRIVER gear is smaller
than the DRIVEN gear. The general rule is - small to
large gear means 'divide' the velocity ratio by the
rpm of the first gear. Divide 75 teeth by 25 teeth to
find the velocity ratio. divide the 60rpm by the
velocity ration (3). The answer is 20rpm.
If A revolves at 60 revs/min what is B?
(Remember small gear to large gear decreases
revs)
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EXAMPLE CALCULATION
Example 5 (Answer)
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EXAMPLE CALCULATION
Example 6 (Question & Answer)
If A revolves at 100 revs/min what is B ?
(Remember small gear to large gear decreases
revs)
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EXAMPLE CALCULATION
Example 7 (Question)
When faced with three gears the question can be
broken down into two parts. First work on Gears A
and B. When this has been solved work on gears B
and C.
The diagram above shows a gear train composed of
three gears. Gear A revolves at 60 revs/min in a
clockwise direction.
What is the output in revolutions per minute at Gear
C?
GEAR A GEAR B GEAR C
In what direction does Gear C revolve ?
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TEETH
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60
TEETH
10
TEETH
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EXAMPLE CALCULATION
Example 7 (Answer)
Next, take B and C. C is smaller, therefore, revs/minute will increase and rotation
will be faster.
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EXAMPLE CALCULATION
Example 8 (Question)
GEAR B
GEAR C
30 TEETH
90 TEETH
15 TEETH
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EXAMPLE CALCULATION
Example 8 (Answer)
Next, take B and C. C is smaller, therefore, revs/minute will increase and rotation
will be faster.
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EXAMPLE CALCULATION
Example 9 (Question)
GEAR
A
120 T
GEAR
B
40 T
GEAR
C
80 T
GEAR
D
20 T
EXAMPLE CALCULATION
Example 9 (Answer)
D is smaller than C,
therefore rotates faster
(increased revs/min).
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EXAMPLE CALCULATION
Example 9 (Answer)
EXAMPLE CALCULATION
Example 10 (Task)
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PULLEY
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INTRODUCTION
What is pulleys
A pulley is a simple machine made with a rope, belt or chain
wrapped around a wheel. The pulley is usually used to lift a heavy
object (load).
What does a pulley do?
A pulley changes thedirection of the force, making it easier to lift
things.
Are all pulleys the same?
No, they are not. There are three types of pulleys:
Fixed Pulley
Movable Pulley
Combined
Pulley
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INTRODUCTION
A single pulley changes the direction of the lifting
force.
For example, if you are lifting a heavy object with a
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INTRODUCTION
A fixed pulley is the only pulley that
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INTRODUCTION
A movable pulley is a pulley
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INTRODUCTION
A combined pulley makes life
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INTRODUCTION
If you add a second pulley,
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INTRODUCTION
The pulley system consists of one or more pulleys and a
PULLEY SYSTEMS
Pulley wheels are grooved so that the belt cannot slip
off. Also, the belt is pulled tight between the two pulley
wheels (in tension). The friction caused by this means
that when the driver rotates the driven follows.
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PULLEY SYSTEMS
Most pulley wheels have a central shaft on which they
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PULLEY SYSTEMS
Velocity Ratio & Revolution per minute
The system shown has a driver pulley attached to a
motor. When the motor is switched on the driver pulley
revolves at 20 rpm. The diameter of the driver pulley
wheel is 200mm and the driven pulley wheel is 400mm.
This means for every single revolution of the larger
driven pulley wheel, the smaller driver pulley wheel
rotates twice. This is due to velocity ratio. The ratio can
be worked out mathematically in different ways.
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PULLEY SYSTEMS
The two most likely methods to determine the velocity
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PULLEY SYSTEMS
This means that the larger pulley wheel (the driven
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PULLEY SYSTEMS
Another example:
The diameter of the driver pulley wheel is 200mm and
the driven pulley wheel is 600mm. This means for every
single revolution of the larger driven pulley wheel, the
smaller driver pulley wheel rotates three times. This due
to velocity ratio. The ratio can be worked out
mathematically in different ways. The two most likely
methods are :
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PULLEY SYSTEMS
This means that the larger pulley wheel (the driven pulley wheel)
PULLEY SYSTEMS
The diameter of the driver pulley wheel is 600mm and
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PULLEY SYSTEMS
This means that the larger pulley wheel (the driver pulley wheel)
PULLEY SYSTEMS
Reversing Rotation
Sometimes it is necessary to reverse the rotation of the
driven pulley wheel in relation to the driver pulley. If the
driver is rotating in an anti-clockwise direction the driven
pulley may be required to rotate in a clockwise direction.
This is achieved by twisting the belt as shown in the
diagram. Care must be taken when this is done as the
belt can rub where it crosses and this may increase
friction or damage it.
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PULLEY SYSTEMS
Example
1.
2.
PULLEY SYSTEMS
Answer
1. Look at the animation below. The final output of pulley F
is a clockwise movement.
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PULLEY SYSTEMS
Answer
2. To answer the question, split the pulleys into pairs and
work out the velocity rotation of each pair. Treat the
pairs
of
pulleys
as
separate
questions.
Use the diameters when dividing and place the largest
number on the top of the division.
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PULLEY SYSTEMS
Pulley wheel A has an rpm of 60. Pulley B is larger and
PULLEY SYSTEMS
Pulley wheel E has the same rpm as pulley D because
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PULLEY SYSTEMS
Pulleys and lifting
Pulley systems can be used
to lift weights safely and
effectively.
The
diagram
shows a pulley attached to a
beam. The rope is pulled
on the effort side and the
weight being lifted is on the
right hand side, called the
load. In general a single
pulley is useful as it allows
the laborer to lift the weight
without bending his back.
This means it is much safer
to lift the weight.
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PULLEY SYSTEMS
The diagrams below show how a pulley can be
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PULLEY SYSTEMS
Pulleys and lifting
When using pulleys for lifting the formulas for mechanical
advantage and velocity ratio are very important. The
formulas are shown below.
FORMULAS RELATING TO MECHANICAL ADVANTAGE
Mechanical advantage is defined as the ratio of load to
effort. Pulley systems rely on this important relationship
between load and effort. The higher the mechanical
advantage, the easier it is to lift a weight.
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PULLEY SYSTEMS
The formula is best understood by writing it within a
PULLEY SYSTEMS
The pulley to the left is
suspended
and
as
a
consequence
the
mechanical advantage is
increased. This happens
because the rope on the left
and right of the pulley are
both lifting the LOAD, they
each lift half its weight. The
load is split into 2. The
calculation is shown below.
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PULLEY SYSTEMS
FORMULAS RELATING TO VELOCITY RATIO
Velocity Ratio (sometimes called movement ratio)- is
defined as the ratio of the distance moved by the
effort to the distance moved by the load.
The formula is also best understood by writing it within
a triangle.
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PULLEY SYSTEMS
Using
PULLEY SYSTEMS
A pulley system with the effort applied from previous slide is
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the mechanical
advantage and velocity ratio
for this pulley system
2. Work out the efficiency of this
pulley system.
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80
100N load?
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