Gear Ratios & Torque

Gear Ratios and Torque
Review of Torque: Torque is a twisting force, like turning a screwdriver or doorknob, or turning a wrench or
bike pedals. Its units are force times distance. For example, if your wrench is 10 inches long and you push on the
end with a force of 48 lb, your bolt is tightened to 48 lb * 10 inches = 48 in*lb = 4 ft*lb. Or if you push down on a
bike pedal with 70 lb of body weight and the crank arm is 1 foot long, you have 70 ft*lb of torque going into your
bike drivetrain.
Gears: Gears are used to change direction of rotation and/or speed of rotation.
Two gears having the same number of teeth rotate in opposite directions at the same speed. In general, any time
you have two gears meshing together the direction of rotation changes.
Rack and pinion is used for steering systems on cars. The pinion is a small round gear; the rack is a flat gear.
The rack and pinion converts rotating motion to linear (straight-line) motion.
Bevel gears are used when you want to have input and output shafts non-parallel (car differential for rear-drive)
A worm gear rotates one turn of the input shaft for each gear tooth of the output shaft. It cant be back driven,
which may be useful for a robot arm lifting something. It also has higher friction than other types of gears.
The Input shaft is the one you are turning with the engine, a hand crank, an electric motor, or the steering
wheel. It is attached to the drive gear. The Output shaft is the one attached to the driven gear. The driven
gear is driven by the drive gear.
If you have an 8 tooth gear driving a 24 tooth gear, the 24 tooth (driven gear) will turn 1/3 as fast as the 8 tooth
input gear since each gear moves one tooth at a time. You can calculate the speed of the output shaft as follows:
Output speed = Input speed * drive teeth / driven teeth
Example: Output speed = 30 rpm * 8 teeth / 24 teeth = 10 rpm = 10 revolutions per minute.
If you have multiple gears you can multiply by each ratio of gears. Suppose the 24 tooth gear in the above
example is attached to a shaft which has an 8 tooth gear. Both of these gears rotate at the same speed since they
are attached to the same shaft. The 8 tooth gear drives a 40 tooth gear. So the output speed is:
Output speed = 30 rpm * 8 teeth / 24 teeth * 8 teeth / 40 teeth = 2 rpm
In this case the output rotation is in the same direction as the input rotation since there are two sets of gears,
reversing direction twice.
We visited a grist mill which used four sets of wooden gears to multiply the water wheels speed. They acted
like bevel gears, changing direction four times. The grindstones speed was 12 times the water wheel speed.
This allowed the mill to grind more corn per hour than most other gristmills, which had a lower gear ratio.
Here is a basic relationship for geartrains: Torque times Speed = Power. Except for friction losses, power remains a
constant in a gear train. In our example above, speed was 15 times smaller on the output shaft, which means torque
was 15 times greater! Our robot kits electric motors have high speed and low torque. If we want a slower speed and
higher torque for drive wheels of a robot, we will have to design a geartrain that slows down the speed. This will
multiply the torque.
Another example of gearing is a bicycle chain and sprocket system (each sprocket rotates one chain link at a time).
Usually there are more teeth on the chainring (attached to the the crank) than the rear sprocket. So the output speed
(the rear wheel) is faster than the input speed (the pedals and crank). Bikers sometimes choose their sprocket sizes
by calculating the gear ratios in gear inches. This is done by dividing the number of teeth on the chainring (drive
gear) by the number of teeth on the rear sprocket and multiplying by the wheel diameter. My touring bike has these
ratios for low & high gear:
26 tooth granny gear chainring / 34 tooth rear sprocket * 27 inch wheel = 20.6 gear inches
48 tooth large front chainring / 13 tooth rear sprocket * 27 inch wheel = 100 gear inches.
Racing bikes have a much narrower gear range, say 60-110 gear inches. You can even calculate how fast youre
going if you know your pedal cadence or rotating speed in revolutions per minute. 90-100 rpm is the most
efficient pedal cadence for long distance riding: higher speed than the usual 60 rpm many people ride at, but easier
on the knees & muscles since you dont have to push as hard (lower torque). The circumference of the wheel is
3.1416 times its diameter, so this is the distance traveled in one wheel revolution. This ratio of circumference to
diameter is represented by the Greek letter Pi, written . So heres my bike speed when lugging up a long hill at 60
pedal rpm:
60 rev/min * 26 teeth / 34 teeth * 27 inches * 3.1416 = 3892 inches/minute. Not too useful, so we convert units:
3892 inches / minute * 60 minutes / hr * 1 ft / 12 in * 1 mile / 5280 ft = 3.7 miles per hour.
This isnt very fast but it sure beats pushing the bike up the hill! Coming down the other side in top gear:
110 rev/min * 48 teeth / 13 teeth * 27 inches * 3.1416 * 60 min/hr * 1 ft / 12 in * 1 mile / 5280 ft = 32.6 mph.

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