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    Book - Gears - India

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    desetek
    This document proposes a new gearbox design for driving rope drums in cranes. [1] The design uses a 3-stage helical gearbox with a planetary gear stage attached to directly drive the rope drum. [2] This evenly distributes torque around the drum circumference compared to a single pinion/bull gear arrangement. [3] The document provides details on the gear design, calculations, and manufacturing process to demonstrate the innovative new design.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Book - Gears - India

    Uploaded by

    desetek
    324 views12 pages
    This document proposes a new gearbox design for driving rope drums in cranes. [1] The design uses a 3-stage helical gearbox with a planetary gear stage attached to directly drive the rope drum. [2] This evenly distributes torque around the drum circumference compared to a single pinion/bull gear arrangement. [3] The document provides details on the gear design, calculations, and manufacturing process to demonstrate the innovative new design.

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    This document proposes a new gearbox design for driving rope drums in cranes. [1] The design uses a 3-stage helical gearbox with a planetary gear stage attached to directly drive the rope drum. [2] This evenly distributes torque around the drum circumference compared to a single pinion/bull gear arrangement. [3] The document provides details on the gear design, calculations, and manufacturing process to demonstrate the innovative new design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    324 views12 pages

    Book - Gears - India

    Uploaded by

    desetek
    This document proposes a new gearbox design for driving rope drums in cranes. [1] The design uses a 3-stage helical gearbox with a planetary gear stage attached to directly drive the rope drum. [2] This evenly distributes torque around the drum circumference compared to a single pinion/bull gear arrangement. [3] The document provides details on the gear design, calculations, and manufacturing process to demonstrate the innovative new design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 12

    Book

    6
    RAJANI HOIST & CRANES PRESENTS

    Crane Gearbox
    Helical/Planetary train
    MULTISTAGE HELICAL CUM PLANETARY DESIGN, CALCULATIONS & APPLICATION

    Crane duty gearbox Design proposal

    DOUBLE GEAR
    Transmission Elements
    Powered by
     Double Gear transmission elements
    #7 Muthumari chetty street. Mannady,Broadway,Chennai, INDIA
    Mob +91-9791222047
    E-mail: ceo.doublegear@gmail.com, www.doublegear.co.in

    Over 20 years, DOUBLE GEAR has earned a nationally recognized reputation for
    expertise in power transmission engineering and automation, cranes, hoist and crane duty
    modular gearbox design would helps engineers and manufacturers to construct robust
    infrastructures without any complications and completely tested & trusted.

    This is a promotional package, Strictly Not for Commercial purpose


    WELCOME

    Good Morning, I am Nagarajan from INDIA doing material handling


    equipment manufacturing, supplying and exporting, I always used to dream
    something innovative way to develop concepts and ideas in my field of
    engineering

    So for I have designed various components for the cranes, For example
    gearboxes, Electrical wire rope Hoists, electrical safety circuits and accessories.
    Among these, my Drum rope guide design, Cross pulling prevention
    Mechanisms, hypocycloid limit switches are very famously accepted in my
    colleagues organizations

    This time I have developed new design for gearboxes, It is very innovative idea
    for carne applications particularly for driving Rope drum application. Normally
    Drums are driven by Center shaft/ bull gear with pinion, which consume more
    power and make the gearbox stressful. The reason is the driven element is
    getting load from outer circumference, while driving element is laboring from
    center of the load. This might make the torque depletion

    By arranging The final stage Planetary method, The generated torque is evenly
    distributed to the all parts of the rotating part with Ring gear attached inside the
    drum and more safe from single shaft/pinion failure

    Comparing to conventional method by attaching Bull Gear with pinion, it is


    very compact and efficient , I would like to share my concept with you for
    further developments and improvements. I like to hear your valuable opinions,
    please share if you like this

    Thanks
    Nagarajan.B +91 9791222047 ( CEO)
    rajanihoistandcranes@gmail.com

    Thursday, May 9, 2019

    i
    SECTION 1 Basic idea

    Picture showing how the Gear box has been assembled

    This is a 3 stage helical gearbox with a planetary gear attached in final stage.
    Helical Gear box could be 35:1 ratio to 120: 1 Ration possible for minimum
    25Kw to 5 Kw power rating while final stage is 3.3 Ratio, totally 115:1 to 375:1
    ratio gearbox is possible. The planetary gear RIM gear should be attached in to
    the drum for final torque delivery. Total Gearbox Center Distance is 550mm

    ii
    SECTION 2 Data Sheet of the helical part

    Picture shows the Data Sheets of the Helical Gears manufacturing details

    This data sheets shows the design, calculations and Gear manufacturing
    details. The total gearbox design follows DIN 3990 method B drafting.
    Gearbox has been split in to 140+190+220=550mm. Blank OD, Gear
    cutting Details and Quality inspection details are given. Please see below
    topic for further details

    iii
    SECTION 3 Gear Design Details

    A close look of the Gear Finishing

    The strength calculation (tooth fracture, pitting, wear and temperature


    safeties) The strength calculations are carried out according to norms
    (DIN 3990, ISO 6336, etc.). it is maintained 15 Degree helix left for Gears
    and The same Right angle for pinion to balanced operation

    Furthermore, it is necessary to have some knowledge about gear


    technology, as you have to interpret the results. In general, one can say
    that, according to DIN 3990, part 11 (Industrial gear boxes), a safety
    factor for the root of 1.4 and a safety factor for Hertzian stress of 1 is
    sufficient. But we maintain 1.5 Service factors

    iv
    • Application Factor (service factor)
    The application factor considers uncertainties in load and impacts. It is
    always larger than or equal as 1. A hint for the factor can be found in the
    following table and more comprehensive information is available in DIN
    3990, DIN 3991 or ISO 6336.

    Working Working condition of the driven


    condition of machine
    the Driving
    Force Uniform Moderate Medium Heavy
    Uniform 1 1.25 1.5 1.75
    Moderate
    Impact 1.1 1.35 1.6 1.85
    Medium
    Impact 1.25 1.5 1.75 2
    Heavy Impact 1.5 1.75 2 2.25

    • Tooth thickness deviations (backlash)


    The geometry of the gears is calculated for backlash free state. To prevent
    the gears from jamming, the tooth thickness is manufactured slightly
    smaller (than the theoretical value). This decrease of the tooth thickness is
    called tooth thickness deviation. The upper tooth thickness deviation
    represents the maximal allowable thickness and the lower the minimal.
    Tolerance according DIN 3967

    Centre Distance
    Optimizing the centre distance regarding balanced sliding At a
    predetermined addendum modification factor for gear, the centre distance
    is calculated with this option, to compensate for balanced sliding of the
    gear pair. The calculation is carried out with automatic tip radius reduction
    according DIN 3960 Tolerance according to ISO (z.B. js6)

    v
    SECTION 4 Gear Quality Control method

    Picture shows how Gears and pinions are meshing

    All gears and pinions are having Addendum modification factor for
    balances sliding for noiseless operation. the proposal represents the
    addendum modification required for balanced specific sliding between
    pinion and wheel

    While Gears and Pinions are manufacturing, Span measurement over the
    no of teeth is strictly maintained according to the Addendum
    modifications and Center Distance. If the gears are designed for profile
    grounding,

    vi
    A close look of the Specific Sliding

    Specific sliding is shown as condition of sliding where


    engaged flanks slides to transfer the rotation except
    area of pitch point

    Sliding velocity is the relative velocity in a transverse plane of a


    common contact point between mating gear teeth. As shown in
    Figure it is the vectorial difference between the two rolling
    velocities that are tangential to the tooth profiles and
    perpendicular to the line of action. See references AGMA ( 2005)
    and ISO ( 2007) for gear nomenclature and definitions of terms.

    vii
    SECTION 5 How the Drum and Gearbox is connected

    Picture Shown Rope drum connected in to the Gearbox

    The planetary Rim gear is fastened in to the Drum inside. While the
    Carrier is fixed with Gearbox Housing, The planet Gears will rotate ring
    gears subsequently drum will rotate on the speed of Sun gear to Rim Gear
    ratio

    Drum Rotation always Same direction to Motor Shaft rotation


    Due to 3 stage and Planetary gears

    viii
    Picture Shown Open View

    Advantages:
    • Drum Circumference Evenly get Torque
    • Easy to maintenance For Serving
    • Consuming Less Power
    • More Compact for larger size drums

    Disadvantages (I feel some improvements requires)

    1. More moving parts


    2. Unique Ring gears required for Different OD Drums
    3. Manufacturing Cost Slightly increased

    ix
    The actual performances of this Design could be justified after
    manufactured and tested, Engineers, amateurs and friends Please give
    your suggestions and opinions for improvements

    I have future plans for implementing energy saving alpha starting


    gearboxes, Rapide Speed Gearboxes and compressors for Cross travel
    also. Definitely I would share my experience. Stay touched

    Please Note: This a prototype proposal. Still not verified & tested, If you
    like it, Please request me, I will send you manufacturing Drawings and
    specifications. Try to do improve yourself and share your experience &
    knowledge

    Thanks For Reading

    Nagarajan
    CEO, Rajani Hoist and cranes
    BANGALORE , INDIA

    Saturday, May 11, 2019

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