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Gearbox Design Dimensioning Calculations

This document discusses the dimensioning of gearboxes. It describes: 1. The connection methods for different gearbox stages, including a glued connection for the first sun gear and a press fit connection for the second sun gear. 2. Calculations for the lifetime of ball bearings in the gearbox, including the radial load, speed, and load rating of the bearings. 3. Performing calculations in KISSsys to optimize gear parameters and define the structure, efficiency, ratios, inertia, backlash, and rated torque of the gearbox.

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Blaze123x
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122 views

Gearbox Design Dimensioning Calculations

This document discusses the dimensioning of gearboxes. It describes: 1. The connection methods for different gearbox stages, including a glued connection for the first sun gear and a press fit connection for the second sun gear. 2. Calculations for the lifetime of ball bearings in the gearbox, including the radial load, speed, and load rating of the bearings. 3. Performing calculations in KISSsys to optimize gear parameters and define the structure, efficiency, ratios, inertia, backlash, and rated torque of the gearbox.

Uploaded by

Blaze123x
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Dimensioning of Gearboxes

Dimensioning

Glued 1. Stage Press fit 2. Stage Ball bearings Feather key


connection connection

2
Dimensioning
Glued connection of the first sun gear (Henkel, technical books)
τ
 Safety factor: S = C � zul
τT
 τzul : permitted torsional stress (26.5 N/mm2, Loctite 648)
 τT : working torsional stress
 C: constant factor (clearance, temperature, materials, alternating stress,…)
 Datasheet: max. torque for one-stage gearboxes
Failed motor shaft connection

Press fit of the second sun gear (KISSsoft, DIN 7190)


 Definition of the tolerances
 Dimensioning for plastic deformation of shaft and hub
 Tightest fit: smallest hole of the carrier and biggest shaft diameter
 Calculation of the safety factors for both parts
 Dimensioning for slide through
 Loosest fit: biggest hole of the carrier and smallest shaft diameter
 Calculation of the safety factor
 Datasheet: max. torque of two-stage gearboxes Failed press fit

3
Dimensioning
Lifetime calculation of ball bearings (KISSsys, ISO 281)
a b
Known:
FB,r Fr
 Radial load: Fr = 306 N
 Speed of output shaft: n = 100 rpm
 Distance between ball bearings: a = 8 mm
 Distance between ball bearing A and radial load: b = 14 mm
FA,r
 Ball bearing NSK 608 DU:
 dynamic load rating C = 3300 N Sketch for lifetime calculation (GP42)
 static load rating C0 = 1370 N

Unknown:
 Lifetime L10h

Calculation:
 Radial load @ A: FA,r = Fr·(a+b)/a = 306·22/8 = 841.5 N
 Equivalent load: P = FA,r = 841,5 N
 Lifetime: Lh10 = (C/P)3·106/n/60 = (3300/841,5)3·106/100/60 = 10.000 h
 Datasheet: max. radial load Fr Custom solution (GP42)

4
Dimensioning
Calculations in KISSsys
 Set structure of gearbox and define calculations
 Optimisation of gear parameters
 Datasheet: efficiency, ratios, inertia, backlash, rated torque
(for given lifetime and speed)

Planetary stage calculation

Shaft calculation User interface

5
High-torque
Planetary Gearboxes

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