Project Details

The mechanism needs to fulfill a certain set of requirements such as power and output speeds. To achieve such requirements, the project was divided in the following stages:

  • Selection and dimensioning of the gear transmission components.
  • Dimensioning of the structural system and device architecture.
  • Technical project of the device, creation of drawings for manufacturing.

    • Calculations

    To develop a capable robust device capable, the following calculations were performed:
  • Dimensioning of parallel gears;
  • Dimensioning of conical gears;
  • Calculation of gear forces;
  • Calculation of forces in supports (bearings);
  • Dimensioning of bearings;
  • Shaft key stress analysis;
  • Shaft yield strength;
  • Shaft rigidity strength;
  • Shaft Failure analysis and Fatigue life estimation.

    • Design for Manufacturing

    The device's casing was decided to be made in two halves. This would allow easy maintenance and also facilitate the casting procedure. The device would also incorporate appropriate sealing according to working environment conditions.

    Project Gallery

    A compilation of pictures and drawings of the speed reducer gearbox.

    Core Gears

    This is the first draft gear structure for the speed reducer.

    First Assembly Concept

    The first overview of what the final product would look like.

    Top View of the Final Gear Structure

    The final gear transmission structure. It is possible to visualize the shaft profile for assembly of elastic rings, bearings and gears.

    Main Assembly First Render

    High resolution layout: input shaft side view.

    Main Assembly Second Render

    High resolution layout: rotating arm output shaft side view.

    Fully assembled speed reducer

    Assembly Drawing

    A technical drawing of the speed reducer.

    Conclusion

    This project involved a constant need of adaptation due to the many possible equipment failure situations. It was crucial to ensure that calculations had no mistakes and that the system provides a safety factor high enough to resist unpredicted stress. It proved to be a good oportunity to understand the different stages of a project development and also a chance to analyse what the market has to offer in terms of equipment, such as motors, bearings and gears.

    Solidworks

    3D CAD; CAE

    Project Engineering

    Dimensioning and Selection of mechanical components.

    DFM & DFA

    Design for Manufacturing & Assembly

    Teamwork

    Adaptability

    Problem Solving