Documente Academic
Documente Profesional
Documente Cultură
Gearbox Study
Paul Titchener
October 23, 2014
C ONTENTS
1 Executive Summary
Mouth . . . . . . . . . .
Front Legs . . . . . . .
Rear Leg Transmission
Clock . . . . . . . . . .
4
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4
4
5
5
4 Analysis
7
8
8
10
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10
12
12
12
12
5 Structure
13
6 Power
13
13
14
L IST OF F IGURES
0.1
1.1
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
3.5
3.6
Gearbox render . . . . . . . . . . . . . . . . . . . . .
Example of Gearbox Simulation . . . . . . . . . . .
Alligator Mouth . . . . . . . . . . . . . . . . . . . . .
Alligator Legs . . . . . . . . . . . . . . . . . . . . . .
Alligator Back Leg Transmission . . . . . . . . . . .
Alligator Clock . . . . . . . . . . . . . . . . . . . . . .
Example of a MiniBajaGearbox . . . . . . . . . . . .
One of the gearbox side plates. . . . . . . . . . . . .
Nema 56 Face mount motor, McMaster 59845K540
Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Design . . . . . . . . . . . . . . . . . . . . . . .
Example Shaft . . . . . . . . . . . . . . . . . . . . . .
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1
3
4
4
5
6
6
7
7
8
9
9
4.1 Factor of Safety for the Gearbox Housing. The pocketing pattern is noticeable
in the coloring, but the FS never drops below 10. . . . . . . . . . . . . . . . . . .
4.2 Stress applied to the gearbox. Areas of high stress are made stronger by webbing
patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Displacement of the gearbox. This metric is why the gearbox was not lightened
further. Displacement does not excede .05mm (.002") . . . . . . . . . . . . . . .
7.1 Free Body Diagram of Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Free Body Diagram of Shaft 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Free Body Diagram of Shaft 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
13
14
14
1 E XECUTIVE S UMMARY
The purpose of this study was to design a gearbox to be used in a robotic fish. We decided
that we wanted to focus more on the gearbox side of the project than the aquatic fish, so we
designed five gearboxes and focused less on topics such as waterproofing, system integration
and buoyancy. With this end in mind, we decided to build a robotic alligator, and create a
large baseplate to mount everything on. The alligator is modeled after the alligator in Peter
Pan, so it also has a ticking clock inside of it.
The five gearboxes we designed were a gearbox to open the mouth, a gearbox to move the
front legs, a gearbox to move the back legs, a gearbox to move the hands on a clock inside the
alligator and a gearbox to actuate the tail.
My personal goal in this project was to use more of the analysis techniques that we learned
in Mechanics of Solids and Structures to drive mechanical design. Because of this, I chose to
design a simpler gearbox, that simply converted a high speed motor to a high torque output,
but to both use a very high power motor (2 horsepower) and to analyze the system to see if
and where if could fail. I calculated the radial and axial forces on the gears and used these
numbers to create a robust housing for a very high force gear-train.
2.1 M OUTH
Eric designed a mouth that can both open and stick out its tongue. This is accomplished
with a gearbox that both turns a rotary joint to open the mouth and pushes on a rack gear in
order to extend the tongue. The gearbox has a gear stacking of 12:72, 21:72, for a total ratio of
1:20.57.
2.4 C LOCK
Alex wanted to design a system with an unusual gear mechanism, so he chose to look into
designing a Geneva drive. This mechanism was first developed by Swiss clockmakers, and is
used to make a clock tick. Fittingly, he used in in the clock that identifies our alligator as the
animal from Peter Pan. The clock is made up of a motor driving a gear train that controls the
speed of the three hands. The second hand moves 60 times as fast as the minute hand, which
in turn moves 12 times as fast as the hour hand.
With this inspiration in mind, I designed a gearbox that has two CNC machined aluminum
side plates. One of these side plates also integrates sidewalls that retain oil. Both side plates
are lightened using a triangular pattern of webbing.
The motor bolts to one of these side plates and drives the geartrain. Bearings are pressed into
each sideplate. They are located using precision bored bearing holes and the bearing flange.
4 A NALYSIS
Loads were calculated on both the housing of the gearbox to determine how much weight
could reasonably be removed from the side plates. The gears themselves were also analyzed
to ensure that the gear teeth will not shear under the loads applied to them.
Figure 4.1: Factor of Safety for the Gearbox Housing. The pocketing pattern is noticeable in
the coloring, but the FS never drops below 10.
10
Figure 4.2: Stress applied to the gearbox. Areas of high stress are made stronger by webbing
patterns.
Figure 4.3: Displacement of the gearbox. This metric is why the gearbox was not lightened
further. Displacement does not excede .05mm (.002")
11
(4.1)
12
5 S TRUCTURE
All of the components of the alligator are mounted on a large extrusion. This gives us a very
large, open space to work with and also connects all of our components effectively.
6 P OWER
The motor selected was a 2 HP face mount, Nema 56 motor from McMaster. More details are
available in the Motor Power section.
13
14
RPM = 1750
RadPS = 1750 /60 * 2*pi; %radians/second
%1 kg
um2/s3 - so watts/radps = torque
MaxTorque = W/RadPS;
T = MaxTorque * 8.8507457
%% Stage 1
T1 = T
DP1 = 12;
Teeth1 = 14;
FW1 = .75;
R1 = Teeth1/DP1/2;
F1 = T1/R1;
Fa1 = F1*tand(14.5);
%% Stage2
T2 = T1*6
DP2 = 8;
Teeth2 = 14;
FW2 = 1.25;
R2 = Teeth2/DP2/2;
F2 = T2/R2;
Fa2 = F2*tand(14.5);
%% Stage3
T3 = T2*5;
DP3 = 6;
Teeth3 = 12;
FW3 = 1.5;
R3 = Teeth3/DP3/2;
F3 = T3/R3;
Fa3 = F3*tand(14.5);
%% Output
Tout = T3*5
15
F22A = asin(2.125/5.25);
F22 = [Fa2 * cos(F22A) ; -Fa2 * sin(F22A) ; 0];
F22pos = [-3.75 * cos(F22A) ; 3.75 * sin(F22A) ; 2.8475 - 1.25/2];
F23A = F31A; %perpendicular, just switch cos and sin
F23 = [F3*sin(F23A) ; -F3 *cos(F23A) ; 0];
F23pos = F21pos;
F24A = F22A %perpendicular see above
F24 = [-F2*sin(F24A) ; -F2 *cos(F24A) ; 0];
F24pos = F22pos;
16
F12A =atan(1.5/3.798);
F12 = [Fa1 * cos(F21A) ; Fa1 * sin(F21A) ; 0];
F12pos = [-4.5 * cos(F12A) ; -4.5 * sin(F12A) ; .975 + .75/2];
F13A = F11A; %perpendicular, just switch cos and sin
F13 = [F2*sin(F13A) ; F2 *cos(F13A) ; 0];
F13pos = F11pos;
F14A = F12A %perpendicular see above
F14 = [-F1*sin(F14A) ; F1 *cos(F14A) ; 0];
F14pos = F12pos;
17
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
CROC-920
TailMotor 59845K540
CROC-402
CROC-404
SecondStagePinion
CROC-405
CROC-403
CROC-406
CROC-407
GEAR 6 DP 12 TEETH
95584A211
91251A621
10
9712K82
11
CROC-409
Stage 1 Shaft
12
.625x.0775
Stage 1 Spacer
13
.75 x .035
Stage 1 Spacer
14
1x.065
Stage 1 Spacer
15
CROC-411
16
9712K86
NONE
17
9712K94
18
CROC-412
Output Shaft
19
CROC-413
LargeGearboxSideAssembly
20
CROC-414
SmallSideAssembly
19
10
11
14
10
17
18
20
13
12
15
16
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/14/2014
10/23/2014
DATE
F. SCHENEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
ASSEMBLY
TailGearBox
FINISH
SIZE
FILENAME
PART #
NONE
CROC-400
CROC-400
SCALE
1:8
SHEET
REV
10
1 OF 1
A-000
ITEM NO.
PART NUMBER
10
DESCRIPTION
QTY.
TailGearBoxHousingA
CROC-401
6383K244
6383K251
6383K257
97395A485
3
D
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/23/2014
10/23/2014
DATE
F. SCHENEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
ASSEMBLY
LargeGearboxSideAssembly
FINISH
SIZE
FILENAME
PART #
NONE
CROC-413
CROC-413
SCALE
1:4
SHEET
REV
10
1 OF 1
B
ITEM NO.
PART NUMBER
10
DESCRIPTION
QTY.
TailGearBoxTopPlate
CROC-408
6383K244
6383K251
6384K373
2
C
1
3
D
NOTES:
F
1.
2.
3.
DRAWN BY
DATE
APPROVED BY
DATE
10/23/2014
PROJECTION
DATE
STANDARD TOLERANCES
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
DESIGNED BY
P.TITCHENER
MATERIAL
ASSEMBLY
SmallSideAssembly
FINISH
SIZE
FILENAME
PART #
NONE
CROC-414
CROC-414
SCALE
1:8
SHEET
REV
10
1 OF 1
A
A
5.086
5.063
4.906
4.883
2.077
1.500
C
B
.000
C
10
3.500
6.000
6.500
2.707
3.632
4.132
7.994
7.494
5.967
10.768
12.489
14.566
16.643
17.816
17.316
2.077
.625
C
.003 A B C
3.288
3.772
.003 A B C
.003 A B C
6X
RIGHT
+.000
.250 - .001
1.
2.
3.
.500
.005 A B C
NOTES:
F
BACK
6X
.313
1.500
3/8-16 UNC
.750
.005 A B C
3.201
4X
3.274
12.489
12.202
12.075
16.643
4.998
5.493
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401
SCALE
1:3
SHEET
REV
10
2 OF 3
A
1.80
+.000
2.000 - .001
10
2.750
2.813
3.200
3.225
2.750
2.813
3.320
3.345
0
2.750
2.830
3.280
3.305
3.438
3.500
+.020
1.520 - .000
+.000
1.375 - .001
+.020
1.875 - .000
+.000
1.750 - .001
+.020
2.125 - .000
1.18
1.55
SECTION B-B
SCALE 1 : 3
SECTION A-A
SCALE 1 : 3
SECTION C-C
SCALE 1 : 3
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401
SCALE
1:3
SHEET
REV
10
2 OF 3
A
10
0
.300
.430
14.566
6.875
4.500
SECTION D-D
SCALE 1 : 3
LEFT
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
6061-T6 (SS)
TailGearBoxHousingA
FINISH
SIZE
FILENAME
PART #
NONE
CROC-401
CROC-401
SCALE
1:3
SHEET
REV
10
2 OF 3
A
10
1.25
4.50 BCD
+.005
.750 - .000
4X
2.36
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/20/2014
10/23/2014
DATE
F.SCHNEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
4130 STEEL
GEAR 8 DP 60 TEETH
FINISH
SIZE
FILENAME
PART #
NONE
CROC-405
CROC-405
SCALE
1:2
SHEET
REV
10
1 OF 1
A
10
.625" HEX
1.250
.625
+.000
.625 - .003
.625
3.813
3.313
1.235
.582
NOTES:
F
1.
2.
3.
0.XX
0.01
0.XXX
0.005
0.XXXX
0.0005
10/21/2014
10/23/2014
DATE
F.SCHENEIDER
PROJECTION
DATE
APPROVED BY
DRAWN BY
P.TITCHENER
STANDARD TOLERANCES
DATE
P.TITCHENER
DESIGNED BY
10/23/2014
MATERIAL
Stage 1 Shaft
FINISH
SIZE
FILENAME
PART #
NONE
CROC-409
CROC-409
SCALE
1:1
SHEET
REV
10
1 OF 1
A