Project - Guided Gear Design for an Escalator Background It is necessary to for you to design a gearbox system for a passenger escalator. For design purposes, the escalator may be considered as steps mounted on two endless chains, where each chain passes over two 300 mm pitch-circle-diemeter (PCD) sprockets with a centre distance of 12 m, and a difference in height of 6 metres, as shown in Figure 1. The escalator has 26 steps, each 800 mm wide, which are pin jointed to the chains and carried on fixed slide ways coincident with the full length of both chains. The weight of each step and its portion of the chain is 27 kg. The escalator must he capable of moving fully laden with passengers up the incline at approximately 0.8 ms-1, continuously for 10 hours per day, for 300 days per year. It can be assumed that, when fully laden, each step 's supporting two people each with a weight of 75 kg The coefficient of friction between the steps and the slide is 0.1. ‘The drive for the escalator is provided by a geared motor with an output speed of 200 rpm through a single reduction helical gearbox. Flexible couplings are to be used between the geared motor and gearbox, and between the gearbox and escalator. These may be assumed to be capable of transmitting torque, but not bending moments. In designing the gearboy, it is advisable to make an allowance for a50% overload. A schematic diagram of the drive system is given in Figure 2. Prior Knowledge A colleague has provided a preliminary estimate for the design of the gears and has suggested a module of 4 mm might be appropriate. This colleague also pointed out that in order to avoid the need for undercutting of the gear teeth, a minimum number of 1 teeth would be required on either gear. However, these are preliminary estimates, and they will need to be checked in your analysis, Design Constraints ‘The gears are to be manufactured from EN27 steel forgings and will have a standard involute profile, with a 20° pressure angle and a helixangle of 30°. Assume 95% efficiency of gears. The shafts are to be machined either from carbon steel or from alloy steel, For carbon steel, a yield stress of 280 MPa may be assumed. Foralloy steel,a yield stress of 460 MPa may be assumed,Figure 1 - Schematic Diagram of Escalator Drive Figure 2 - Plan View of Transmission geared motor G flexible coupling Description of Task helical reduction gearbox exible coupling { escalator upper | sprocket shaft As part of your design, you will need to undertake the following tasks: Estimate the loads imposed on the escalator; Calculate the torque required from the gearbox; Calculate the gear forces; Determine the face width of the gears; Assess whether the preliminary estimates for the gear size are satisfactory;‘© Suggest any modifications to the gear design if necessary; + List all assumptions, + Provide concluding marks for the selected design You can use and ISO and BS Specification documents (provided) and a data table (provided) as a guide to help you design of the gears (e.g. face width, module, number of teeth). The design must meet the following constraints to be considered as optimised Constraints must satisfy Diameter of pinion gear (d1) > 2 x Axial pitch (P,) Face width ofthe pinion gear (b) < Diameter of pinion gear (d1) ‘Actual contact stress (au) < Allowable contact stress (ow) (pinion gear) Actual root bending stress (1) < Permissible tooth root bending stress (cir) (pinion gear) © Actual contact stress (on) < Allowable contact stress (oir)? (driven wheel) * Actual root bending stress (a+) < Permissible tooth root bending stress (ore) (driven wheel) You will be required to submit a report which describes the design challenges, as, well as the approach that you have taken in designing each of the items. Any assumptions that you make should be mentioned in your report. The main body of the report should not exceed 3 pages in length. It would he appropriate to include a summary of your calculations (table 2) in your report, but detailed calculations should be attached as an appendix, rather than being included in the main body of the report. Assessment The assessment for this task will be based on a report. The mark that is achieved for the report will contribute 15% towards vour finalmark for the ~ teats The following criteria will be used to assess the reports: Final report Introduction to the overall design task (10%) Description of the key features of your design and the rationale for the design choices that have been made (30%) ‘= Design calculations (50%) © Overall quality of report (10%) Timelines ‘The project will start on Friday October 29.2015 for this project will be carried out over 5 weeks of the semester. The deadline for the submission of the report is 11:00pm on The following guide is provided to assist in managing the progress of the project. Table 1: Suggested Timetable for each Project TaskWeek | Task Famiiliarisation with task. Read the ISO and BS support documentation. Sketch a body diagram. Estimate loads, friction and torque imposed on the escalator. Calculate the gear Stress, loads, reactions and dimensions. Use the data table to assist the gear design. Assess suitability of preliminary gear design. + Refine gear design (if necessary). © SubmitReport. Table 2: Suggested calculations It is necessary to for you provide results for the following and append th e calculations. Calculation | Description Result | Units Number z Angle of incline of elevator (0) 3 Individual loads on sprocket (1) 4 Individual loads on sprocket (2) 5 Friction on slide (i) _ 6 Friction on slide (f:) 7 Load on sprocket (F) 8 ‘Torque on sprocket (7) _ 9 ‘Angular velocity of sprocket (@) 10 | Gearing ratio (u) 11 | The allowable contact stress (ie) 12 |The actual contact stress (sup) 13 | The permissible tooth root bending “stress (on) |__14 | The actual root bending stress (07) 15 | Axial pitch (P.) 16 | Normal pitch (P.) 17 ‘Transverse pitch (P,) _ 4 18 | Wheel diameter (diz) 19 | Tangential forces on the gears (Fh) 20 | Pinion torque (7) 21 | Number of teeth on the wheel (z2)