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Lec #3_GearBox Design-Part 2

Presentation · November 2018

DOI: 10.13140/RG.2.2.19680.12801

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MECHANICAL DESIGN
DPE 301
Mohamed Ibrahim Shaat

Zagazig University

Mechanical Deign & Production Eng. Department

Fall 2018
Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram

• A Ray Diagram is used to define the transmission ratio between two
successive shafts.

• In Ray Diagram, rays are drawn representing the transmission

between shafts.

• Rays are drawn for the lowest speed of the last shaft.
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Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram

Example:

Design a gear box for a machine to give 12 speeds ranging from 31.5 rpm to
2000 rpm. The power is supplied by an electric motor running at 1440 rpm,
through a V-belt drive with a speed reduction of 1.44.

Given: 𝑍 = 12, 𝑁𝑚𝑎𝑥 = 2000 rpm, 𝑁𝑚𝑖𝑛 = 31.5 rpm, 𝑁 = 3, 𝑁𝑚 = 1440 rpm,
transmission from the motor shaft to the first shaft of the gearbox is 1.44.

The structural formula is:

𝑍 = 2 1 3 2 2(6)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram Motor

Shaft I II III IV
1. If the motor speed is reduced via a belt
drive or a gear train before entering the
gearbox, draw 𝑁 + 2 vertical lines. If not,
draw 𝑁 + 1 vertical lines.
2. Name the shafts on the vertical lines. If
there is a reduction of the motor speed,
starting naming the shafts from the
second vertical line on the left.
3. Draw 𝑍 + 1 or 𝑍 horizontal lines.
4. Mark all the calculated speeds on the
last shaft (the line on the right). 2(1) 3(2) 2(6)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram Motor

Shaft I II III IV
5. Draw the 3rd Stage: 2(6) 2 Rays
with 6 speed steps.

• Mark a point at the minimum speed

(31.5).

• Move 6 steps (till 250) and mark

another point (remember two rays
 two points).

• Calculate 31.5/0.25 = 126.

• Select the nearest lower speed to

2(1) 3(2) 2(6)
126, which is 125.
Mohamed Shaat MECHANICAL DESIGN ZU
Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram Motor

Shaft I II III IV
5. Draw the 3rd Stage: 2(6) 2 Rays
with 6 speed steps.

• Does the obtained speed (125) is

higher than the speed at the second
point (250)?
If No, mark a point at speed (125) on
Shaft III.
If yes, choose a value higher than 0.25
that make the point on Shaft III
between the two points marked on
2(1) 3(2) 2(6)
Shaft IV.
Mohamed Shaat MECHANICAL DESIGN ZU
Design Procedure of Multi-Speed Gear Boxes

Motor
STEP 4: Draw Ray Diagram Shaft I II III IV
5. Draw the 3rd Stage: 2(6) 2 Rays
with 6 speed steps.

• Connect the marked points with

lines (see blue lines).

Note: Why 0.25? For a compact

gearbox with a suitable radial
distances between shafts, the
transmission ratio between any two
shafts should be within the range:
2(1) 3(2) 2(6)
𝟎. 𝟓 ≤ 𝒊 ≤ 𝟒
Mohamed Shaat MECHANICAL DESIGN ZU
Design Procedure of Multi-Speed Gear Boxes

Motor
STEP 4: Draw Ray Diagram Shaft I II III IV
6. Draw the 2nd Stage: 3(2) 3 Rays
with 2 speed steps.

• From the point on Shaft III, mark

other two points with a step 2 (go
up). (Remember 3 ray  3 points on
Shaft III).

• Calculate 125/0.25 = 500.

• Mark a point at 500 on Shaft II.

• Connect three lines as shown (3 2(1) 3(2) 2(6)

green lines).
Mohamed Shaat MECHANICAL DESIGN ZU
Design Procedure of Multi-Speed Gear Boxes

STEP 4: Draw Ray Diagram Motor

Shaft I II III IV
7. Draw the 1st Stage: 2(1) 2 Rays
with 1 speed steps.

• From the point on Shaft II, mark

another points with a step 1 (go up).

• Calculate the speed of Shaft I:

𝑁𝑚 1440
= = 1000
𝑖𝑏𝑒𝑙𝑡 1.44
• Mark a point at 1000 on Shaft I.

• Connect two lines as shown (2 purple

2(1) 3(2) 2(6)
lines).
Mohamed Shaat MECHANICAL DESIGN ZU
Design Procedure of Multi-Speed Gear Boxes

Motor
STEP 4: Draw Ray Diagram Shaft I II III IV
8. Draw a line from the point on Shaft I
to the a point at the speed of the Motor
Shaft. (See the pink line).

2(1) 3(2) 2(6)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

Motor
STEP 5: Draw Speed Chart Shaft I II III IV
Similar to the Ray Diagram, draw the
remaining rays according to the
structural formula, as shown.

2(1) 3(2) 2(6)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

The objective in this step is to draw a
gearing diagram of the gearbox based on
the structural formula and the speed chart.

EXAMPLE: Z=2(1)2(2)

1. The speed chart indicates no speed

change from the motor shaft (MS) to Shaft
I. Thus, the motor can be directly coupled
to Shaft I or a belt derive system (as the
one shown) can be used with 𝑖 = 1.

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

EXAMPLE: Z=2(1)2(2)

2. From Shaft I to Shaft II there are two

probabilities of speed. One of them with 𝑖 = 1
and the other one will reduce the speed to 784
from 1097.6. Therefore, sliding mesh two-gears
system can be used for the speed transmission
from Shaft I to Shaft II (see gears a, a’, b, b’).

Notes:

• Gear a should be smaller than gear b to give

lower speed.

• Gears b and b’ have the same number of teeth

(𝑖 = 1).

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

EXAMPLE: Z=2(1)2(2)

3. Stage 2 is similar to Stage 1.

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

EXAMPLE: Z=2(1)3(2)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

EXAMPLE: Z=3(1)3(2)

Mohamed Shaat MECHANICAL DESIGN ZU

Design Procedure of Multi-Speed Gear Boxes

STEP 6: Draw Gearing diagram

EXAMPLE: Z=3(1)3(2)

Mohamed Shaat MECHANICAL DESIGN ZU

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