MEEE30003, Machine Design, Swinburne S1 2017

1. CRICOS 00111D TOID 3059
Acrylic Gear Box Creative
Process
Alex, Marcus, Matt And
Jordan

2. Design Considerations
• Standardised Motor
• Lifting of 10kg weight 500mm up a 1000mm long
ramp rested on a bench 725mm high
• Mounting Board in EN216,EN217, secured
through studs on board and nuts provided
• We have performance indicators to hit

3. Performance Indicators
• p= (mgh)*(mgh)/(Vit)*(tD^3)
• s= (p-pmin)*10%/(pmax-pin) +10%
• p= perfromace
• s= score for project
• m= mass lifted (kg)
• g= gravity (m/s^2)
• h= height of lifted weight (m)
• V= voltage(V)
• I= current (A)
• D= max axial length of gear box

4. Creative Process

5. Group Communication
• Matt, Marcus, Alex, Jordan
• Formation of group/first meeting
• Began with individualising ideas:
- allowed for a breath of ideas
• Brought together ideas into group
• Sketching of initial plans
• Presenting today

6. Individual Brainstorms
• Gears(which works in for our needs)
• Adhesives
• Line we use (string/fishing line)
• Lubricant
• Assembly
• Use of SCAMPER and 635 brainstorming
methods for breath of ideas
• Plans for Gear systems

7. Brainstorms Part 1- Gears
 Spur Gears
Straight teeth
Easily cut/designed in CAD and implemented into
gear systems
Gears are linearly placed and mounted on parallel
shafts
Low speed, high noise, wear easily
Can be constructed in wide range of gear sizes and
that the gear ratio can be altered for specific toque or speed
output
 Planetary Gears
Consists of an outer ring, sun gear and planet gears
The one gear is the input which transmits torque to
the other gears
Torque is divided equally among the planetary gears
Highly efficient, and small in size
Reduced wear on gear system due to the torque
being dived between gears

8. Brainstorm Part 2 – Adhesives
Epoxy: two part glue for mix, withstands vibrations and
shock, designed for non-porous surfaces, waterproof
PVA: Easily available, glue excess common, setting time 1
hour
Hide Glue: Not waterproof,
Cyanoacrylate(super glue): fast curing, can fracture under
impact, very quick setting time, careful when handling
Polyurethane: activated by moisture, waterproof
 Note: could use a lock-in system so there would be no use
of glue, only thing to consider it is difficult to implement, but
it also means parts are easily reusable

9. Brainstorms Part 3 - Line
 Brained Fishing Line
Little or no stretch, abrasion resistant, thin
 Monofilament Fishing Line
Good knot strength, abrasion resistant, mid to high strength
 Fluro Carbon Fishing Line
Low stretch, excellent abrasion resistance, good knot strength, stiff, high cost

10. Brainstorms Part 4 - Lubricant
 Oils
Low resistance, high friction when exposed to dust or dirt
Used in small spaces
Short lasting
 Greases
Typically used for gears and bearings
Long lasting
Seals out contaminates
Can be messy
 Penetrating Lubricates
Short lasting
low viscosity
Infiltrates small areas

11. Beginning of Design Process
• Basic calculations of gear box, for
testing environment
• Design of gear box

12. Design #1 -
• From gear set one a double
reduction motor would
decrease the output speed and
increase the output torque
• Conversely, with the gear set
two switched around(gears to
pinions and pinions to gears) it
show the increase in output
speed causes a decrease in
output torque

13. Design #2 -
Gear box consists of:
 3 big gears,
 4 small gears (1 as pinion)
 4 shafts
 8 pin locks
 1.2m of fishing line
 1 motor
Gear specification:
Small gear:
 Number of teeth (N) = 10
 Pitch diameter (D) = 0.5 inch = 12.7 mm
 Diametral pitch (P) = 20
 Pressure angle (PA) = 20o
Big gear:
 Number of teeth (N) = 40
 Pitch diameter (D) = 2 inch = 50.8 mm
 Diametral pitch (P) = 20
 Pressure angle (PA) = 20o
Gears Ratio RPM
1 1:1 360
2 1:1 360
3 1:1 360
4 1:1 360
5 1:1 360
6 4:1 90
7 4:1 90

14. Design #2 – Part 2
Gear box consists of:
 4 big gears
 4 small gears (1 as pinion)
 4 shafts
 8 pin locks
 1.2m of fishing line
 1 motor
Gear specification:
Small gear:
 Number of teeth (N) = 10
 Pitch diameter (D) = 0.5 inch = 12.7 mm
 Diametral pitch (P) = 20
 Pressure angle (PA) = 20o
Big gear:
 Number of teeth (N) = 40
 Pitch diameter (D) = 2 inch = 50.8 mm
 Diametral pitch (P) = 20
 Pressure angle (PA) = 20o
Gears Ratio RPM
1 1:1 360
2 4:1 90
3 4:1 90
4 16:1 22.5
5 16:1 22.5
6 64:1 5.63
7 64:1 5.63

15. Finishing Notes
• Approximate needed output torque 0.3147Nm
• Motor output toque 0.008Nm
• Static force of the object (assuming static
coefficient is 0.5) is 104.9N
• Kinetic force of the object (assuming kinetic
coefficient is 0.2) is 84.64N
• Incline Angle is 46.47 degrees

16. Design #3
• Assuming torque wanted is 0.32Nm
• N = 25 teeth
• Output force by the gearbox is 106.7N
(more than static force)

17. Extra Notes