Abstract
The generator generate optimum electrical energy if drive system sends the power from turbine to generator with the direction of rotation and speed as needed. The object of this research, how to design spur gear transmission apply for pico hydropower. There are several point to design spur gear transmission, i.e. the bending stress and contact stress on the teeth, and shear stress on the shaft. The strength of the tooth and shaft, simulation using by Ansys Workbench 14.5. Materials used to manufacture gears is polyamide 6 and the shaft material is teflon. Furthermore if design allowable the process of manufacture can be begin, and if manufacture finished, carried testing transmission on the pico hydropower prototype. The result of this research are the design spur gear transmission have total gear ratio 1: 2.65 with two pairs of gears each 1:1.73 and 1 : 1.52. Simulate using by Anys Workbench 14.5 shows the value maximum bending stress 6,1453 MPa on the gear driven first mate, the contact stress 15,415 MPa on the gears driving first mate, and shear stress 1,7688 MPa on the output shaft. Experimental test show the gear transmission produce electric power higher than the electric power produced by direct transmission.
Highlights
The generator works optimally when the drive system sends turbine power with the appropriate rotation direction and speed
The purpose of this study is to investigate the bending stress and contact stress on the gears and shear stress on the multilevel shaft using numerical simulation methods using Ansys Workbench 14.5 software
The results of this study show that the greatest bending stress occurs at the root of the tooth, the largest contact voltage occurs in the pitch line, while the shear stress on the multilevel shaft occurs at the smallest diameter
Summary
Pico hydro merupakan pembangkit listrik tenaga air dengan daya maksimal yang dapat dihasilkan 5 Kw. Beberapa penelitian sebelumnya menyatakan dalam menganalisis tegangan bending [12,13,14,15,16,17] dan tegangan kontak [10, 18] pada roda gigi lurus menggunakan metode numerik menunjukkan hasil nilai tegangan maksimal yang tidak jauh berbeda dengan perhitungan secara teoritis. Hasil analisa simulasi numerik menunjukkan tidak adanya perbedaan dengan analisa eksperimental, pada pengujian eksperimental menunjukkan potensi kegagalan karena tegangan bending terjadi pada akar gigi, dan keausan terjadi pada bagian yang mengamali kontak antar gigi atau bagian involute atai pitch line [22]. Obyek dari penelitian ini terletak pada analisa distribusi tegangan bending dan tegangan kontak pada transmisi roda gigi dengan material polymer nylon 6, serta analisa tegangan geser yang terjadi pada poros menggunakan material polyamide 6, sehingga diketahui kelayakan roda gigi dan poros yang dirancang sebagai sistem transmisi melalui nilai keamananya. Selain itu dapat diketahui titik paling kritis atau kemungkinan terjadi kegagalan kerja pada design
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