Differential Gearbox Research Articles

Development of the manipulator hinge based on the original planetary differential gearbox

For manipulation in small spaces, a compact hinge based on an original planetary differential gearbox is pro-posed. The kinematic diagram of the gearbox is described, the methodology for choosing its optimal parameters is outlined, and compared with wave and traditional planetary gearboxes from leading companies. A joint design is presented, including a planetary differential gearbox, motor, an angle sensor and slip rings. A manipulator built on the basis of the proposed hinges is described.

Material Selection for Differential Gearbox under Torque Conditions: A Simulation-Based Study

Abstract: This research paper conducts an in-depth exploration into the structural behaviors of three distinct materials—Cast Iron, Copper Alloy, and Magnesium Alloy—within the framework of a differential gearbox under varying torque loads. Employing finite element analysis through ANSYS, the investigation systematically scrutinizes critical parameters such as total deformations, equivalent stress (von Mises stress), and shear stress. The primary aim is to offer insights that guide material selection strategies and enhance the optimization of design processes in automotive applications. The results illuminate nuanced material responses when exposed to torque conditions, presenting implications for real-world gear assembly scenarios. This study significantly contributes to the evolving knowledge base in automotive engineering, providing a foundation for wellinformed decision-making in material selection and design optimization for differential gearboxes.

Modeling and Structural Analysis of Rear End Differential Gear Box at Different Speeds with Different Materials

The main aim of this project work is to perform mechanical design & structural analysis of differential gear box. This is necessary when the vehicle turns. The Differential gear is a part for all four wheeler, wheel reserved the power from engine to gear box then by drive shaft to differential gear. A differential is a gear train that transmits an engine's torque to the wheels. During a turn, the outer and inner wheels of the vehicle are forced to travel along paths of different radii. A differential allows the outer driving wheel to rotate at a faster speed when compared to the inner driving wheel during a turn. The analysis is conducted to verify the best material for the gears in the gear box at higher speeds by analyzing stress, strain, total deformation and also by considering weight reduction. Generally, materials used for gears and gear shafts are Cast Iron, magnesium alloy, Cast steel. This project is testing different materials like Aluminum alloy material for reducing the weight of the differential gear box. In this work the differential gear box is designed with Catia V5R20 software. The complete design is imported to ANSYS 14.5 software and analyzed. This analysis is conducted to know the best material for gears in the gearbox at high speed. We consider the factors like stress, strain, total deformation. When comparing the stress, strain total deformation values of the three materials like cast steel, aluminum alloy, magnesium alloy for different speeds at 2400 rpm, 4400 and 115N-m torque. By observing analysis the Result will be displayed and compared to find the most suitable design

Diagnostic indicators of tooth flank wear based on the analysis of tooth spectral component parameters

The wear of gear tooth flanks of aircraft gas turbine engines is the most common and the most dangerous of their defects. Practice shows that vibroacoustic diagnostics is the most effective method for monitoring the technical condition of rotary machines, including gears. It has been shown that, in this case, it is difficult to use a widely applied diagnostic indicator of gear tooth flank wear as the intensity of an n-dimensional vector from a series of tooth harmonics. This is due to the need to measure vibration parameters in a wide frequency range and low intensity of higher tooth harmonics. The factors affecting the kinematic error, such as: technological factors (manufacturing and assembly defects), operational mode-related factors (speed, temperature, transmitted load), design-related factors (flexibility of gearing parts, tooth flank modification), and tooth flank wear, lead to a significant increase in the width of the tooth spectral component. This allowed us to suggest diagnostic indicators of wear based on the analysis of changes in its width. Using the example of a turboprop differential gearbox, we experimentally confirmed that the use of an auto power spectrum with filter width much smaller than the width of the tooth spectral component is ineffective in studying the defect being considered. The parameters of the spectral component of the first tooth harmonic such as its width at the selected levels relative to the maximum value and their combinations, and the tooth harmonic intensity defined as a function of the power spectrum density are more sensitive to wear. The resulting dependences of the proposed parameters on the amount of wear have a pronounced non-linear nature. These diagnostic indicators allow several-fold reduction of the frequency range being analyzed.

Effects of rotational speed on the natural frequency of the differential bevel gear

With the development of techniques for the use of gears and their many shapes and types, the mechanical need for them has become great, especially in the use of them in the field of cars, and the most important of these types are bevel gears, as these gears are considered essential in differential gears. The use of differential gears in mechanics in general helps to reduce noise in the movement, but there must be vibration resulting from this movement, and accordingly, bevel gears and the effect of rotating gears on free vibration have been studied. Variable gears were used according to a simulation program and the study of the free vibrations that occur to them. The effect of rotational speed on the natural vibration greatly affects the transmission of movement in the car and increases the fault distortions that occur in the differential gearbox. The result shows the natural vibration reached at the speed of 5000 rpm, and the value of the vibration reached 3564.5 Hz, which is the highest value compared to the remaining speed. The distortion at a speed of 1,000 rpm. The process of rotation and natural vibration affects the deformations and stresses that get on the gears themselves. The natural vibration is greatly reduced when the number of clamping places for the differential gear is increased. Compared to the presence of two spinning tires, the vibration value reduced. At a rotating speed of 5000 rpm, it is known that increasing the rotational speed raises the value 3015.9 Hz with one tire revolution with one tire rotation, the huge strains influence the little gears in the differential gearbox. The greatest value of distortion is 0.00067 m at 5000 rpm, which is the largest value of deformation compared to the rest of the employed rotational rates with one tire revolution.

Increasing the sensitivity and expanding the functionality of bipolar analysis of rotary machine vibrations

Vibration-acoustic diagnostics of rotary machine defects is the most effective method for non-destructive testing of their technical condition. Practice shows that its successful use largely depends on a set of available methods for analyzing vibration processes. Gears are the most common and heavy-duty components that largely determine the overall vibratory condition of a machine. There is quite a variety of methods for vibration-based diagnostics of gear defects. They include an interesting method of bipolar analysis which consists in separate analysis of the positive and negative parts of a vibration signal with subsequent formation of the diagnostic indicator in the form of differences, ratios, etc. The method is aimed at assessing the quality of gearbox assembly by the position of the tooth contact pattern. Limited area of use and low sensitivity is a disadvantage of this method. The paper shows that the use of broadband vibration maxima in the application of bipolar analysis in vibration-based diagnostics of rotary machine defects significantly increases its efficiency. Using the example of wear of tooth flanks in the sun gear satellite gears pair and the value of the backlash in the differential gearbox of a turboprop engine, it was found to be ensured by increasing the sensitivity of the method and expanding its functionality. In our analysis, we used statistics of gearboxes with different degrees of wear of the tooth flanks and repaired gearboxes with different backlashes. In this case, a wide set of well-known diagnostic indicators can be used: intensity of n-dimensional vectors of informative series, parameters of individual harmonics, amplitude modulation depth, probabilistic characteristics in selected frequency bands, dimensionless discriminants, cepstra, etc. The paper presents some examples of these methods.

РАБОТА КОЛЕСНОГО ДИФФЕРЕНЦИАЛА В ПРОЦЕССЕ РАЗГОНА ПАХОТНОГО АГРЕГАТА

The use of ballast on wheeled tractors leads to over-compaction of the soil, including sub-arable horizons. When overclocking arable units with buried working bodies at operating speed, the engine will inevitably enter the overload mode. This leads to a decrease in productivity, fuel overspending, and deterioration of environmental indicators. The authors proposed for the first time to equip the driving wheels with built-in differentials. The basis of the wheel differential development concept is the eccentric application of external loads and the driving torque to the wheel. The purpose of the research is to identify structural and operational factors affecting the efficiency of the wheel differential, to establish the nature of the relationships between them. The operation of the driving wheel tire occurs under conditions of a deformed support surface. Acceleration of a mobile power vehicle with a built-in differential in the wheels is presented as a two-stage process. The first stage of acceleration corresponds to the operation of the gearbox in the planetary gearbox mode, the second stage - in the differential gearbox mode. The translational movement of the wheel, its rotation along the bearing surface is possible if the torque on the wheel rim is provided by the moment of friction force in the contact spot. The rotation of the bearing gear along the epicyclical gear, the formation of the tilting and lever moments in the wheel reducer contribute to the advancement of the pressure center along the length of the contact spot in the oncoming sector of the wheel, an increase in the friction force and tangential force, ensuring smooth starting of the tractor unit. After overcoming the moment of inertia of the rotating and translationally moving masses of the unit, the value of the required moment decreases. The driving bearing gear, remaining in the lower position, rotates the wheel. The gearbox has switched to differential operation. At the same time, the driver performs angular oscillations, the magnitude of which depends on the conditions of movement of the wheel and the traction resistance of the unit. The amount of torque required depends on the design parameters of the built-in differential, operating conditions, and gravity applied to the bearing drive gear of the planetary gearbox

Design and Fatigue Optimization of Drive Shaft

This work aims towards the design and optimization of the drive shaft as there is increasing demand for weight reduction in an automobile vehicle. The drive shaft is basically a torque transmitting element which transmit the torque from the differential gearbox to the respective wheels. In general, the drive shafts are subjected to fluctuating loads as the torque requirement changes according to the road conditions. Due to this, the drive shaft should be designed considering fatigue failure. The Maruti Suzuki Ertiga model is chosen for design and optimization of the drive shaft. For the fatigue life predicting of the drive shaft, the S-N curve approach is used. Furthermore, the inner diameter of the shaft is varied to obtain the optimized diameter of a hollow shaft which can withstand these fluctuating loads without failure. Along with fatigue life prediction, the natural frequency of the hollow shaft is also calculated. Furthermore, the parametric analysis is carried out of fatigue FOS, Von mises stress, weight and natural frequency of the shaft by varying the diameter ratio of the hollow shaft, and the nature of variation of these parameters are plotted in their respective graphs. The design is validated by performing FEA analysis for each case of a hollow shaft using Ansys software. Finally, from the FEA analysis we conclude that the optimized dimensions of the hollow drive shaft are safe.

Design and Analysis of an Open Differential

A transmission or gearbox provides speed and torque conversions from a rotating power source to another device using gear ratios. The most common use is in motor vehicles, where the transmission adapts the output of the internal combustion engine to the drive wheels. Such engines need to operate at a relatively high rotational speed, which is inappropriate for starting, stopping, and slower travel. The transmission reduces the higher engine speed to the slower wheel speed, increasing torque in the process. We have designed a differential gearbox and tried to create the frictional contact between two mating gears. And we have performed the structural analysis on gear box by providing the torque to the assembly of crown gear and pinion gear, assembly of inner gears- spider gears and side gears and crown gear with the cage to attach spider gears. We have selected two kinds of alloy steel and have compared the factor of safety and structural analysis of the both.

Early Detection of Failure of Spiral Bevel Gears Used in Differential Gearbox

Early Detection of Failure of Spiral Bevel Gears Used in Differential Gearbox

Preliminary Design Framework for the Power Gearbox in a Contra-Rotating Open Rotor

Abstract Geared contra-rotating open rotors have the potential to further reduce fuel consumption relative to geared turbofans, but require a more-complex speed-reducing transmission system to drive the propellers. Hitherto, the preliminary design for such transmission systems has been reported independently of the overall engine modeling or has been limited by many predetermined engine constraints. This has restricted the feasible design space of the transmission systems. A simple transmissions preliminary design approach is needed that does not involve complicated mechanical assessments and can be integrated with engine preliminary design studies. This paper presents a novel design framework for sizing a double-helical differential planetary gearbox for a contra-rotating open rotor. An up-to-date methodology is proposed for the design of maximum load capacity gears for this application based on the power-transmitted, durability, and space envelope requirements. The methodology was validated with published data, demonstrating only very minor differences in geometry dimensions. Parametric analyses have been made to assess the impact of the design assumptions on gearbox dimensions. The framework also enables the identification of feasible torque ratios between the output shafts of the speed-reducer and the contra-rotating propellers driven by them. The impact of the torque ratio on the size of the gearbox has been analyzed for equal propeller rotational speeds and different speed ratios between the output shafts. This study shows that potential torque ratios lie between 1.1 and 1.33, with the higher ratios enabling more compact gearboxes having four or five planet gears.

A magnetorheological fluid based planetary gear transmission for mechanical power-flow control

Power transmission for mechanical systems often involves the use of clutching- or dissipative-elements to protect drive systems and provide steady output power. As standard implementations in motor-driven systems, these devices operate passively or in discrete states, providing limited controllability to the power output. This paper presents a magnetorheological-fluid-based differential (planetary) gear transmission which serves to variably couple motor power through a sun gear input to a load affixed to a planet carrier output. This is achieved both rapidly and continuously through controlled slippage between the ring gear of the device and its casing. Compared to conventional MR clutches, the unique functionality of the differential gearbox enables use of an MR brake with lower inertia than an in-line clutch. Through control of current supplied to the energizing electromagnet of brake component of the transmission, simple and reversible governing of output torque and speed is achieved. This behaviour is modelled and verified through testing, showing a 349% variation in brake torque for constant speed tests from the off state to the maximum capacity of the device, with a 262% variation in brake torque under a harmonic input displacement also observed. The versatility of the device demonstrated through PID speed and torque control.

Analysis and Simulation of the Electrical-Differential System of a Grab-Ship-Unloader-Crane

In the field of port handling for bulk-cargo with heavy load and high speed, the differential gear box is usually used for towing wire ropes, and then realizing the Horizontal transport and vertical unloading of goods. However, the design and manufacture of gear device which is difficult to maintenance is of high cost. Thus, there is a kind of electric differential system to realize the loading and unloading of cargo at present. This article focus on the transmission mode and the process of loading-unloading of electric differential device. With the kinematic model based on the Lagrange's equation, the electrical differential system state model is established. Several AMESim simulations of the system is used to analyzing the energy transfer of combined action under the condition of electric differential. It helps to learn which path are used and the proportion on each line of energy. Finally, in this article, the difference of the energy transfer characteristics between the traditional mechanical transmission and the electrical differential drive system are analyzed. It provides guidance for design and use of equipment transmission system.

Investigation of the characteristics of the component of vibration of gas turbine engine gearbox that causes fatigue failures of its structural elements in case of tooth flank wear

The paper presents an analysis of the component of vibration of the NK-12MP turboprop engine differential gearbox that is generated by the wear of the flanks of the teeth of the sun gear planet gear assembly pair and at certain values of its intensity may cause fatigue breakdown of the engines structural elements. A complex of diagnostic indicators is determined on the basis of this component. Its intensity is shown to be maximal in steady-state operation of the engine with the greatest run time. The data obtained by the spectrum of maxima are shown to have higher information content as compared to the autospectrum data. The complex of diagnostic indicators proposed on the basis of the component under consideration makes it possible to successfully control the technical condition of the differential gearbox by the defects of gear tooth flank wear.

A Comprehensive Review on the Transmission System of Electrical All-Terrain Vehicle

The purpose of this study is to explore the differences between the traditional or gasoline All-Terrain Vehicles (ATV) and the electrical ATVs. From the previous researches, it is evident in recent decades that electrical vehicles are environment-friendly and do not produce polluted gases to the environment. The research provides important insights about electrical vehicles and advantages over gasoline-powered ATVs. The paper highlights the use of electric motors with different types of batteries and strengths that make electrical ATVs highly effective as a “low performance” vehicle for simple activities. With the extensive literature review and comparative analysis, the paper indicates important findings that the transmission or the power drive system enhances the performance of the motor due to the use of a differential gearbox. The paper concludes that electric motor delivers better load resistance and effective performance.

Analytical and Numerical Approach on Design of Cageless Open Differential Unit

A differential is a gear train that transmits an engine’s torque to the wheels. During a turn, the outer and inner wheels of the vehicle are forced to travel along paths of different radii. A differential allows the outer driving wheel to rotate at a faster speed when compared to the inner driving wheel during a turn. It is designed such that, increase in speed of one wheel is balanced by a decrease in speed of the other. This ensures that the vehicle can negotiate a turning without slipping. The gears in the differential are supported by a cage which results in its bulky appearance and heavy form. This causes a number of disadvantages such as difference in length of the driveshafts and offset center of mass of the system due to asymmetrical design. Such a cage also adds additional weight to the vehicle and increases fuel consumption as a consequence. Its elimination results in a more compact and lightweight configuration. This paper focuses on the complete methodology of designing and analyzing a cageless differential. Various materials were considered for the assembly and one with adequate properties of strength, wear resistance and other core parameters was selected. Gear ratios were obtained through theoretical calculation and the values were used as input for designing using Solidworks software. Finite element analysis of the gear train was carried out using ANSYS Workbench to test the structural integrity and durability of the system through various types of analysis such as linear static structural, fatigue and explicit dynamic analysis. The results proved that the design meets the desired functionality and is an improvement to the conventional type of differential gearbox.

Vibration diagnostics of lateral clearance value in the toothed gearing of differential gearbox of a turboprop engine

Vibration diagnostics of lateral clearance value in the toothed gearing of differential gearbox of a turboprop engine

Analysis on the Force and Life of Gearbox in Double-Rotor Wind Turbine

In order to study the force and life of the key components in the gearbox of an existing double-rotor wind turbine, the design and structural parameters of the gearbox in the traditional National Renewable Energy Laboratory (NREL) 5 MW single-rotor wind turbine are adopted, and the fixed ring gear of the first planetary stage transmission is released to form a differential gearbox suitable for a double-rotor wind turbine with two inputs. The double input is used to connect the double rotor. Subsequently, the characteristics of the gearbox in a double-rotor wind turbine are discussed. On the basis of the constant rated power of the whole wind turbine, the total power is divided into two parts, which are allocated to the double rotors, then two rotational speeds of the two inputs are given according to different power ratios by complying with the matching principle of force and moment. Furthermore, the force acting on the pitch circle of the planet gear, as well as the force and life of the planet bearing of the two-stage planetary transmission are calculated and compared with a single-rotor wind turbine. The results show that the structural advantages of a double-rotor wind turbine can reduce the stress of key components of the gearbox and increase the life span of the planet bearing, thereby the life of the whole gearbox is improved and the downtime of the whole wind turbine is reduced.

Study On Speed Control Mechanism With Differential Gear Box By Cae Tools

This paper gives the comparative study among various techniques used to control the speed of three phase induction motor. Gear trains are one of the major reduction control technique in automobiles and the industrial sector. Present work focuses on the design development and analysis of a gear box with reduction. The objectives taken from the prior necessity, checked for three different motor speeds for better quality with low normal and high RPM. The motor connected to a reduction gear box known as differential gear box. The design analysed on the basis of motor speed that is RPM (2400 rpm, 6400rpm and 500 rpm). Material used for gear box and gears are EN24, the whole model developed in CATIA and the stresses observed in ANSYS. The possible output of initial analysis looks better than normal conventional materials.

Modelling and 3D Printing of Differential Gear Box

Modelling and 3D Printing of Differential Gear Box