Gear Reduction Unit Research Articles

Design and development of hydraulic controlled tractor front mounted twin conveyor onion (Allium cepa) digger

In India and many developing countries harvesting of onion (Allium cepa L.) crop is done manually which is cumbersome and time-consuming. The tractor-operated front-mounted twin conveyor onion digger was designed and developed during 2019 in Divisional Workshop (Farm Machinery and Power Engineering) at Govind Ballabh Pant University of Agriculture and Technology, Pantnagar, Uttarakhand. It had five blades made of mild steel (320 mm × 150 mm × 12 mm size) bolted to the base plate instead of one single share to strengthen the share. Onion and soil were separated over conveying unit. Power from the rear PTO (Power take-off) of a tractor to the front-mounted digging unit was conveyed through a power transmission unit which consisted of a gear reduction unit, V-belt and pulley arrangement, and 40 mm diameter of the propeller shaft. The lifting, lowering, and depth were controlled with the help of two single-acting hydraulic cylinders. The biometric and physical properties of onion bulbs (Agri found light red) were found average with equatorial and polar diameter, plant height, neck thickness, and weight of onion dry leaves as 36.19 and 37.19 mm, 284.05 mm, 6.80 mm and 30.19 g respectively. The average soil cone index, moisture content, and bulk density (before transplanting and harvesting) of soil were observed to be 1 kg/cm2, 17.22,12.58%, and 1.50, 1.38 g/cm3 respectively. The performance evaluation in the field found a maximum percentage of exposed and minimum damaged bulbs as 82.55% and 13.51% respectively, at a forwarding speed of 1.5 kmph and conveyor speed of 2 kmph. The field efficiency of the machine was 87.46%.

Development of low-cost self-propelled multi-purpose power unit

The self-propelled multipurpose power unit was developed in the laboratory of Farm Machinery and Power Engineering, JNKVV, Jabalpur for small farmers. The prime mower is powered by a 5hp diesel engine. The V-belt drive is provided for the transmission of power from the engine to the traction wheels. An adjustable accelerator wire is connected to the governor for adjusting the engine speed according to the requirement. The worm gear reduction unit is located at the axle having a speed reduction ratio of 20:1. A telescopic type frame is provided to support the end of the adjustable output shaft with the help of a bearing. The handle is modified to vary the height from 1.0 to 1.3 m from the ground. The additional lug cage wheel is connected to the transport wheel to increase the traction. Noise and Vibration isolators are provided between the engine and chassis to reduce the noise level and vibration. The noise level of the power unit was suitable for 8 working hr. The range of noise with load conditions is 60, 65, 70 (dB) and without load conditions 74, 79, 86 (dB), this limit of noise is under the permissible limit 90db. Vibration range according to optimum rpm 1200, rated rpm 1500 and maximum rpm 1800 so the output range of vibration in Handle 130 μm and chassis 217 μm, Handle 127 μm and chassis 198 μm, Handle 121 μm and chassis 193 μm.

CES 2022: Less is More

AbstractScaled‐down show still delivers top‐notch exhibits and innovation aplenty.

Design and development of power operated walking type weeder cum furrow maker for vegetable crops

The developed power operated weeder cum furrow maker machine consists of discarded scooter engine, gear reduction unit, shafts, chain sprocket mechanism, blade wheel, furrow maker plough. It is durable to bear the loads while operating the machine. Weeding working width can be adjusted from 30 cm to 70 cm with two rows working at a time. Furrow maker easily covers the row spacing of 25 cm. Engine rotates at 215 rpm which in firstly reduced by gear reduction at 16:38 and then reduction in wheel takes place with chain sprocket mechanism of 14:38.

Performance evaluation of self-propelled power operated cutter bar mower

The power-operated cutter bar mower unit was developed in the laboratory of Farm Machinery and Power Engineering, JNKVV, Jabalpur for small farmers. The prime mower is powered by a 5hp diesel engine. The V-belt drive is provided for transmission of power from the engine to the traction wheels. An adjustable accelerator wire is connected to the governor for adjusting the engine speed according to the requirement. The worm gear reduction unit is located at the axle having a speed reduction ratio of 20:1. The cutter bar mower consisted of six main components including the cutting, transmission, power, handling, frame, and transporting units. Two skids were attached to the cutter bar unit, one on each side, to control cutting height. Performance tests of the mower resulted in an average 0.08 ha/h effective field capacity, 1.40 L/h fuel consumption, 0.761 field efficiency, 2 km/hr of average speed, and 30 mm cutting height.

An Electric Drive for a Drilling Rig Top Drive System

The operation of a drilling rig top drive system (TDS) in drilling practice at a great depth or during the construction of a drill pipe stand in the case of failure of one of two motors is considered. In the existing kinematic scheme of most domestic and foreign TDSs, the two motors are mechanically rigidly connected to the drive shaft through a gear reduction unit. It is proposed to replace the gearbox with rigid mechanical connections with a double planetary gear reducer and, thereby, ensure the operation of the electric drive with two independent mechanical channels. Such a kinematic scheme with independent mechanical channels makes it possible to provide the drilling rig operation at great depths in the case of failure of one of the drives and when constructing pipes when disassembling the drilling string. Due to a wider range of torque control for each of the two channels, in the case of failure of one of the drives, the proposed scheme implements the indicated operating modes at a reduced speed, avoiding expensive downtime. The static mechanical characteristics of the TDS for the existing and proposed systems are presented. The calculation of the mechanical converter providing the required gear ratios for each of the mechanical channels is performed. The operation of the control system and power distribution unit of two drives is considered.

Design and output characteristic analysis for power head of truck-mounted drilling rig

Truck-mounted drilling rig is an important equipment for coalbed methane drilling construction, and the power head is one of the main actuators for truck-mounted drilling rig which has significant influence on technical feature of drilling rig. Now the power head of the rig is mostly driven by the motor + gear reduction unit to drive the main axle, the load change with the time, which had more influence on the rotation circuit. At the basis of analysis on load characteristics, a hydraulic control system with two-pump and two-circuit control was designed. The dynamic analysis model of the system is established, and the output characteristics of the system under no-load starting and on load starting are analysed. The analysis results show that: the response time of no-load starting pressure is 0.3s, the response time of on load starting pressure is 0.9s, the greater the load, the longer the response time; the output speed of the system reaches 120 r/min in the stable state.

Analysis of axial forces in harmonic drives of mining machines and heavy industrial equipment

Special features of arising axial forces in heavy-duty harmonic gear drives with the disk wave generator are described. As a result of research performed, it is found that kinematic pairs formed by the wave generator disks and the flexspline serve as a source of axial forces in heavy-duty harmonic gear drives. The disclosure of physics of the effects taking place in the elastic kinematic pairs: disk – flexspline, determination of nature of axial forces acting in the area of the wave generator under load, allows uprating of the performance data, lifting of load-carrying capacity restrictions and providing full development of heavy-duty harmonic gear drives. The force analysis of the results of the experimental research of axial forces in the heavy-duty harmonic gear drives with the disk wave generator, arising in kinematic pairs: disk – flexspline - has been carried out. Axial forces were measured employing the method of strain gauging of the flexsplines of the heavy-duty waveform gear reduction units tested under the laboratory and production-line conditions of heavy engineering, with the adjustable load conditions. Functional connection of axial forces values with the harmonic gear drives design features has been established, depending on the external loads.

Development of Precision Positioning Stage

The growing demand for positioning accuracy in machines with high speed plays an important role in achieving high productivity gain. A system that is capable to achieve both coarse (macro) and fine (micro) positioning finds a variety of applications in precision positioning. In the proposed work, a macro positioning stage is developed with a ball screw actuator and a micro positioning stage is developed with an additional gear reduction unit. The coarse and fine positioning with friction compensation is achieved and the steady state error is minimized. The developed system is controlled using a programmable logic controller and operated with human machine interface.

Refining methods of vibration diagnostics of wear of turbo-prop engine differential speed reduction unit gear teeth

The paper presents results of complex research of vibration behavior of the differential reduction gear unit of a turboprop engine on the basis of statistics of products with repaired reduction gears and those placed under repair. The conducted research made it possible to establish the source of resonant oscillations of the compressor design elements leading to their breakage. It is established that this source is determined by the kinematics of the reduction gear unit and is associated with the wear of its gear teeth. Standards for the intensity of the appropriate discrete component of the reduction gear vibration spectrum and those for the amount of permissible wear are substantiated and established on the basis of the work carried out. A complex of diagnostic parameters of wear based on intensity components of the auto-spectrum and the spectrum of maxima, the depth of amplitude modulation in some narrow-band processes, their characteristics based on the parameters of the current frequency and mutual characteristics was identified. It is shown that for the whole complex of the diagnostic parameters obtained their dependence on the wear value is satisfactorily approximated by a linear characteristic. The obtained results can serve as a basis for the development of a complex of methods of differential reduction gear vibration diagnostics.

마그네틱 기어를 이용한 2단 감속 장치

Magnetic gears exhibit torque transfer densities that are comparable to those of helical gears because all the permanent magnets arranged along the circumferential direction contribute to power transmission. However, the reduction ratio that can be realized with a single magnetic gear is not theoretically limited; however, this parameter is not effective in a single gear owing to the decrease in the magnetic strength of the permanent magnet depending on its volume. High reduction ratio can be realized by connecting multiple magnetic gears in series. This study examines the power transfer characteristics of a double reduction gear unit with two magnetic gears having a reduction ratio of 1/3.25. The theoretical modeling, frequency response characteristics, and control test results of this system implemented using hardware are described in detail.

An improved model for dynamic analysis of a double-helical gear reduction unit by hybrid user-defined elements: Experimental and numerical validation

This paper introduces an improved model generated by hybrid user-defined element method (HUELM) for dynamic analysis of a double-helical gear reduction unit. Based on theories of structural dynamics and system dynamics, the model consists of four developed elements to respectively simulate the gear pair, bearings, flexible shafts and the housing. A closed-loop test rig is constructed to validate the model: an encoder-based method is applied to measure vibration acceleration of the gear pair, and accelerometer-based measurement systems are employed to obtain the dynamic responses of the housing. Furthermore, two additional models by the finite element method (FEM) and the lumped mass method (LMM) are constructed for numerical comparison to illustrate the HUELM's substantial advantages. Compared with the LMM, the HUELM is of capacity to investigate the interaction among the subsystems; moreover, it is more efficient than the FEM primarily because of the integrated tooth contact analysis method and loaded tooth contact analysis method. It is demonstrated that the predictions by the HUELM match well with the experimental data in terms of meshing frequencies and vibration responses. It is also concluded from the numerical comparison that the HUELM is appropriate for dynamic analysis, particularly of large complex transmission equipment.

Investigation on Multiple Algorithms for Multi-Objective Optimization of Gear Box

The field of gear design is an extremely important area in engineering. In this work a spur gear reduction unit is considered. A review of relevant literatures in the area of gear design indicates that compact design of gearbox involves a complicated engineering analysis. This work deals with the simultaneous optimization of the power and dimensions of a gearbox, which are of conflicting nature. The focus is on developing a design space which is based on module, pinion teeth and face-width by using MATLAB. The feasible points are obtained through different multi-objective algorithms using various constraints obtained from different novel literatures. Attention has been devoted in various novel constraints like critical scoring criterion number, flash temperature, minimum film thickness, involute interference and contact ratio. The output from various algorithms like genetic algorithm, fmincon (constrained nonlinear minimization), NSGA-II etc. are compared to generate the best result. Hence, this is a much more precise approach for obtaining practical values of the module, pinion teeth and face-width for a minimum centre distance and a maximum power transmission for any given material.

Decision-based design-driven material selection: A normative-prescriptive approach for simultaneous selection of material and geometric variables in gear design

The performance of the material is changed when it takes a human created shape and shape is given on the basis of performance of materials. In this paper we explore the selection of material and geometric variables simultaneously in Hazelrigg's decision-based design (DBD) framework by introducing Suh's design axioms (SDA), Multiple Attribute Utility Theory (MAUT), and Analytical Hierarchy Process (AHP) where the design space is discrete and two stages spur gear reduction unit is considered as a case study. SDA is not a conventional abbreviation. For the sake of diagram and to harmonize with other abbreviations it is shortened as SDA. In SDA customer requirements are translated into functional requirements to generate the alternatives within geometric constraints.

Intensification of the Students’ Self-Development Process When Performing Design and Settlement Works on the “Machine Parts” Course

The article addresses issues related to the methodology of intensifying self-development process when performing t design and settlement works on the “Machine Parts” course for the students studying in such areas of training as “Technology” and “Vocational Education” with the use of computer technologies. At the same time, there are formulated the required pedagogical conditions that must be provided to all participants of the educational process, and accordingly, there are disclosed methodological aspects of the design and settlement work performance by means of specialized computer software. This in turn makes it possible to intensify the students’ self-development process during the study of the “Machine parts” course. To succeed in the intensification of the students’ self-development process when performing design and settlement works on the “Machine Parts” course, there should be develop appropriate pedagogical conditions. The most effective implementation of this methodology may be performed through the usage of specialized computer software. There is provided a technology of designing two-stage parallel-shaft reduction gear unit based on specialized computer software Compass 3D. Implementation of specialized computer software when performing a course project on “Machine Parts” allows intensifying the self-development quality of students within the educational process.

고속철도차량 감속구동장치 진동특성 분석

The gear-reduction units of Korean high-speed trains consist of a motor reduction unit, an axle gear box reduction unit, and a tripod joint shaft. A reduction gear unit is a gearbox used to reduce the rotational speed of the input shaft to a slower rotational speed on the output shaft. This reduction in output speed helps to increase torque. Defective reduction gear units in high-speed trains are caused by damage to the gear or by gear fatigue. To diagnose potential problems, it is important to know the vibration characteristics of the reduction gear units. In this study, we analyzed the vibration characteristics of reduction gears under various conditions. The test setup included a full-scale test rig to evaluate reduction gear under both normal and extreme operating conditions.

Why Superhydrophobicity Is Crucial for a Water-Jumping Microrobot? Experimental and Theoretical Investigations

This study reported for the first time a novel microrobot that could continuously jump on the water surface without sinking, imitating the excellent aquatic locomotive behaviors of a water strider. The robot consisted of three supporting legs and two actuating legs made from superhydrophobic nickel foam and a driving system that included a miniature direct-current motor and a reduction gear unit. In spite of weighing 11 g, the microrobot jumped 14 cm high and 35 cm long at each leap. In order to better understand the jumping mechanism on the water surface, the variation of forces exerted on the supporting legs was carefully analyzed and calculated based on numerical models and computational simulations. Results demonstrated that superhydrophobicity was crucial for increasing the upward force of the supporting legs and reducing the energy consumption in the process of jumping. Although bionic microrobots mimicking the horizontal skating motions of aquatic insects have been fabricated in the past years, few studies reported a miniature robot capable of continuously jumping on the water surface as agile as a real water strider. Therefore, the present finding not only offers a possibility for vividly imitating and better understanding the amazing water-jumping capability of aquatic insects but also extends the application of porous and superhydrophobic materials to advanced robotic systems.

운행특성을 고려한 철도차량 감속기의 피로해석

Abstract To assure the safety of rolling stock, it is important to perform the fatigue analysis of reduction gear unit in rolling stock considering a variation of velocity and traction motor capability. This paper presents fatigue analysis of the damage of reduction gear unit of railway vehicle under variable amplitude loading(VAL) based on quasi-static fatigue analysis using finite element model and linear Miner's rule. The VAL for the simulation was constructed from the tractive effort curve and train run curves of railway vehicle under commercial operation condition using MSC.ADAMS dynamic analysis. The finite element model for evaluating the carburizing effect on the gear surface was used for predicting the fatigue life of the middle gear based on strain-life based approach. The results showed that the frequent high starting torque due to a quick start as well as increasing numbers of stops at station would decrease the fatigue life of reduction gear unit. Key Words : Fatigue Analysis, Reduction Gears, Rolling Stock, Operating Characteristics

Fundamentals of the design of chain planetary reduction gear units with fine-module toothed chains

Fundamentals of the design of chain planetary reduction gear units with fine-module toothed chains

Through-Tubing-Conveyed ESP Replacement - Live Well Intervention

This article, written by Assistant Technology Editor Karen Bybee, contains highlights of paper SPE 116822, "Thru- Tubing Conveyed ESP Pump Replacement - Live-Well Intervention," by Walter Dinkins, SPE, and Steve Tetzlaff, Baker Hughes; John C. Patterson, SPE, Hai Hunt, SPE, Peter Nezaticky, SPE, and James Rogers, SPE, ConocoPhillips; and Bret Chambers, BP plc, originally prepared for the 2008 SPE Annual Technical Conference and Exhibition, Denver, 21-24 September. The paper has not been peer reviewed. Through-tubing-conveyed (TTC) electrical-submersible-pump (ESP) technology was developed to address the high cost and long lead times associated with North Slope rig workovers to pull and replace worn or plugged pumps. TTC technology allows ESPs to be changed in live wells without the need to kill the well and work it over. When a TTC pump replacement is performed, the pump is pulled and replaced with slickline or coiled tubing while the tubing, seal section, motor, power cable, and downhole gauges remain in place. Introduction The first TTC systems were installed in West Sak development wells on the North Slope of Alaska in 1998. The first systems were TTC electrical submersible progressing-cavity pumps (TTCESPCPs). In 2001, TTC technology was expanded to include centrifugal pumps to achieve higher production rates. The centrifugal TTC pumps were given the designation TTCESP. TTCESP lift systems continue to be the preferred equipment for the West Sak field. TTC technology is particularly applicable in wells with high solids production in which the pump is the primary failure mode. TTC technology also provides a means to upsize, downsize, or add pump components such as rotary gas separators without rig intervention on live wells. TTCESPCP and TTCESP Components From bottom to top, the rig-deployed (tubing-conveyed) components of a TTCESPCP consists of motor centralizer, motor, gear-reduction unit, tandem seal sections, and TTC crossover. A power cable is clamped to the outside of the tubing and is run from the motor to surface, and a separate instrument wire is run for a downhole gauge located in a side-pocket mandrel above the ESP assembly. The TTC crossover (Fig. 1) is what allows pumps to be pulled while the motor, gear-reduction unit, seal section, tubing, instrument wire, and power cable are left downhole. The slickline-deployed TTC components consist of a pump assembly, a packoff assembly, and a slipstop. The pump assembly consists of a pump "eye" (Fig. 2), which couples the pump to the TTC crossover, and pump and discharge assembly, which includes a centralizer and fishing neck.