Gearbox
Design
Features
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Input speed of 3000 rpm down to 185+-10rpm
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Maximum output torque of 2800 Nm
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2-stage gearbox was selected with transmission ratios of 5.06 and 3.24
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Full set of SKF spherical roller bearings, appropriate fasteners, and a lubrication system to maximise longevity of all components.
Gear Selection
British standard for pressure angle is 20 degrees (Tandwiel, N/A), meaning that the recommended minimum number of teeth is 18 for any pinion or gear.
The values produced adhere to this recommendation.
A safety factor of 2 ensures the maximum allowable stress is 400 MPa on the pinion, which was far below the yield stress of 800MPa for the material used and produced a gearset that fits comfortably within the specification outlined by the brief.
A rigorous calculation process was enacted to achieve a 99.1% accuracy to the target output speed.
Shaft Design
Static analysis including stress concentration and fatigue calculations were conducted for each of the three shafts to ensure their dimensions and features were designed to sustain the required 10,000 cycles of continuous combined torsional and bending load.
Bearing Selection
Suitable bearings to take the calculated loads were selected from the catalogue of SKF Roller bearings as recommended by the brief.
Housing
Designed bespoke for the size of the gearbox and remains within the size constraints specified by the brief.
Custom machined bearing caps seal the otherwise exposed bearings, protecting them from outside interference.
High-strength aluminium alloy plate, with a splash lubrication system designed to lubricate both gears and bearings.
Design allows for easy access in the event of any maintenance/oil changes that may be required
68 or 100 ISO VG rated oil for lubrication chosen via reduction ratio calculations
