Epi Cyclic
Epi Cyclic
Epi Cyclic
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Improving Electromagnetic Interference Shielding Effectiveness using Copper Reinforced Sustainable Foam View project
Design and Analysis of an Epicyclic Gearbox for an Electric Drivetrain View project
All content following this page was uploaded by Timir Patel on 08 October 2019.
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6834 & Sciences Publication
Design and Analysis of an Epicyclic Gearbox for an Electric Drivetrain
Applications
Heavy-duty arbors, bushings, wear pins, bearings, sprockets,
gears and shafts etc. Or can be used for high tensile
applications un carburized but through hardened and
tempered [5].
Table-II: Material Properties (EN10084 - 18CrNiMo7 )[5]
Typical Chemical Analysis
Carbon 0.18%
Silicon 0.20%
Manganese 0.70%
Chromium 1.65%
Nickel 1.55%
Fig. 1. Planetary Gear Arrangement Molybdenu
0.30%
m
IV. DESIGN PARAMETERS Typical Mechanical Properties – Quenched and Tempered at
200⁰ C
The motor used is the EMRAX 208 which is an AC 3-phase Yield Tensile
Elongatio Impac Hardnes
synchronous motor which delivers a maximum power of Section Strengt Strengt
n t Izod s
75kW. The maximum torque obtained is 120 N-m@5500 h h
mm MPa MPa % J HB
RPM. Now, assuming the weight (m) of the car with the
25 1050 1295 14 45 380
driver will be 320 kg and the radius (r) of the wheel is 9
50 950 1160 15 51 340
inches, to achieve a speed of 0-100 km/h or 0-27.77 m/s in
100 815 1010 16 53 300
less than 4 seconds (which is our target), the acceleration
should be, Gear Calculation
We initially assumed the module(m) as 2 mm and number of
teeth on planet gears (Zp) are 18 as suggested by AGMA. As
the planet and the sun gear are made of the same material so
Now, to find the torque required at the differential will be,
by default, the planet is going to be treated as the weaker
element and all the designs are based on the planet.
Thus, if we need 507.67 N-m at the differential, then the
(1)
Final Drive gear ratio needed will be
[6]
(2)
The top speed in RPM when the gear ratio is 4.5 is From the above two equations we get the values shown in
table-III,
Therefore, Table-III: Dimensional Values of gear
Sr. Type No of Diameter RPM
No teeth
1. Planet 36 72 1834
Thus, the design parameters for the transmission system are 2. Sun 72 144 5500
shown in table-I, 3. Ring 144 288 0
Table-I: Design Parameters for the transmission system
Torque at the differential 507.67 N-m
RPM at the differential 1223 RPM
Final Drive Ratio 4.5
Now, the transmission ratio from the chain drive, which is
connected to the differential, will be 1.5.
Therefore, the transmission ratio required from the planetary
gear set would be,
Gear box ratio,
V. GEAR DESIGN
Gear Material
18CrNiMo7- 6 Chrome-Nickel-Moly Carburizing Steel
Fig. 2. Sun Gear
generally supplied annealed to HB 229(max). Carburized
and heat treated, it develops a hard wear resistant case of
HRC 60-63 and a tough strong core with a typical tensile
strength range of 900-1300 MPa, in small to fairly large
sections [5]. The material properties are shown in table-II.
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6835 & Sciences Publication
International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-3, September 2019
(6)
Where: -
σw is the allowable stress
Pc is the circular pitch which is equal to π times of module
yp is the form factor which is based on tooth profile (20°
involute) and number of teeth
b is the face width of the planet
(7)
(8)
(9)
(10)
Fig. 3. Planet Gear By using the Lewis equation, the face width can be
calculated for the sun, planet and the ring gears.
Beam Strength (Fs)
Considering a gear tooth as a cantilever beam its strength
can be calculated under the tangential load.
(11)
Dynamic Load (Fd)
It is sum of tangential load (Ft) and dynamic induced load
(Fi)
(12)
(13)
Wear Load (Fw)
(14)
Note: - When both the criteria are satisfied only than the
gear design should be consider as a SAFE design.
(5)
By using all the input values and the above equations are
From the above three equations, Pitch line velocity and gear design calculation is c complete and the output values
Tangential Load is calculated. are in table-IV.
Lewis Equation
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6836 & Sciences Publication
Design and Analysis of an Epicyclic Gearbox for an Electric Drivetrain
(19) (26)
The normal force acting on the gear Fn is calculated in
(20) equation (18).
(27)
(21)
Here, kb and kt are the combined shock and fatigue factors
for bending moment and twisting moment respectively. (28)
Using the values for the equivalent torque and the equivalent
moment, we can find the diameter using the equations given
below. (29)
Now, the diameter of the shaft can be calculated using the
equations (20), (21), (22), (23), (24) and (25) and following
the same procedure as the input shaft. For the output shaft
that is connected to the carrier, the same equations are used.
The final diameters for the shafts are given in table-V. The
carrier shaft and the carrier
are shown in figure 8 and
(23) figure 9 respectively.
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6837 & Sciences Publication
International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-3, September 2019
(32)
The dynamic load rating (C) is calculated using the below
formula.
(33)
The bearing selected based on the values obtained is the
SKF NKIS20 which is shown in figure 10 [9]. The
characteristics of the needle roller bearing are as follows: -
Inner race diameter = 20 mm, Outer race diameter = 42 mm,
Dynamic Load factor = 32500 N, Race width = 20 mm.
(31)
(34)
The life of the bearing (Lh) is assumed according to the
where, V40 = Kinematic Viscosity @ 40°C, cSt
required time. For our case, the life was 4000 hrs. This life
V1 = Pitch line velocity of
is converted to life in revolutions (L) used the below
the lowest speed gear, feet
equation.
per minute (fpm)
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6838 & Sciences Publication
Design and Analysis of an Epicyclic Gearbox for an Electric Drivetrain
= 0.262 X speed (pinion rpm) X pinion diameter (inches) generated by the hot lubricant oil. The casing is shown in
If there is no oil cooler on the industrial gear drive, it’s best figure 12.
to determine the maximum expected ambient temperature
during operation and:
1. Increase one ISO Viscosity Grade if the ambient
temperature exceeds 95oF (35oC).
2. Increase two ISO Viscosity Grades if the ambient
temperature exceeds 122°F (50°C).
Method 2
A decent method for deciding the necessary viscosity for a
gear drive is the AGMA 9005-E02 "Industrial Gear
Lubrication" standard (in the past AGMA-D94). The
AGMA 9005-E02 standard shows recommended viscosity
grades for industrial gear drives working under ordinary Fig. 12. Gearbox Housing
loads over a scope of speeds and surrounding temperatures
[11]. X. SIMULATIONS
Calculated viscosity index (VI) is 76.988 by equation (34) at
40°C and from the plot given in figure 11 at temperature of The CAD models are used to simulate the operating
70°C VI is 68. So, finally a lubrication oil of viscosity index conditions and ANSYS Workbench is used to simulate the
of 68 is selected. structural strength of the gears. The static structural
simulation is selected in ANSYS Workbench. The CAD
models are made using SOLIDWORKS. The mesh used is
shown in figures 12 and 16. The results are shown in the
below figures 13, 14, 15 and 17.
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6839 & Sciences Publication
International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-3, September 2019
Gear Specifications
Module 2 mm
Face Width 20 mm
Teeth-Sun 72
Teeth-Planet 36
Teeth-Ring 144
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6840 & Sciences Publication
Design and Analysis of an Epicyclic Gearbox for an Electric Drivetrain
Output Shaft 25 mm
Bearing Specifications
XII. CONCLUSIONS
The result of this project is a very compact epicyclic gear
reduction custom designed for the formula student electric
car. We went through an iterative design process and all
mechanical drivetrain components were scrutinized and
researched to result in the lightest design possible. This
report is significant research for the long-term vision of
Formula student cars. In this project the gear box is designed
and analyzed under static and wear load point of view
keeping the optimum light weight design in the mind. A
lubrication mechanism and suitable lube oil is also selected
for the gear box along with suitable bearings.
ACKNOWLEDGEMENTS
Fig. 18. Gearbox Assembly
We would like to thank our faculty advisor, Dr. Bhaskara
Rao, for guiding us through the elementary phase of the
project. We would also like to thank our professor Dr.V
Umasankar, for helping us in selecting lubrication
mechanism and lubrication oil. We would also like to show
our gratitude towards VITC Formula Electric for providing
us with necessary resources to carry out our research.
REFERENCES
1. Design and Optimization of Planetary Gearbox for a Formula Student
Vehicle – Soovadeep Bakshi, Parveen Dhillon, and Teja Maruvada-
Indian Institute of Technology Bombay - Bakshi et al / SAE Int. J.
Mater. Manf. / Volume 7, Issue 3 (June 2014)
2. Theory of Machines-Third Edition-S.S Rattan-Tata McGraw Hill
Private Limited
3. [3] Emrax-208-User’s Manual for Advanced Axial Flux Synchronous
Motors and Generators.
4. Design And Realization Of a Lightweight Mechanical Drivetrain For
an electric Formula Student Race Car – Hannah Daled, Raf
Schoenaers.
5. S.T -Steel and Tube Private limited. -Stronger Everywhere-Case
Hardening Steel 18CrNiMo7- 6 or 17CrNiMo6
Fig. 19. Gearbox interior without carrier 6. Design Of Two Stage Planetary Gear Train For High Reduction
Ratio- Prabhakar Vitthal Pawar, P.R. Kukarni - International Journal
of Research in Engineering and Technology eISSN: 2319-1163 |
pISSN: 2321-7308 Volume: 04 Issue: 06 June-2015
7. Analysis of Quenching Parameters in AISI 4340 Steel by Using
Design of Experiments – Marlon Muniz Nunesa, Eduardo Miguel da
Silvab, Reny Angela Renzettia, Tarcisio Gonçalves Britoa - Materials
Research. 2019; 22(1): e20180315
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6841 & Sciences Publication
International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-3, September 2019
AUTHOR PROFILE
Published By:
Retrieval Number: C5787098319/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI:10.35940/ijrte.C5787.098319 6842 & Sciences Publication
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