BB502 Xd07aen E1
BB502 Xd07aen E1
BB502 Xd07aen E1
LEARNING
DRIVES 1 ACTIVITY
PACKET
BB502-XD07AEN
LEARNING ACTIVITY PACKET 7
INTRODUCTION
In the last LAP, you learned about gear drives which only have two gears. In this
LAP, you will continue your study of gear drives by exploring the operation and
applications of gear drives which have more than two gears. Multiple pairs of gears can
be used to drive multiple output shafts, create higher gear ratios, and reverse the direction
of rotation of output shafts which are on the same axis as the input shaft. These setups are
quite common in gear reducers and other machinery.
Also, this LAP will continue your study of couplings by learning about solid
couplings. Solid couplings are used both for very small and very large motors. They
are also used to extend the length of a shaft by connecting it to another shaft. The major
disadvantage of solid couplings is that they can tolerate no misalignment.
ITEMS NEEDED
Amatrol Supplied
950-ME1 Mechanical Drives 1 Learning System
Gear drives can have more than two gears in the gear train. These additional
gears act either as idlers or to drive an additional output shaft. As mentioned in an
earlier LAP, idler gears are used mainly to change the direction of rotation or to
transfer the power to a shaft which is located further away from the driver shaft.
INPUT
GEAR
IDLER
GEARS OUTPUT
GEAR
10
TEETH
20
30 TEETH
TEETH
60
TEETH
A B C
R= × ×
B C D
60 10 20 60
R= × × =
10 20 30 30
Notice that the number of teeth of both idler gears are used twice in the formula.
Therefore, they cancel each other out as shown.
This calculation results in a gear ratio of 2:1. This is the same gear ratio you
would get if you calculated the gear ratio without accounting for the idler gears
(60 / 30 = 2). Since the idler gears do not affect the gear ratio, they do not affect
the speed or torque. The same formulas used in the previous LAP to calculate the
speed and torque of two gears can therefore be used to calculate the output of a
gear drive with multiple gears.
OUTPUT
A GEAR
IDLER
INPUT GEARS
GEAR
D C
B
10
TEETH
20
30 TEETH
TEETH
60
TEETH
OUTPUT OUTPUT
OUTPUT
SHAFT 1 SHAFT 2
SHAFT 3
TORQUE TORQUE
TORQUE = 20 in-lbs
30 in-lbs 15 in-lbs
INPUT
GEAR
20 TEETH
IDLER
MOTOR GEAR
15 TEETH
TOTAL INPUT
TORQUE
The total torque required from the input shaft is calculated by summing the
torques that would be required to drive each output shaft by itself. The torque
created at the driver shaft by each output shaft is found by dividing the output
torque by the gear ratio.
Output Torque
Input Torque =
Gear Ratio
For example, the torque created at the driver shaft by gear 3 is found by dividing
shaft 3’s output torque by its gear ratio as follows:
T3 = 20/3 = 6.7 in-lbs.
Procedure Overview
In this procedure, you will use the formulas just described to determine
speed and torque of either the driver or the driven shaft of a gear drive which
has more than one output gear.
1. Calculate the driven shaft speeds of the two output gears of the gear drive
system shown in figure 5.
Gear 1 Shaft Speed _______________________________________ (RPM)
INPUT IDLER
(DRIVER) 10 TEETH
15 TEETH
OUTPUT
(DRIVEN)
IDLER
10 TEETH
20 TEETH
1000 RPM
500 in-lbs
INPUT
GEAR
10 TEETH
OUTPUT 1
30 TEETH
200 in-lbs
400RPM
20 TEETH
200 RPM
OUTPUT 2
15 TEETH
500 in-lbs
20 TEETH
A compound gear drive is a type of gear train that has two or more gears
mounted on one shaft, as shown in figure 8. These gears can be mounted anywhere
on the shaft, either next to each other or on opposite sides of the shaft.
COMPOUND
GEAR 1
INPUT
OUTPUT
OUTPUT
SHAFT 1 OUTPUT
SHAFT 2
INPUT
GEAR
COMPOUND
SHAFT
MOTOR
A third type of application for the compound gear drive is to create a gear
reduction between two shafts which are located on the same axis, as shown in
figure 10. This is called a reverted gear drive.
COMPOUND
SHAFT
INPUT
SHAFT
OUTPUT
SHAFT
MOTOR
The concepts which were used to calculate speed and torque of simple
multiple-gear gear drives can also be applied to compound gear drives with one
minor change. The gear ratio of any gears that are mounted on the same shaft must
be included in the calculation. In effect, these gear ratios must be combined as
shown in the following formula:
Driver Speed (RPM) ⎡ Pitch Dia. Driven ⎤ ⎡ Pitch Dia. Com Input ⎤
= ×
Driven Speed (RPM) ⎢⎣ Pitch Dia. Driver ⎥⎦ ⎢⎣ Pitch Dia. Com Output ⎥⎦
OR
Driver Speed (RPM) ⎡ No. Teeth Driven ⎤ ⎡ No. Teeth Com Input ⎤
= ×
Driven Speed (RPM) ⎢⎣ No. Teeth Driver ⎥⎦ ⎢⎣ No. Teeth Com Output ⎥⎦
As you can see, the formulas for speed are the same as the simple gear drive
except that they are multiplied by the gear ratio of the compound gears. Like a
simple gear drive, idler gears have no effect of the output speed.
DRIVEN GEAR
COMPOUND 30 TEETH
OUTPUT GEAR
20 TEETH
DRIVER COMPOUND
GEAR INPUT GEAR
10 TEETH 10 TEETH
1800 RPM
MOTOR
In a similar way, the torque output is also determined by combining the two
gear ratios. These formulas are as follows:
OR
Procedure Overview
In this procedure, you will use the formulas just described to determine
speed and torque of either the driver or the driven shaft of a compound gear
drive.
1. Calculate the driven shaft speed of the compound gear drive system shown in
figure 12.
Driven Shaft Speed _______________________________________ (RPM)
DRIVEN GEAR
COMPOUND 30 TEETH
OUTPUT GEAR
20 TEETH
DRIVER
GEAR COMPOUND
15 TEETH INPUT GEAR
1500 RPM 20 TEETH
750 in-lbs
MOTOR
DRIVEN GEAR
COMPOUND
10 TEETH
OUTPUT GEAR 1850 RPM
20 TEETH 250 in-lbs
DRIVER COMPOUND
GEAR INPUT GEAR
25 TEETH 10 TEETH
MOTOR
2000
COMPOUND
GEAR 3
1000 20 TEETH
COMPOUND
OUTPUT GEAR 2
20 TEETH
COMPOUND
GEAR 1
10 TEETH COMPOUND
DRIVER GEAR 4
GEAR 10 TEETH
10 TEETH
DRIVEN
GEAR
20 TEETH
MOTOR
OUTPUT
SHAFT
2000 RPM TORQUE 400 in-lbs
SPEED 1000 RPM
2. To calculate the speed and torque of a multiple shaft drive, you only
need the gear ratio of the output gear and the driver gear. All other
gears are ___________.
3. A(n) ___________ shaft drive has a driver gear and several output
gears.
5. When calculating the speed and torque of a(n) ___________ drive, you
need to apply all gears that are mounted to the same shaft.
6. ___________ gear drives have more than one gear mounted on the
same shaft.
Each gear which is added to a gear train causes the driven gear’s rotation direc-
tion to change. When there are only two gears, the driven gear turns in the opposite
direction to the driver gear, as shown in figure 15. If one gear is added, either an
idler gear or another driven gear, the direction of rotation of the first driven gear
will be the same as the driver gear.
INPUT OUTPUT
CW CCW
TURN CCW
FROM THIS
SIDE
COMPOUND
OUTPUT GEAR
DRIVEN
GEAR
MOTOR CW
DRIVER INPUT
GEAR COMPOUND
GEAR
VIEW
DIRECTION
CW
A final point to remember about the direction of rotation is that these rules are
based on looking at the rotation of the output shaft from the same side from which
you viewed the input shaft. If you are viewing the output shaft from the opposite
side, the direction of rotation is reversed. For example, the output shaft in figure 16
turns CW when you look at the shaft from the side indicated by the arrow. From
the opposite side the shaft turns CCW.
Procedure Overview
In this procedure, you will use the even/odd rule to determine the direction
of rotation of various gear drives. This is a basic skill you will need in order
to understand the operation of gear-driven machinery. You will also apply this
skill when designing or modifying existing gear drives.
1. Determine the direction of rotation of the output shaft of the gear drive
system shown in figure 17. Give your answer as either clockwise (CW) or
counterclockwise (CCW) while looking at the end of the shaft indicated by
the arrow shown in the figure.
Direction of Rotation _________________________________ (CW/CCW)
CW
MOTOR
OUTPUT
MOTOR CW
INPUT
OUTPUT
MOTOR
CW
INPUT
CW
OUTPUT
MOTOR
OUTPUT
MOTOR
CW
In each of the above cases, you should have found the resultant direction of
rotation to be counterclockwise (CCW).
Each shaft in a multiple shaft drive system must be individually aligned. The
alignment procedures for each shaft are the same as those for a single shaft drive
system. Although each shaft in the system must be individually aligned, there is
a certain order in which to align the shafts. Normally, the order of alignment is to
start with the last output shaft in the drive and work backwards toward the driver
shaft.
For example, in figure 22, generator #2 and the motor should be aligned first
and generator #1 and the motor last. For the first alignment, the motor is the move-
able machine. For the second alignment it is the stationary machine while gener-
ator #1 acts as the moveable machine.
MOVEABLE
MOVEABLE MACHINE/ STATIONARY
MACHINE STATIONARY MACHINE
MACHINE
GENERATOR GENERATOR
MOTOR
#1 #2
Before you start the installation and alignment procedure, determine the actual
height of each shaft. To allow for shims to be added to align the shaft during the
alignment procedure, the driven shaft of each component should be slightly higher
than the driver shaft. The amount of difference in height depends on how uneven
the surface is. A good height difference to start with is 0.010 to 0.015 inches. This
means that each shaft must be progressively lower than the one downstream.
SIDE VIEW
GEAR 2
GEAR 1
H2
H1
OVERHEAD VIEW
GEARS
BEARING
PARALLEL
AXES
Procedure Overview
In this procedure, you will assemble and align a spur gear drive which uses
multiple gears. First, you will assemble a simple gear system which uses two
gears and an idler. Then you will assemble a compound drive. In addition to
learning how to align a multiple shaft system, this skill will allow you to verify
the speed and torque characteristics of multiple shaft drives.
1. Perform the following safety checkout to prepare for working with power
transmission equipment. Make sure that you are able to answer yes to each
item before proceeding.
SHAFT 3 (12")
SHAFT 2 (6")
GEAR 1
GEAR 2
SHAFT 1 (12")
E. Place one Gear Motor Riser under each of the motor feet.
F. Locate four bolts with the specifications 5/16-18UNC-2A x 2-1/2 Hex
Head, along with compatible flat washers, lock washers, and nuts.
G. Fasten the motor base and risers to the work surface by assembling bolts,
washers, and nuts.
Use a criss-cross pattern to tighten the bolts.
NOTE
Review LAP 3 if needed for the details of this procedure.
WARNING
Do not operate the mechanical drive system without the guard in place.
Also, do not attempt to open or bypass the guard at any time during operation.
Performing any of these actions will create a hazard situation.
SHAFT 4
8"
PRONY
BRAKE
GEAR 7
SHAFT 3
GEAR 2 12"
SHAFT 2 GEAR 6
6"
_____________________________________________________________
32. Disassemble the components and store them.
1. Each gear that is added to a gear train causes the direction of rotation
to _____________.
3. An odd number of gears in a gear train causes the driven shaft to rotate
in the _______________ direction as the driver shaft.
Solid couplings rigidly connect two shafts together to make them a rigid unit.
They are used when it is necessary to either extend the length of a shaft or provide
a means of disconnecting the shaft. Solid couplings are rarely used to connect
motors to driven components such as pumps and gearboxes because they do not
allow any misalignment. The only exception is when there is the need for absolute
alignment.
SOLID
SHAFT COUPLING HAFT 2
Sleeve couplings can either be solid or split. The solid sleeve coupling is a
solid cylinder of metal which is designed to slide over the two shafts and clamp
them together by means of a set screw on each shaft, as shown in figure 32. To
install this type, the two shafts must be able to be moved away from each other.
Sleeve couplings are mainly used on smaller shafts having diameters less than
6 inches, while larger shafts use flange couplings. Since they do not allow any
misalignment, they are mainly used on longer shafts. This is due to the fact that
any misalignment in longer shafts can be compensated by the distance between the
bearings.
The basic procedure for installing and aligning a sleeve coupling is first to level
the two shafts and make them the same height. Before doing this, place the sleeve
coupling on one of the two shafts to be coupled and to slide it back on the shaft, as
shown in figure 34. Then level and align the shafts. The process is completed by
sliding the coupling onto the other shaft and clamping it to each shaft.
LEVEL
SOLID
COUPLING
In some cases, the sleeve coupling is used to extend the length of a shaft by
connecting another shaft which is not independently supported, as shown in figure
35. Here, there is not any alignment to be done. Simply insert the extension shaft
through the bearing on its end, slide the sleeve onto the other end of the shaft; and
bring the two shafts together so that each shaft is inserted into the coupling and the
gap between the two shafts is approximately 0.125 inch.
MOTOR
COUPLING BEARINGS
GEAR
FLOATING
SHAFT
SOLID SOLID
COUPLING COUPLING
Procedure Overview
In this procedure, you will attach the Constant Speed Motor to a drive shaft
using a solid sleeve coupling. The alignment method used will be a variation of
the straight edge and feeler gauge method.
1. Perform the following safety checkout to prepare for working with power
transmission equipment. Make sure that you are able to answer yes to each
item before proceeding.
SLEEVE
COUPLING
E. Place one Constant Speed Motor Riser under each of the motor feet.
F. Locate four bolts with the specifications 5/16-18UNC-2A x 1-1/2 Hex
Head, along with compatible flat washers, lock washers, and nuts.
G. Fasten the motor and risers to the work surface by assembling bolts,
washers, and nuts.
Use a criss-cross pattern to tighten the bolts.
B. Use a hex key wrench to back out the two set screws on the coupling so
that it can slide smoothly over the shaft.
C. Clean the shafts’ keyseats and the coupling’s keyseat with a wire brush to
make sure that no dirt or burrs are in the keyseats.
D. Obtain two 3/16-inch x 1-inch long square keys
E. Make sure the keys fit by sliding each key into the keyseat of one shaft and
one side of the coupling.
They should slide in without forcing and have no play.
F. Remove the keys from the keyseats and set them aside for now.
G. Slide the coupling without the keys onto one of the shafts and pull it back
from the shaft as far as it will go.
You will complete the mounting of the coupling after you have aligned the
shafts.
FEELER SOLID
GAUGE STRAIGHT EDGE
COUPLING
3 2 1
POINT POINT
1 2
3 2 1
L
E
L LB
B SHIM RATIO =
L
E
3 2 1
OVERHEAD VIEW
STRAIGHT
EDGE
3 2 1
I. Loosen the motor mounting bolts and adjust the motor position so that the
two shafts are in horizontal alignment.
J. Tighten the motor mounting bolts.
K. Recheck the vertical alignment again to make sure it is still good. Correct
it if needed.
8. Perform the following substeps to mount the coupling.
A. Rotate the two shafts so that their keyseats are positioned at 0 degrees.
B. Slide a key into the keyseat of each shaft and line up each key flush with
the end of its shaft.
SOLID
COUPLING
D. Tighten coupling’s two set screws onto the keys to complete the assembly.
9. Perform the following substeps to connect and start the Constant Speed
Motor.
A. Make sure that the safety switch power cord is plugged into a wall outlet
B. Connect the Constant Speed Motor’s power cord to the Motor Control
Unit through the Motor Port.
C. Make sure that the Motor Power switch is in the OFF or down position.
D. Install the guard.
WARNING
Do not operate the mechanical drive system without the guard in place.
Also, do not attempt to open or bypass the guard at any time during operation.
Performing any of these actions will create a hazardous situation.
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