1

Abstract

By studying these processes, students may get insight into the theory behind machine

construction. The course requires us to work on a group project. Students' task is to create a gear-

box for a single-girder overhead crane. We were required to construct a gearbox using the provided

materials, which included shafts, keys or press fits, rolling element bearings, seals, and housing.

The knowledge we obtain from studying machine theory, thermodynamics, and the statics and

dynamics of materials is put to use in our investigations of the mechanism. It is the design of the

housing that first establishes the length of the shaft. The safety factor of the shaft may be

determined using this data.

Once we have collected all of the data and calculated the numbers, we can begin creating the

gear, bearing, and key. Next, the output key will be evaluated to determine which one is the most

vulnerable. A number of computer applications are used in addition to traditional manual calculation

to facilitate the acceleration of work. The students are making use of computer programs that we are

familiar with. Our gears, shaft, bearings, and housing were designed and sketched in PTC Creo

Parametric, while our calculations were done in Microsoft Excel. Using these tools, we can collect

more accurate data, allowing us to fine-tune the gearbox design process.

Introduction

Cranes are specialized machinery that can raise and lower loads and be moved along a

horizontal plane. A hoist, some kind of rope or chain, and some sheaves might be incorporated. The

bulk of its applications involve heavy lifting and transportation. It uses mechanical advantage,

provided by one or more basic devices, to move loads more quickly than a single person could. The

transportation sector uses cranes for loading and unloading cargo, the construction sector for

moving materials, and the industrial sector for assembling massive machinery. In the wide world of

cranes, "single girder overhead crane" is a frequent kind. Due to their increased lifting capacity and
 2

ability to go longer distances, top-running overhead cranes, also known as bridge cranes, are the

most productive lifting alternative.

The higher value given by a single-girder overhead crane for our unique application,

decreased manufacturing costs, and more inexpensive final pricing were the deciding factors in our

selection of this model over a double-girder overhead crane. A low headroom monorail hoist is used

in top-running overhead cranes to make the most of available ceiling space and reduce unneeded

bulk. This is the most cost-effective option for structures with a span more than 90 feet. Utilizing a

single girder design will help us save money without sacrificing functionality. Over the course of

the crane's lifespan, we will save money on new support structures because of the lower wheel loads

that will enable us to expand the lifting capabilities of our runway structure without any more

upgrades. Most of the work of operating the crane is handled by the gearbox. Gears and gear trains

are used in the propeller shaft and the speed-changing gears that transfer power from an engine to a

live axle to convert the speed and torque from a rotating power source to another device. Three

shafts, six bearings, three keys, one train gear, and one girder make up the gearbox.

Work Package 3: Quality Function Deployment Analysis

A gearbox is a device that combines a power source with a transmission system to apply that

power in a controlled way. A transmission is "an system of parts comprising speed-changing gears

and the propeller shaft," according to Merriam-Webster. This is how power is delivered from the

engine to the live axle. The gearbox or gear train is the simplest kind of transmission, and it is

responsible for transforming rotational speed and torque. A gear train is a set of gears mounted to a

chassis in such a manner that their teeth mesh. Without any slippage between gears, rotation is

imparted smoothly when the pitch rings of engaged gears roll over each other. Transmission shafts,

or simply shafts, are used in almost all types of rotating machinery to transmit both torque and

rotational motion.
 3

This is why we've decided to use a "single grider overhead crane" for our construction. The

single girder overhead crane's light-duty load capacity (1360 kg) is perfect for this situation.

Second, it offers the lowest total cost of ownership since it uses the fewest and simplest components

compared to competing systems. Challenge: create a gearbox for a 5hp motor running at 1800rpm.

Lifting a 1360-kilogram load at a pace of 10 meters per minute with a safety factor greater than one

is required of the power output. All of the criteria have been satisfied, as shown by the computations

below.

Work Package 4:Spur Gear Design

A gear train is the most fundamental mechanism, and it's the one that allows you to transfer

rotational motion from one shaft to another. The gears that are attached to each shaft will each have

their own distinct gear ratio. When we were developing the gear box for an overhead crane with a

single girder, we decided to go with a gear ratio of 1:5.209. The proposed gear train is made up of a

ring gear in addition to two spur gears on each side of it. Spur gears constitute the vast majority of

all gear types. They are supported by parallel shafts and feature teeth that are consistently aligned

straight. In order to achieve very great reductions in gear size, several spur gears are typically

employed in combination with one another. As a point of reference, the gear train was developed

with the help of Shingley's Mechanical Engineering Create.

ω2 =1800 rpm

di = 47.9mm

ω5 = 66.34 rpm

As a compound reversing gear train

Let the two steps of compression be the same for the least possible package size. In addition,

satisfying the line requirement on the input and output shafts is achieved simply by having the two

stages equal.

From the ratio above, find the minimum number of teeth,Np.

Assume,

 k-1

 Pressure angle, Ø = 20 °

 Gear Ratio = 5.209

Find outer and intermediate speed (rpm)

To determine the torque, return to the power relationship,

If the height of the gearbox as a whole is 22 inches, then the minimum diametric pitch should be

about 1.5 inches, with the same thickness assumed for the walls and clearances.

Start with P = 7 teeth/in

Circular pitch

Base pitch

Nominal Center

Addendum/Dedendum

Whole Depth

Clearance
 6

Diametral pitch,

Outside Diameter

Pinion:

Gear:

Get pitch line velocities and transmitted loads for input and output gears,

For gears 2 and 3, assume F=1.3 due to the reduced load.

The reaction force at the bearings may be calculated by drawing a free body diagram of the output

shaft.
 7

Work Package 5:Shaft Design

Shaft The weight of the gear is a force that pulls down on the shaft. The tension on the shaft may be

calculated with the assistance of the gear's mass. Cost and complexity of design for the complete

gearbox factor into the decision of what material to use in the construction of the shaft.

Calculation of the input shaft

There were not many forces and stresses found for the first shaft's computation. When the gear's

mass presses down on the shaft's hub, it exerts a force in the axial direction. The amount of torque

acting on the shaft is proportional to the amount of power supplied by the motor. Input power and

angular velocity may be found on the website listed on the project description page.
 8

Now we can calculate the shaft moments. It was expected that the gears would sit smack in the

middle of the 4-inch gap between the bearings, which required just little support. As a result, the

bending moments are greatest in the middle and the bearing reaction forces are equal to one-half the

gear forces.

The safety factor of surface N, 1, may now be used to calculate the shaft's diameter. Evaluating

success using the DE-Goodman criteria. Due of its simplicity and conservatism, this criteria works

well for the preliminary layout. If we set Ta = Mm = 0, then

Some forces and stresses were obtained for the second shaft computation, but not many. Because

the crane has a load on its output shaft, there is an axial force acting on the shaft. As a consequence

of the gear's torque, there is an applied force on the shaft. Based on the gear ratio, the shaft's torque

output may be determined.

Tm= 103.74 Nm

Ma = 967.266 Nm

Work Package 6:Bearing Selection

Ball bearings are used in the construction of the gearbox. The balls in a ball bearing are kept at

uniform distances from the raceway by use of a retainer. Two bearings were used for the

calculation, and it was believed that tangential forces were distributed evenly between them. The
 10

factor of safety for the bearing was determined after taking into account many aspects, including the

shaft diameter, the dynamic loading, and the static loading..

Work Package 7:Solid works drawing and Simulation

Fig: Intermediate shaft

Fig:Input shaft
 11

Fig:Housing

Fig:Gear 2

Fig:Gear 3
 12

Fig:Gear 5

Design Summary

Nuts and bolts, welded fittings, other types of fasteners, and so on were used throughout the process

of putting the project's many components and the structure together. The sequence in which the

different components of the machine are assembled is as follows: the metal roller is fixed to the

ends of the base with the assistance of bolts and nuts. With the help of the arc welding equipment,

the base and the mast were joined together permanently. The skeleton appearance of the machine is

achieved by pivoting the boom to the mast using bolts and nuts in order to enable movement of the

boom. This creates the skeletal appearance of the machine. The load locking mechanism was part of

the lift cylinder, which also included bolts and other types of fasteners. The handle of the lever has

been attached to the back of the mast, which means that the machine is now ready for use.

Discussion

Once the machine's construction was finished, it was put through a series of testing to determine not

only how effectively it worked, but also how reliable it would be when used in the future.The test

was carried out with loads ranging from fifty to one hundred kilograms, and the findings showed
 13

that the amount of effort required to trigger the lift cylinder increased in direct proportion to the

load. The apparatus that was supposed to keep the weight in place at varying heights performed

well. It was observed that both the lifting arm and the boom moved very slowly, and that the

movement of the boom was slowed down at a few different heights.

The following is how the lift heights were measured:

When the boom is fully extended, the minimum height that may be lifted is 0.225 meters.

When the boom is completely extended, the lowest height that may be lifted is 0.37 meters.

When fully extended, the boom has a maximum load capacity of one meter's worth of weight.

When fully extended, the boom has a maximum lifting capacity of 0.82 meters.

The first version of the portable crane was built using electric motors, and it was designed to be

transportable on wheels so that it could be used for raising and jacking on the floors of the machine

shop. It is also possible for it to take the place of the overhead crane in a shop by being used to

transport items all throughout the store. In addition to its usage as a jack, it is put to use in the

loading and unloading of goods at transportation and haulage businesses. Simply pushing a button

is all that is required to start the motor, and utilizing the switches for lifting and booming is just as

simple and straightforward as it is effective. The fact that the portable crane runs on batteries,

which, owing to their nature, cannot be recharged at the location in question, presents a possible

disadvantage for the device. The batteries will eventually run out of power.

Conclusion

The creation of this object is not a simple task. In order to complete this task, we will need to

acquire knowledge in machine design, programming, the Solid Works laboratory, statics, dynamics,

and material mechanics. Additionally, we will need to construct a crane. Even down to the housing,

spur gears, bearings, shafts, keys, and lubricants, we are acquainted with the procedures and

methods necessary to construct a single girder overhead crane. While we were working on our

designs, we also discussed ways and strategies for accurately applying the Machine Design
 14

formulae and satisfying quality standards. This was done while we were working on our designs.

Throughout the whole of this project, there have been a lot of legitimate assumptions made, such as

the gear ratio, the length of the keys, and the number of teeth on the gear. These assumptions have

enabled us to finish the entire process of developing the product we are working on. We have also

taken into consideration the size and weight of the gearbox after it has been put to continuous

operation for ten years. We have determined that the design of the gearbox included a fault, which

was a contributing factor in the gearbox's failure. As engineers, it is our responsibility to continually

put the theoretical information we have gained into practice. This will allow us to make better use

of the resources we have and come up with inventive solutions for the benefit of future generations.

The fact that the job is difficult due to the nature of the project does not deter us from carrying it out

since we like doing it. We came into issues such as not knowing what to create it out of, how large it

needed to be, and whether or not a typical television would fit inside of it. It is true that we are

capable of discovering solutions to the issues. Now that we have completed this project, we have a

clearer concept of the minimal safety factor that should be applied to each component. Therefore, it

is reasonable to assert that the goal of the project has been accomplished.

References

Qin, Z., Wu, Y., Eizad, A., Lee, K., & Lyu, S. (2019). Design and evaluation of two-stage planetary

gearbox for special-purpose industrial machinery †. 33(12), 5943–5950.

https://doi.org/10.1007/s12206-019-1139-7

Qin, Z., Wu, Y., & Lyu, S. (2018). A Review of Recent Advances in Design Optimization of
 15

Gearbox. 19(11), 1753–1762. https://doi.org/10.1007/s12541-018-0203-z

Rassokha, V., & Isaychev, V. (2017). New Design of the Automobile Automatic Gearbox Providing

Driving Simplification and Driver Fatigue Decrease. Transportation Research Procedia,

20(September 2016), 544–549. https://doi.org/10.1016/j.trpro.2017.01.088

Victoria, R., Petrescu, V., Aversa, R., Apicella, A., Ion, F., & Petrescu, T. (2018). Dynamic Synthesis

of a Classic , Manual Gearbox. https://doi.org/10.3844/ajeassp.2018.586.597

Zdziennicki, Z., & Maciejczyk, A. (2016). Calculation and Design Case Example. April.