Mechanical and Robotic & Mechatronic Engineering - Design of a Two-stage Speed Reducer - Case Study Writing Assignment

Assignment Task:

Design Requirements 
Overview For the design project, we assume a manufacturing company need a two-stage speed reducer which is required to install in their assembly line as

1. Electric motor;
2. Belt drive or chain drive 
3. Gear driver-based speed reducer
4. Coupling 
5. Roller 
6. Conveyor belt.  

Functions

The functions of the gear type speed reducer are as follows:

1. To receive power from an electric motor through a rotating shaft.

2. To transmit the power through machine elements that reduces the rotational speed to a desired value.

3. To deliver the power at the lower speed to an output shaft, it ultimately drives the conveyor system.
Working conditions

• The components 5 and 6 are parts of a conveyor system, which is running 16 hr/day, 5 days per week, with a design life of 10 years. This is approximately 40,000 hours of operation and its operation is generally smooth.
• The roller has a diameter of 350 mm and a torque of 1400 N.m is applied on it. The speed of the conveyor belt is 0.5 m/s, which is permitted to vary . 5%.
• The speed reduction ratio of the speed reducer should be controlled in a range of 3.46 to 3.53 for each stage.
• A mechanical efficiency of greater than 95% is desirable.
• Flexible couplings may be used to connect the output shaft directly to the shaft of the roller for the conveyor system.

Selection Criteria

1. Safety: The speed reducer should operate safely and provide a safe environment for people near the machine.

2. Cost: Low cost is desirable so that the gearbox appeals to a large set of customers.

3. Size: compact design with a small size is preferred.

4. High reliability.

5. Low maintenance.

6. Smooth operation: low noise and vibration.

Methodology

You will be allocated to a team of 2-3 students to achieve the design goal with creative ideas together and for equity, a peer-review report to evaluate each team member’s contribution is employed with the group slides and design report for submission at the end of the semester as required in the learning guide. In your team you should have a unified and clear target to design the two-stage speed reducer and its accessories including belt/chain drive to transfer the power and torque from the electrical motor to the input shaft of the speed inducer and a coupling to connect the output shaft of the speed reducer with the input shaft of the conveyor as required. The team members should have a discussion to allocate the design tasks evenly.       
Your design will involve in the following commonly-used machine elements: Gear drives , Belt and Chain Drives , Keys, Couplings and Seals , Machine Housing , Shafts , Bearings

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