Names of Students

Haseeb Ahsan (70139229)

Azeem Shan (70140626)
Hamza Asif (70136101)

Semester - 5th

System Molding and Analysis

Assignment – 1st
Submit to: Sir Hamid Iftikhar

Mechanical Engineering Department

 System Molding and Analysis

Aim/purpose
To study the motion analysis of planetary gear system by changing the its gear ratio.

Design requirements
We required planetary gearbox having gear ratio 1:3.

Objective
▪ Explain planetary gearbox system.
▪ Calculation of number of teeth by using the gear ratio.
▪ Perform motion analysis on different configurations & discuss the plots.

Introduction to Planetary Gear Box

A planetary gearbox (also known as an epicyclic gearbox) is a type of gear system that
consists of three main components:

1. Sun Gear: The central gear positioned in the middle.

2. Planet Gears: Multiple gears that revolve around the sun gear and are held in place by a
rotating carrier.
3. Ring Gear: An outer ring with internal teeth that mesh with the planet gears.

In a planetary gearbox, the planet gears rotate around the sun gear, while also rotating on their
own axes within the ring gear. This unique arrangement allows for compact, efficient power
transmission with high torque output.
Applications of Planetary Gear Box
Planetary gearboxes are versatile and used across many applications due to their high
efficiency, compact design, and ability to handle high torque in small spaces. Here are some
common applications:

1. Automotive Transmissions

• Planetary gearboxes are widely used in automatic transmissions for cars, where their
compact size, high torque output, and ability to provide multiple gear ratios make them
ideal.
• They enable smooth and efficient shifting between gears, providing both speed and torque
control.

2. Industrial Machinery

• Cranes and hoists: Planetary gearboxes are used in lifting equipment because they offer
the necessary torque for moving heavy loads with precision.
• Conveyors: In material handling systems, planetary gearboxes provide the power needed
for conveyors and other movement applications in factories.
• Mixers and agitators: In industries such as food, chemicals, and pharmaceuticals,
planetary gearboxes provide consistent speed and power for mixing materials.

3. Wind Turbines

• Planetary gearboxes are used to increase the rotational speed from the blades to the
generator, allowing efficient energy conversion. Their durability and ability to handle high
torque loads are especially beneficial in wind energy applications.

4. Robotics and Automation

• Planetary gearboxes are preferred in robotic arms and precision automation due to their
compact size, high torque, and low backlash. They allow for smooth, controlled
movements with high accuracy.

5. Aerospace and Defense

• Planetary gearboxes are used in various aerospace applications, including in aircraft

engines, landing gear systems, and even space applications. Their high-power density and
reliability make them suitable for the demands of aerospace environments.
6. Construction Equipment

• Heavy machinery like excavators, bulldozers, and loaders rely on planetary gearboxes for
power transmission, particularly in drive systems and track propulsion where high torque
is required in compact spaces.

7. Electric Vehicles (EVs)

• In electric vehicle drivetrains, planetary gearboxes help manage the power delivery from
electric motors, improving efficiency and allowing better control over speed and torque.
They are used in both passenger and commercial EVs.

8. Medical Equipment

• Planetary gearboxes are used in medical devices such as MRI machines, X-ray systems,
and surgical robots, where their precision and reliability are critical.

9. Printing and Packaging Equipment

• In high-speed printing and packaging machines, planetary gearboxes provide the

controlled, smooth movement needed for accurate positioning and consistency.

10. Marine Applications

• Planetary gearboxes are used in marine propulsion systems and winches, providing the
torque and control needed for ship movement and stability. Their robustness makes them
ideal for withstanding the marine environment.

Which modifications can be made in the planetary gearbox?

The following modifications can be made to enhance the performance of the planetary gearbox.

• Changing gear ratios: Alter the number of teeth on the sun, planet, or ring gears to achieve
desired output speeds and torque characteristics.
• High-strength materials: Use materials like hardened steel, titanium, or carbon fiber
composites to handle higher loads and improve durability.
• Multiple stages: Adding additional planetary stages increases the gear ratio range,
providing higher torque output or speed reduction.
• Adding more planet gears: Increasing the number of planets in the carrier distributes the
load more evenly, enabling the gearbox to handle more torque.
 • Preloaded bearings: Preloading bearings can reduce backlash and improve precision,
which is useful in high-accuracy applications.
• High-performance lubricants: Specialized oils or greases improve heat dissipation,
reduce wear, and enhance gearbox longevity.
• Cooling mechanisms: Adding cooling systems (such as oil coolers or fins on the housing)
helps prevent overheating in high-power applications.
• Custom tooth profiles: Using optimized tooth profiles enhances efficiency, smoothness,
and wear resistance.
• Lightweight materials: Using aluminum alloys or composite materials for the housing can
reduce weight without compromising strength, ideal for mobile applications.
• Control electronics: Integrating electronics for load control, speed modulation, or
predictive maintenance.

Faults of Planetary Gearbox During Performance

Planetary gearboxes are durable and efficient, but they can still encounter various faults,
especially under high-stress or poorly maintained conditions. Here are some common issues:

1. Wear and Tear on Gears

• Pitting: Small pits or holes form on gear surfaces due to repeated contact stresses, often
from heavy loads.
• Scuffing: Heat and insufficient lubrication can cause the surfaces of gear teeth to adhere
and wear down.

2. Bearing Failures

• Bearing fatigue: Repeated loads can lead to fatigue in bearings, causing noise, vibration,
and eventual failure.
• Misalignment: Misaligned shafts and gears increase stress on bearings, leading to
accelerated wear.
• Contamination: Dirt or debris in the gearbox can damage bearings, especially when
combined with inadequate lubrication.

3. Overheating

• Insufficient lubrication: Poor lubrication results in higher friction and heat, leading to
overheating and faster degradation of components.
• Excessive load or speed: Operating beyond the gearbox’s rated load or speed can cause
overheating, leading to thermal expansion and reduced component life.

4. Misalignment

• Gear misalignment: Incorrect alignment during assembly or due to wear over time can
lead to improper gear meshing, increased friction, and accelerated wear.
 • Shaft misalignment: Misalignment in shafts connected to the gearbox causes uneven
loads and premature bearing or gear failure.

5. Lubrication Issues

• Inadequate lubrication: Poor or insufficient lubrication can lead to metal-to-metal

contact, causing wear and overheating.
• Lubricant contamination: Contaminants like dirt, water, or metal particles in the
lubricant can cause wear and corrosion, accelerating gearbox degradation.
Calculation of number of teeth by using the gear ratio
Procedure
All the gears have taken from the Solid Works library, by using module 1, face width is 10mm and
pressure angle according to the module 1 that given by the Solid works by default.

Planetary Gear

Ring Gear
Sun Gear:

Carrier
Assembly:

And we use bearing type 284 to connect planetary gear and carrier

The detail of these parts is on the drawing sheets

Motion Analysis
We make 3 configurations
Case1: (Default)
Case2: Sun gear is the fix and RPM is applied at carrier and get output at the ring
gear. (Generator / engine input)
Case3: Carrier is fixed and RPM is applied at Sun Gear. And output is taken at ring
gear. (Motor input)
Case 1:

Angular velocity

Angular Acceleration
Case 2:
Angular velocity

Angular Acceleration
Case 3:
Angular velocity

Angular Acceleration
Conclusion:
In default case the angular velocity and acceleration at the input and output remain the same. In
case two, RPM is applied at the sun gear. And see how to change the velocity at ring gear. In case
three RPM is applied at the carrier, and sun gear is the fixed and see how RPM is changing at the
output ring gear. The main purpose of this design of planetary gear to see how the velocity change,
when we change the input at the different component and same input is applied at the different
components and see how the RPM’s change at different outputs.

Link of remaining data of assignment

link of remaining data of assignment 1st

https://drive.google.com/drive/folders/1PROasWTXt9KqhJvC-
ABJjQkB9K_e--a7?usp=drive_link