The goal of this project was to design and analyze a gearbox with a gear ratio of 240:1. The gearbox was limited by a series of constraints including strength and life; it needed to have minimum life of 25,000 hours, to be able to support a 50 lbf overhanging load at the output shaft, and achieve a maximum rotational speed of 240 RPM at the input shaft. Manufacturability was also a concern as the designs would have to be implemented using only prototype methods such as milling, turning, tapping, and on purchasable stock.

Methods + Machines Used:
CAD – SolidWorks was used to design, render and animate the gearbox
FEA – to check the effects of the 50 lbf loading on the output shaft
Component Life Analysis – to ensure the bearings met the minimum 25,000 hours
Tolerance Analysis – to ensure all our components fit together and were manufacturable

 

 

Open assembly view.

Open assembly view.

 

The gear layout.

The gear layout.

 

Full exploded view

Full exploded view

 

Closed assembly.

Closed assembly.

 

Case bottom.

Case bottom.

 

Case top.

Case top.

 

Exploded worm gear shaft.

Exploded worm gear shaft.

 

shaft 1 exploded view

Shaft 1 exploded view.

 

 

Worm shaft drawing.

Worm shaft drawing.

 

Shaft 1 drawing.

Shaft 1 drawing.

 

Case drawing.

Case drawing.