Machine Design Components II
Term Project
Design of a Self-Locking Gearbox Having Two Output Shafts
Spring 2025
Due Date: 8-Jul-2025
Introduction
There are some self-locking mechanisms, such as ratchet, back-stop roller bearing (back-stop
clutch), and worm-wheel (worm-gear) systems. The first two systems function in only one
direction, while the third can function in two directions.
Worm-gear power transmission systems achieve a high self-locking property, as high contact
forces between the worm and wheel, combined with a low lead angle, create a high frictional
force that prevents the output shaft from turning the worm back. Moreover, these systems
possess significantly more precision compared to the other two systems, as well as support
both-direction motion.
Multiple Output Gear Reducers
Multiple output gear reducers are types of gearboxes designed to distribute power from a single
input source (such as an electric motor or a combustion engine) to multiple output shafts, each
delivering torque and rotational motion to different driven components. They can used in
applications where one driving force needs to operate several driven components
simultaneously at the same or different speeds and torques.
This wide family of gearboxes has some key features, such as:
- One driving motor powers several output shafts.
- Each output can have different transmission ratios, varying speeds, and torque levels.
- Elimination the need for multiple reducers, saving space and cost.
- Outputs can run at synchronized speeds (like conveyor systems) or independently (for
example multi-axis machinery).
- Space efficiency and compaction compared to using multiple single-output reducers.
- Precision synchronization and ensuring coordinated movement in machines.
These gearboxes can be designed in parallel shaft, right-angle, and planetary configurations, as
respectively illustrated below:
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The mentioned reducers could be employed in various areas, such as:
- Conveyor systems, material handling machines, elevators, cranes, and lifting machines,
for driving multiple pulleys, or rollers
- Packaging machinery, for synchronizing multiple moving parts
- Assembly lines, in order to synchronize lines and prevent the agglomeration
- Automated manufacturing, such as multi-axis robotic arms
- Agricultural equipment, for powering different functions, like multiple power harvesters
- Winches, which are widely employed in ground, sub-ground, mining, and marine
equipment, for towing or lifting.
The Project Description
The self-locking and right-angle gearbox has two output shafts. The draft of the project has been
illustrated below. The input power is transmitted equally to two output shafts. The direction of
rotation of the output shafts is opposite.
The input power may enter clockwise, or counter-clockwise. The output shaft 1 rotates
consonant the input shaft, and the shaft 2 always rotates opposite to the shaft 1.
A comprehensive and detailed design of this system is the subject of the term project of this
course. Various items and activities of the project have to be carried out and submitted as the
following:
1- Design of the kinematic chain of the power transmission system (10 points)
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2- Detail design of the power transmission system 1: Material selection for gears and shafts
with reasons and descriptions, design of gears using the metric version of ANSI/AGMA,
geometric design of the gearbox shafts, static and fatigue design of the gearbox shafts,
geometric and mechanical design of keys, design and selection of bearings, solid
modeling of the assembly and explosive view. Mechanical design and calculations must
be carried out using KISSsoft® (60 points)
3- Selection of the electromotor for the power source (using an Iranian electromotor
manufacturer catalog with some technical descriptions) and solid modeling of the
electromotor (8 points)
4- Detail design of the power transmission system 2: Solid modeling of the gearbox body,
housing cover of bearings, and final assemblage by the gearbox (22 points)
Some Important Notes
1- All calculations must be conducted in the metric system.
2- There is a desirable concentration on conceptual design, knowledge of machine
elements, and software skills in the projects.
3- The report of the project must be submitted in a single PDF file. Other files (such as the
report in Microsoft Word format, picture files, and drawings) will be ignored. If the
drawing files are needed for more accurate investigations, an email will be sent to the
student.
4- Submitting the reference documents (such as data sheets, catalogs, and websites) is
necessary, if it has been emphasis on the description of the project.
Disobedience from the above notes would lead to negative consequences on the project ratings.
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