12V Manual Gear Transmission System
Project Overview
This project presents the design, construction, and analysis of a manually operated 12V gear transmission system engineered to demonstrate the fundamental principles of gear mechanics, torque multiplication, and power transmission. By replicating a real-world multi-gear transmission mechanism on a smaller scale, the system simulates actual gear-changing processes to evaluate the direct impact of varying gear ratios on output speed and torque. It serves as a practical bridge between theoretical mechanical concepts and real-world automotive and industrial applications.
Key Components & Tools
- Mechanical Hardware: A 4-gear bike transmission system, splined main and counter shafts, ball bearings for friction reduction, a manual gear slider, and an output flywheel to stabilize rotational inertia.
- Electrical Hardware: A 12V DC Attron Motor (1600 RPM, 6 Amperes) acting as the primary drive, powered by a 230W AC-to-DC power supply.
- Measurement & Testing: A laser tachometer was utilized for precise experimental RPM data acquisition.
- Software Stack: SolidWorks was employed for 3D CAD modeling, component assembly, and Static Stress Analysis.
Design & SolidWorks Simulation (Stress Analysis)
- A comprehensive 3D CAD model was developed in SolidWorks, ensuring the precise alignment of gears, shafts, and bearings prior to physical assembly.
- Static Stress Analysis was conducted to predict structural behavior under torque loading, specifically evaluating stress concentrations at gear teeth contact points and root areas.
- Simulations analyzed the inverse relationship between face width and bending deformation, allowing for optimized design parameters that enhance durability and mechanical efficiency.
Experimental Testing & Calculations
- Practical experiments validated the mechanical principle that higher gears (lower ratios) increase output speed while decreasing torque, and vice versa.
- Experimental output speeds were successfully recorded across four gear stages using a laser tachometer: Gear 1 (309 RPM), Gear 2 (487 RPM), Gear 3 (501 RPM), and Gear 4 (538.9 RPM).
- Theoretical RPM and torque calculations were compared against empirical data. The analysis successfully identified and quantified mechanical energy losses attributed to bearing friction, motor loading effects, and transmission inefficiencies.
