ME154 7Q Midterm 2019

A 7 speed gearbox is to be designed for a trial vehicle. The vehicle engine specifications are as indicated below.
Use the red power curve and orange torque curve in the leftmost figure. The two other figures indicate typical
values for a four gear transmission, so adapt/extrapolate values for a 7 gear transmission. Power transmitted
from engine is dependent on vehicle speed and tractive force: F t x V.

Gear Ratios Group No.

1st gear 3.78:1 1
2nd gear 2.06:1 2
3rd gear 1.40:1 3
4th gear 1.26:1 4
5th gear 1.00:1 5
6th gear 0.80:1 6
7th gear 0.70:1 7
Vehicle Data
Curb weight 835 kg
Cd drag coefficient 0.485
Front Area 1.85 m2
Rolling Resistance Coefficient 0.0124
Tyre radius 30.9 cm
Maximum Engine Power 25 kW (34 bhp)
Maximum Engine Torque 76 Nm
Maximum Engine rpm 4100 rpm
Design Specifications
Input and output shafts extend 4 inches outside gearbox
Input and output shaft diameter tolerance ±0.001 in
Input and output shaft inline, concentricity ±0.005 in, alignment ±0.001 rad
Chassis mounted with 4 bolts
100% duty cycle
Maintenance schedule: lubrication check every 2000 hrs, change lubrication every 8000 hrs, gears
and bearing life > 12000 hrs, infinite shaft life, gears & bearings & shafts replaceable
Operating temperature range -10o to 120oF
Transmission size overall dimensions L390 mm x W515 mm x H360 mm
Based on the transmission box size, for each group design the following:
Follow the procedure on gear design shown in the case study in Chapter 18. Groups must coordinate
with each other as to the gear sizes designed.
Design the gears for your group, minimizing dimensions to fit the gearbox size while providing an
output speed within the specified range. Be sure to avoid an interference problem in the teeth.
Use spur gears with a 20o pressure angle.
Design the shaft sizes and bearings for the shaft. A typical 4 speed and 5 speed transmission is
indicated below, modify to a 7 speed system.

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