Gear Trains: A Comprehensive Guide

A gear train is an assembly of two or more gears that transmit motion and power
from one shaft to another. They are fundamental in mechanical systems for achieving
desired speed reductions or increases, torque multiplication, and directional
changes. This document provides a comprehensive overview of gear trains, their
nomenclature, types, and relevant formulas.

1. Introduction to Gear Trains

Gear trains are used to:

Change Speed: To reduce or increase the rotational speed from an input (driver) to
an output (driven) shaft.
Change Torque: Inversely related to speed, a speed reduction results in torque
multiplication, and vice versa.
Change Direction: To reverse the direction of rotation of the output shaft relative
to the input.
Transmit Power: Efficiently transfer mechanical power between shafts.
2. Fundamental Concepts and Nomenclature of Gear Trains
Diagram 1: Simple Gear Train (Input, Idler, Output)
(Insert a diagram showing a simple gear train with three gears in series: Driver
(Gear 1), Idler (Gear 2), Driven (Gear 3). Label the input shaft, output shaft, and
show the direction of rotation for each gear.)

Driver Gear (Input Gear): The gear that receives power from the prime mover and
initiates the motion.
Driven Gear (Output Gear): The gear that transmits power to the load or the next
stage of the machine.
Idler Gear: A gear inserted between the driver and driven gear in a simple gear
train. Its primary purpose is to change the direction of rotation of the driven
gear without affecting the overall speed ratio, or to bridge a large center
distance. It does not affect the magnitude of the speed ratio.
Pitch Circle Diameter (d): The diameter of the imaginary circle on a gear where
meshing occurs.
Number of Teeth (N): The count of teeth on a gear.
Angular Velocity (
omega): The rotational speed of a gear, typically in rad/s or rpm.
Speed Ratio (SR) / Velocity Ratio (VR): The ratio of the angular velocity of the
input gear to the angular velocity of the output gear.
SR=
fracomega_inputomega_output
Train Value (e) / Overall Speed Ratio: The ratio of the angular velocity of the
last driven gear to the angular velocity of the first driving gear. It's the
inverse of the speed ratio.
e=
fracomega_outputomega_input=
fractextProductofteethondrivinggearstextProductofteethondrivengears
Also, e=
fracN_driver1timesN_driver2timesdotsN_driven1timesN_driven2timesdots
Torque (T): The rotational force produced by a gear.
Assuming 100% efficiency, T_output
times
omega_output=T_input
times
omega_input
Therefore,
fracT_outputT_input=
fracomega_inputomega_output=SR (Torque ratio is the inverse of the train value)
Direction of Rotation: The way a gear spins (clockwise or counter-clockwise).
3. Types of Gear Trains
Gear trains are broadly classified based on their arrangement and the relative
motion of their axes.

3.1. Simple Gear Train

Description: Consists of a series of gears where each shaft carries only one gear.
Arrangement: Gears are typically arranged in a line.
Speed Ratio: The speed ratio between the input and output depends only on the
number of teeth of the first driver and the last driven gear. Idler gears do not
affect the magnitude of the speed ratio.
Direction:
If the number of external gears in series is odd, the output gear rotates in the
same direction as the input gear.
If the number of external gears in series is even, the output gear rotates in the
opposite direction to the input gear.
Formula:
fracomega_outputomega_input=
fracN_driverN_driven (For a pair of gears)
For a train of gears 1, 2, 3, ..., n:
fracomega_nomega_1=
fracN_1N_n
times(
textDirectionfactor,+1forsame,−1foropposite)
Diagram 2: Simple Gear Train Example
(Insert a simple diagram illustrating a simple gear train with 2 gears (driver,
driven) and another with 3 gears (driver, idler, driven). Show their respective
directions of rotation.)

3.2. Compound Gear Train

Description: A gear train where at least one shaft carries two or more gears that
rotate together as a single unit. This allows for large speed reductions or
increases in a compact space.
Arrangement: Used when a large speed ratio is required within a limited space, or
when the distance between the driver and driven shafts is large.
Speed Ratio: The overall speed ratio is the product of the speed ratios of each
pair of meshing gears.
Formula:
e=
fracomega_outputomega_input=
fractextProductofteethonalldrivinggearstextProductofteethonalldrivengears
e=
fracN_AtimesN_CtimesdotsN_BtimesN_Dtimesdots (where A, C are drivers; B, D are
driven)
Direction is determined by counting the number of external gear meshes, similar to
a simple gear train.
Diagram 3: Compound Gear Train Example
(Insert a diagram showing a compound gear train. For instance, Gear A drives Gear
B, and Gear B is rigidly connected to Gear C, which in turn drives Gear D. Show
N_A, N_B, N_C, N_D and shaft connections.)

3.3. Reverted Gear Train (Coaxial Compound Gear Train)

Description: A special type of compound gear train where the axis of the first gear
(input) and the axis of the last gear (output) are coaxial (lie on the same line).
Arrangement: Commonly found in clocks, lathes, and automotive transmissions.
Conditions:
The sum of the radii (or pitch diameters) of the first pair must be equal to the
sum of the radii (or pitch diameters) of the second pair.
R_A+R_B=R_C+R_D or d_A+d_B=d_C+d_D
Since d=mN, if all gears have the same module (m): N_A+N_B=N_C+N_D
The overall train value is calculated like a compound gear train.
The direction of rotation of the output shaft is usually the same as the input
shaft.
Diagram 4: Reverted Gear Train Example
(Insert a diagram showing a reverted gear train. Clearly show the input and output
shafts are coaxial. Label gears A, B, C, D and their respective shafts.)

3.4. Epicyclic (Planetary) Gear Train

Description: A complex gear train where at least one gear (planet gear) has an axis
of rotation that moves relative to a fixed frame.

Components:

Sun Gear: The central gear, usually fixed or acting as an input/output.

Planet Gears: Gears that revolve around the sun gear and also rotate on their own
axes.
Annulus (Ring Gear): An internal gear that meshes with the planet gears.
Planet Carrier (Arm): A rotating arm that holds the planet gears and causes them to
revolve around the sun gear.
Characteristics:

Offers very high speed ratios in a compact, coaxial arrangement.

Can provide multiple output speeds by fixing different elements (sun, ring, or
carrier).
Can transmit large torques.
Direction of output can be same or opposite depending on which element is fixed.
Formula (Tabular Method / Relative Velocity Method):
This method is generally used to analyze epicyclic gear trains. It involves
considering the relative velocities of the gears when the arm is fixed and then
adding the velocity due to the arm's rotation.

Let:

omega_S: Angular velocity of Sun gear

omega_A: Angular velocity of Annulus (Ring) gear
omega_P: Angular velocity of Planet gear
omega_Arm: Angular velocity of Arm (Carrier)
N_S,N_A,N_P: Number of teeth on Sun, Annulus, Planet respectively.
Example (Arm fixed, Annulus fixed, Sun fixed):

Sr. No. Condition Arm fixed, Sun rotates +x rpm Arm fixed, Annulus rotates +x
rpm Add
omega_Arm to all elements Total Motion
1 Arm 0 0 +
omega_Arm
omega_Arm
2 Sun +
omega_S −
fracN_AN_S
omega_A +
omega_Arm
omega_S
total

3 Annulus −
fracN_SN_A
omega_S +
omega_A +
omega_Arm
omega_A
total

Export to Sheets
*Note: The actual calculation involves systematically applying the speed ratio
formula for simple pairs, then superimposing the arm's motion.*

**Tabular Method (Common Approach):**

| Step No. | Condition of Motion | Arm | Sun | Planet | Annulus |

| :------- | :------------------ | :-- | :-- | :----- | :------ |
| 1 | Arm fixed, Sun turns +1 rev | 0 | +1 | $\frac{-N_S}{N_P}$ | $\
frac{-N_S}{N_A}$ |
| 2 | Arm fixed, Sun turns +x rev | 0 | +x | $x \frac{-N_S}{N_P}$ | $x \
frac{-N_S}{N_A}$ |
| 3 | Add y rev to all elements | +y | +y | +y | +y |
| 4 | Total Motion | y | x+y | $y - x \frac{N_S}{N_P}$ | $y
- x \frac{N_S}{N_A}$ |

By equating the "Total Motion" of two known components (e.g., if sun is fixed,
$x+y=0$; if arm is fixed, $y=0$), you can solve for the unknown speeds.
Diagram 5: Epicyclic Gear Train (Sun, Planet, Ring, Carrier)
(Insert a clear, labeled diagram of an epicyclic gear train showing the sun gear,
planet gears, annulus/ring gear, and the planet carrier/arm.)

4. Gear Train Applications

Automotive Transmissions: Both manual and automatic transmissions extensively use
gear trains (compound and epicyclic) to provide multiple gear ratios for varying
vehicle speeds and loads.
Bicycle Drivetrains: Simple and compound gear trains in derailleur systems.
Machine Tools: Lathes, milling machines, etc., use gear trains to control spindle
speeds and feed rates.
Clocks and Watches: Reverted and simple gear trains for precise timekeeping.
Wind Turbines: Large speed-up gearboxes to match the slow turbine rotation to the
high generator speed.
Robotics: Compact gear trains for precise joint movements.
Agricultural Machinery: Tractors, harvesters, etc.
5. Design Considerations for Gear Trains
Required Speed Ratio: The most fundamental parameter.
Input/Output Speeds and Torques: To determine power requirements and select
appropriate gear sizes.
Space Limitations: Dictates the type of gear train (e.g., epicyclic for compact,
high ratio).
Direction of Rotation: Determines the need for idler gears or specific
configurations.
Efficiency: Each gear mesh has some power loss due to friction. More meshes
generally mean lower overall efficiency. Epicyclic trains can be very efficient if
designed well.
Noise and Vibration: Affected by manufacturing quality, backlash, lubrication, and
type of gears (helical are quieter than spur).
Cost: Influenced by complexity, precision requirements, and materials.
Lubrication: Essential for minimizing wear and heat, maximizing efficiency and
life.
Bearing Loads: Gears transmit forces that must be supported by bearings in the
shafts and housing.
Backlash Management: Crucial for precision applications (e.g., robotics) to prevent
play and improve accuracy.
Thermal Management: Heat generated by friction needs to be dissipated to prevent
lubricant breakdown and material degradation.
6. Conclusion
Gear trains are versatile mechanical systems enabling the precise control of speed,
torque, and direction in countless applications. Understanding their fundamental
types, nomenclature, and design principles is essential for any mechanical engineer
involved in the design or analysis of power transmission systems. The choice of
gear train type depends heavily on the specific application requirements, balancing
factors like speed ratio, space, efficiency, and cost.