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Form: SSC-115-06-08
UNIT
CODE: ENS5114
TITLE: ADVANCED
MECHANCIAL
DESIGN
NAME OF STUDENT (PRINT CLEARLY)
GULATI SIMARDEEP
HIMANSHU HIMANSHU
SINGH AMRITPAL
STAMPALIA MATT
FAMILY NAME FIRST NAME
STUDENT ID. NO.
10371800
10395325
10372947
10387107
SIGNATURE
NAME OF LECTURER (PRINT CLEARLY)
DR. FERDINANDO GUZZOMI
DUE DATE
30/05/2016
Topic of assignment
MAJOR ASSIGNMENT
Group or tutorial (if applicable)
GROUP 4
Course
Y45 MECHANICAL ENGINEERING
Campus
JOONDALUP
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -CHERRY PICKER GEARBOX
Design and Analysis Reports
Simardeep Gulati, 10371800
Himanshu Himanshu, 10395325
Amritpal Singh, 10372947
Matt Stampalia, 10387107P a g e | 1
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Table of Contents.
1. Design Report. ....................................................................................................................................3
1.1. Product Design Specification. .....................................................................................................3
1.1.1 Design Constraints. ...............................................................................................................3
1.1.2. Design Criteria. .....................................................................................................................4
1.2. Product Design Evaluation..........................................................................................................6
1.2.1 First Concept – Two Stage Helical Gear Differential. ...........................................................6
1.2.2. Second Concept – Planetary Gearbox. ................................................................................6
1.2.3 Evaluation..............................................................................................................................7
1.3. Cherry Picker Gearbox Design. ...................................................................................................8
1.4. Manufacturing Details. ...............................................................................................................8
1.5. Cherry Picker Operation............................................................................................................10
1.6. Maintenance. ............................................................................................................................10
2. Analysis Report.................................................................................................................................11
2.1. Australian Standards.................................................................................................................11
2.2. Hydraulic Motor Specifications. ...............................................................................................12
2.3. Wheel Specification. .................................................................................................................12
2.4. Power and Torque Requirements.............................................................................................13
2.5. Planetary Gearbox Ratio and Reactions...................................................................................14
2.5.1 Gear Ratio............................................................................................................................14
2.5.2. Number of Planet Gears. ...................................................................................................15
2.5.3. Planetary Gearbox Free Body Diagrams and Reactions. ..................................................15
2.5.4. Gear Angular Velocities. ....................................................................................................15
2.5.5. Gear Forces.........................................................................................................................15
2.6. Gear Sizing and Specifications. .................................................................................................16
2.6.1. Estimate Gear Size Table....................................................................................................16
2.6.2. Sun Gear AGMA Bending Stress. .......................................................................................16
2.6.3. Sun Gear AGMA Contact Stress. ........................................................................................17
2.6.4. Gear Specification Table. ...................................................................................................18
2.7. Input Shaft.................................................................................................................................19
2.7.1. Input Shaft Fatigue Life......................................................................................................19
2.7.2. Input Shaft Bearing. ...........................................................................................................21
2.7.3. Input Shaft Keyway. ...........................................................................................................22P a g e | 2
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.8. Hub.............................................................................................................................................23
2.8.1. Hub Bearings. .....................................................................................................................23
2.8.2. Hub Ansys FEA....................................................................................................................25
2.8.3. Hub Cover Screws...............................................................................................................25
2.8.4. Wheel Bolts. .......................................................................................................................26
2.9. Ring Gear. ..................................................................................................................................26
2.9.1. Ring Gear Fatigue life. ........................................................................................................26
2.9.2. Ring Gear Keyway. .............................................................................................................28
2.10. Spindle. ....................................................................................................................................29
2.10.1. Spindle Fatigue Life. .........................................................................................................29
2.10.2. Hub Nut. ...........................................................................................................................31
2.10.3. Gearbox Mounting Bolts..................................................................................................32
2.11. Cover........................................................................................................................................33
2.11.1. Cover Ansys FEA. ..............................................................................................................33
2.11.2. Planet Gear Pins Stresses.................................................................................................34
2.11.3. Cover Fastener Screws. ....................................................................................................35
2.12. Cherry Picker Travelling Clearance and Speed.......................................................................36
3. References. .......................................................................................................................................37
4. Engineering Drawings. .....................................................................................................................38P a g e | 3
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
1. Design Report.
1.1. Product Design Specification.
The design of a cherry picker drive wheel gearbox that is driven from a specified hydraulic motor. The
design includes an entire gearbox that will be fastened to the cherry picker chassis and allows
attachment of the wheel and hydraulic motor.
1.1.1 Design Constraints.
Gearbox design requirements:
Gearbox housing must be structural to support vehicle loadings and must have
adequate fasteners.
Each front wheel must support cherry picker with driver and additional payload.
Loadings = cherry picker + payload = 365kg + 25kg = 390kg.
Gearbox must have a coaxial alignment.
Tapered roller bearings for supporting wheel loads.
Reliability and safety factors for agricultural applications.
Gearbox must be serviceable with oil fill and drain locations.
Final design should be a ready-for-manufacture design.
Gearbox design must include the following:
Gear sizing.
Bearing specification.
Shaft design.
Gearbox housing design.
Seal specifications.
Fastener size specifications.
Bracket and Fixture requirements design.
FEA analysis of the complete assembly.
Application factors:
An efficient design thus reducing the travel time between rows.
Gravel ground surface with gradient of up to 150 incline and with coefficient
of friction with tyre, µ = 0.35.
Design to have maximum safe gradient.
A 5m wide spacing between the tree rows.
Gearbox ratio to maximise speed and torque without losing traction.
Maximum cherry picker speed limited to 10km/h.P a g e | 4
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
The design must meet the Client requirements for recommended operation.
Front wheel specifications:
800mm diameter tyre.
8 x M16 bolt holes on a 300mm PCD with 200mm diameter centre hole.
Hydraulic motor specifications:
A single power source of TB0036 series Parker hydraulic motor.
Continuous hydraulic pressure of 125bar (12.5MPa).
Variable flow rate of 0-20L/min for entire hydraulic system.
two motors with 10L/min per motor.
Multiple flange mounting and output shaft selection options.
1.1.2. Design Criteria.
Performance
Design should improve the efficiency of the fruit picking or other agricultural
applications.
Design should operate as reliable as possible to avoid high costs associated with
downtime.
Design must minimize the travel time between the rows.
Design should be serviceable with adequate spacing between components.
Stability
Design should enable the operator to navigate at a maximum safe gradient.
The design should be able to carry a maximum load of 390 kg.
It must have adequate fastening to the vehicle chassis to support external
vehicle loads and internal gearbox loads.
Weight
The design should minimize the weight of the vehicle to reduce the material
costing and increase the efficiency of the agricultural application.
Environment
The design should compensate for the environmental influences; such as wind
forces.
The gearbox design should include proper seals so the fluids in the gearbox do
not leak.
Use of non-toxic and environmentally friendly lubricants.P a g e | 5
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Cost
Design should minimise cost by reducing the material weight.
All materials selected should be durable.
Cost of manufacturing should be minimized by using one type of material as
required avoiding multiple manufacturing techniques.
Number of components and connections should be minimised.
Material
Materials should be lightweight and strong.
Materials should be readily available and low cost.
Material should be durable to maximize life span and reliability.
Materials should be resistant to environmental conditions.
Non- toxic materials.
Manufacture
Design should be easily manufactured to a working product.
Design should utilise common and available manufacturing methods.
Design should minimise complex and special manufacturing processes.
Off the shelf components should be used wherever possible.
Installation
Design should enable a hassle free assembly and disassembly of the gearbox for
overhauling.
Gearbox housing must include adequate fastening to the vehicle chassis to
support all loads.
Maintenance
Gearbox assembly must consist of easily removable and interchangeable parts
for replacement in case of breakage of individual parts or components.
High maintenance parts should be avoided or well-maintained to increase the
life span.
Safety
Design should minimize risk of failure.
Design should minimize risk of injury.
All components must comply with relevant safety standards.P a g e | 6
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
1.2. Product Design Evaluation.
After designing the PDS and deciding on the constraints and criteria of the gearbox designs, it is
necessary to evaluate different design concepts to select the most efficient and suitable design. Some
of the most common differential compound gear trains use spur gears and helical gears. Another
criterion of achieving the desired speed differential is through planetary gears.
1.2.1 First Concept – Two Stage Helical Gear Differential.
In Figure 1, a simple two stage reduction compound gear box is used. Helical gears have teeth inclined
to the axis of rotation and are used to transmit motion from one shaft to another, parallel or nonparallel shafts. Helical gears provide better engagement of teeth during meshing which results in
higher load transfer and are widely used for high speed, high power mechanical applications. A gear
ratio of up to 100 to 1 can be easily achieved from Figure 1 configuration.
Figure 1 Two-stage compound Spur gear train (Richard G.Budynas, 2011)
From Figure 1, the rotary motion is transmitted from input gear 2 to output gear 5 through idlers 3
and 4. All the shafts are supported by the bearings for supporting the transmitted load in radial and
axial direction generated due to the helical gear meshing. This configuration can also result in greater
stresses produced, especially on the smaller gears.
1.2.2. Second Concept – Planetary Gearbox.
For the second design concept, a planetary gearbox is used to achieve desired gear ratio and output.
Spur gears are used for this planetary/epicyclic gear arrangement to avoid complexity of the design,
analysis and manufacturing.
Planetary gear trains provide high power distribution compared to other parallel axis gear trains with
up to 3% efficiency loss per stage. This ensures a higher proportion of input energy transmitted
through the gearbox. A higher stability is also achieved due to increased sharing of the mass and load
distribution between the sun and planet gears. This helps in reducing the contact stresses due to larger
contact area and thus increasing the wear and crack resistance of the meshing tooth.
Figure 2 shows a simple planetary gear system with a sun gear in the centre, meshed with two
planetary gears and a stationary ring gear. The input torque is transmitted from the sun to the planets.
The planets are further connected to the carrier arm and hub which transmits the desired output
torque. The output torque is a function of the gear ratio between the sun and planets. The spindle is
further supported by tapered roller bearings.P a g e | 7
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Figure 2 Planetary Gearbox
1.2.3 Evaluation
This is the most important phase of analysis. Before finalizing a specific design, certain dictating factors
should be taken into consideration. Some of these factors include overall gearbox sizing and weight,
efficiency, cost effective, maintenance, minimum number of components and ease of manufacturing.
The following table is a summary of the evaluation of the previous two concepts with respect to the
desired application. After analysing both aspects of the gear arrangements, the planetary gearbox is
the selected concept which will not only be efficient for the cherry picker gearbox application but will
also adhere to all the constraints and criteria.
As the design is not required for a large scale production and due to the small range of acting loads, a
detailed review of both designs is not necessary.
Table 1 Design Concept Evaluation
Selection Criteria Helical gear
differential
Planetary
Gearbox Notes
Weight Smaller diameter gears can be
used for achieving higher
differential in planetary
arrangement
Size Constraint
Cost
Efficiency Planetary arrangement has higher
efficiency and performance
Load
Transfer/Distribution Increased load sharing
Ease of Manufacturing smaller size and number of gears
Analysis Spur gears are easy to analyse
Maintenance
Better load sharing means less
stresses and less tooth wear and
pittingP a g e | 8
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
1.3. Cherry Picker Gearbox Design.
The final design for cherry picker gearbox shown in figure 3, is a single stage planetary reduction
gearbox, with sun gear as the driver input and output driven via the planetary gears and wheel hub.
The cherry picker gearbox has been designed to maximise operation safety and durability, while
minimise manufacturing cost by minimising custom components and utilising off the shelf
components. Serviceability has been optimised by minimising assembly and maintenance
requirements, by using basic and common tooling, maximising component service life, reducing
component wear with gear oil lubrication and maximised design safety factors. The final gearbox
specifications are.
5.22:1 Reduction Ratio.
239rpm input speed and 50.9Nm input torque.
45.8rpm output speed and 264Nm output torque.
Theoretical 6.9km/h maximum travelling speed for cherry picker on level ground.
9.750 degree maximum safe operating gradient.
SAE85W/140 Gear Oil lubricant, fill and drain using removable G1/2 BSPP Plug in cover.
Figure 3 Cherry Picker Gearbox Model and Section Views
1.4. Manufacturing Details.
This section represents a breakdown of the planetary gearbox manufacturing, with all components
listed in Table 2, bill of materials. The planetary gearbox is to be manufactured by machining gearbox
specific components including gears, shafts and housings, and the acquisition of off the shelf
components including bearings, circlips, fasteners, keyways and seals.
The planetary gear set is to be manufactured from 4140 Nitrided (through hardened) grade 2 steel,
with 200 pressure angle full tooth profile milled or cut. The sun gear is to be milled or cut on the
machined input shaft to minimise gearbox components and connections. 4140 steel is a common
industrial gear material, recommended by AGMA and meets design application and safety
requirements.
The cover, hub nut, pins and spindle planetary gearbox components are to be machined manufactured
using common 1040 carbon steel to minimise manufacture cost and supply timelines. The gearbox
manufacturing is low production and all components including planetary gear set have been designed
for machining, with local machine shops preferred for manufacturing opposed to interstate or
international manufactures.P a g e | 9
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
The hub is to be machined from a single piece of 6061 Aluminium alloy to minimise mass and inertia,
with an 8kg reduction over steel hub while maintaining design safety requirements. The hub may be
manufactured by casting provided strength and durability factors are maintained. The planet gears
use a plain bronze bearing or bush instead of a roller bearing, with low rotation speeds and radial
loads.
Negotiations and quotations for gearbox specific custom components are to be obtained from local
machine shops such as WA Gears, Henderson WA for machining, assembly and shipping of complete
gearbox units including cost per unit and batch production timelines. The off the shelf components
including bearings, circlips, fasteners, keyways and seals are to be purchased from local suppliers
including CBC bearings and State-wide bearings, and supplied to preferred manufacture. Gearbox
supply estimations are $1000-$1500 per unit, excluding hydraulic pump and inclusive of frame and
wheel fasteners and GST.
Table 2 Bill of Materials
Item
No. Part No. Description Qty. Material
1 P-CPG01 Spindle 1 1040 Carbon Steel
2 P-CPG02 Ring gear 1
4140 Nitrided (through
3 P-CPG03 Sun gear/Input hardened) Steel, Grade 2
Shaft 1
4 P-CPG04 Hub 1 6061 Aluminium Alloy
5 P-CPG05 Cover 1 1040 Carbon Steel
6 SKF- 6008 Input Shaft Bearing 1 Supplier Part
7 SKF- 30216 Hub Bearing 2 Supplier Part
8 P-CPG06 Shim 1 1040 Carbon Steel
9 P-CPG07 40mm External
circlip 1 Supplier Component
10 P-CPG08 68mm Internal
circlip 1 Supplier Component
11 SKF 40x68x10 Seal Input Shat Seal 1 Supplier Component
12 SKF 110x130x12
Seal Hub Seal 1 Supplier Component
13 10x8x36 Key Spindle Key 1 Supplier Component
14 P-CPG09 Lock Washer 1 1040 Carbon Steel
15 P-CPG10 Hub nut 1 1040 Carbon Steel
16 P-CPG11 Pin 2 1040 Carbon Steel
17 P-CPG12 Thrust Washer 4 Bronze
18 P-CPG13 Planet Gear 2 4140 Nitrided (through
hardened) Steel, Grade 2
19 P-CPG14 Planet Gear Bearing 2 Bronze
20 P-CPG15 30mm External
circlip 2 Supplier Component
21 P-CPG16 3.5x165 ID O-Ring 1 Supplier Component
22 M8 x 25 mm Cover cap screw 8 1040 Carbon SteelP a g e | 10
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
1.5. Cherry Picker Operation.
The gearbox design has a safe operating gradient of 9.750 degrees and theoretical maximum speed on
level ground of 6.9km/h. The orchard owner should allow 5.75m traveling clearance at the end of the
tree rows to allow the cherry picker to navigate between rows. It is recommended the operator should
travel between the rows in a zig zag pattern, turning the cherry picker around half way between rows
by rolling back down slope. The travelling path for cherry picker is 11.5m between rows when
travelling in zig zag path, opposed to 15.5m when travelling in straight path. The zig zag path also
reduces the travelling clearance width by 2m at the end of rows, allowing more trees per row and
reduced travelling times.
1.6. Maintenance.
The gearbox design has been optimised for durability and serviceability, with operation service life
designed for approximately 20000h greater than recommended cherry picker service life. Regular
1000h service intervals are recommended to maintain gearbox performance and requires basic
adjustments, inspections and maintenance tasks using basic hand tools including. 1000h
recommended service tasks are.
Check and re-tension gearbox mounting bolts.
Check hub bearings for free-play and adjust.
Change gearbox oil.P a g e | 11
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2. Analysis Report.
2.1. Australian Standards.
Australian standards AS/NZS 1418.10:2011 Cranes, Hoists and Winches Part 10: Mobile Elevating Work
Platform, outlines standards related to the design requirements of cherry pickers specific to orchard
MEWPS.
AS/NZS 1418.10:2011 Section 5.2.4 Brakes (see Clause 2.2.12)
Non-slewing orchard MEWPs with lift height up to 4 m limited to slopes of maximum 5-degrees
may be fitted with hydraulic retardation brakes only, provided the arrangement is designed to
prevent the drive motors from losing braking effect during overrun. The creep rate shall not
exceed 2 m/h when parked facing either uphill or downhill on a 5-degree slope. A warning shall
be included in the instruction manual and displayed on the MEWP, which shall state that the
MEWP drive wheels are required to be chocked if parked on a slope, to prevent the MEWP
from creeping.
AS/NZS 1418.10:2011 Section 5.2.5 Maximum Travelling Speed.
o 5.2.5.1 Maximum travel speed in the elevated position (see Clause 2.2.15)
Travel speeds for orchard MEWPs with the operator platform in the elevated travel
position shall be limited to the following:
(a) 1.5 m/s at a platform floor height of 4.0 m or below.
(b) 1.0 m/s at a platform floor height above 4.0 m and below 6.5 m.
(c) 0.7 m/s at a platform floor height above 6.5 m.
Where MEWPs are designed to employ variable speed limits based on the height
ranges above, the speed limiting mechanism shall be automatic and shall be fitted
with a safety device in accordance with Clause 2.10.
o 5.2.5.2 Maximum travel speed in the lowered travel position
Where the maximum travel speed in the lowered travel position exceeds the maximum
travel speed in the elevated position, the MEWP shall satisfy the requirements of the
kerb and depression test (Clause 3.6.3.2.2) at the lowered travel position, with the
height of the kerb (obstruction) increased to 150 mm. An additional requirement to be
demonstrated during the test is that the MEWP is designed so that the operator is not
at risk of injury by impact with the guardrail or at risk of being catapulted from the
platform.
AS/NZS 1418.10:2011 Section 5.2.6 Stopping distances (see Clause 2.2.16)
Orchard MEWPs travelling at the maximum speeds given in Clauses 5.2.5.1 and 5.2.5.2, on the
maximum specified slope, shall be capable of being stopped at distances not greater those
given in Figure 2.2.16.
(Australian/New Zealand Standards, 2016)
The design of the cherry picker gearbox will be to maximise operation gradient, opposed to maximum
speed as AS1418.10:2011 specifies design requirements for cherry pickers traveling at 5.4km/h
(1.5m/s) or greater and operating at above 4m height. As no specifications are provided in regards to
cherry pickers operation specifications and dimensions, compliance with AS1418/10:2011 is unable to
be determined and additional design requirements may be required for final cherry picker and
gearbox including brakes and stabilizers.P a g e | 12
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.2. Hydraulic Motor Specifications.
Parker TB36 hydraulic motor is used to drive the gearbox operating at a continuous 125bar pressure,
with 10L/min flow rate per motor (Entire hydraulic system has 20L/min flow rate). The hydraulic motor
configuration number is TB0036-A-W-26-0-AAAA, with SAE A 2 bolt flange and 25mm input shaft with
8mm key, Hydraulic ports are G1/2 BSPP and the motor is supplied in black paint. For specifications
please refer to parker TB series catalogue at.
http://www.parker.com/Literature/Hydraulic%20Pump%20&%20Motor/HY13-1590-009-TBSeries_20140718.pdf
The maximum TB36 motor torque is 50.9Nm for 125bar pressure and 10L/min flow rate from TB series
catalogue (Parker Hannifin Corporation, 2016). The calculation of motor maximum speed is by linear
interpretation of speed values given in imperial units for TB36 motor of 172rpm at 7.57L/min (2gpm)
and 277rpm at 11.36L/min.
𝜇𝐵𝐵𝐠= 𝐰 + (𝐱 − 𝐰) 𝐠− 𝐰
𝐱 − 𝐰
= 172𝐵𝐠+ (277𝐵𝐠− 172𝐵𝐩
10𝐯𝐵𝐠− 7.57𝐯𝐵𝐍
11.36𝐯𝐵𝐠− 7.57𝐯𝐵𝐍
𝜇𝐵𝐵𝐠= 239𝐵𝐍
The maximum motor speed is 239rpm for 10L/min for 125bar pressure and 10L/min flow rate from
TB series catalogue (Parker Hannifin Corporation, 2016).
2.3. Wheel Specification.
The client has specified a 0.8m diameter wheel with 8 x M16 on a 300mm PCD stud pattern and
200mm centre hole. No tyre or rim specification have been provided, so its assumed for design
purposes that the wheel (solidworks model shown in figure 4), uses a 31.5/13.5-15 8ply tyre and R15
x 10 rim with the following approximate dimensions.
800mm tyre outside diameter.
350mm tyre width.
8 x M16 on 300mm PCD stud pattern.
200mm centre hole.
370mm internal rim clearance.
Rim offset centralised.
Figure 4 Solidworks model of Wheel for design purposesP a g e | 13
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.4. Power and Torque Requirements.
Determine the maximum output torque and incline angle for the cherry picker with a wheel diameter
of d = 0.8m carrying a load of m = 390kg on a surface with coefficient of friction 𝐠= 0.35. shown in
figure 5, is the wheel free body diagram.
Figure 5 Wheel Free Body Diagram
𝐵𝐵𝐠= 𝐵
𝐵𝐵𝐵𝐵𝐠= 𝐮 𝐵 cos 𝐍
𝐍
𝐵𝐵𝐵𝐵𝐵 = 𝐵ℎ𝐵𝐵 = 𝐵 sin 𝐍
𝐵ℎ𝐵𝐵 is required to move the cherry picker up the incline and 𝐵𝐵𝐵𝐵𝐠is the maximum force that
can be applied to the cherry picker, however 𝐵𝐵𝐵𝐵𝐵 = 𝐵ℎ𝐵𝐵 and acts against 𝐵𝐵𝐵𝐵𝐠so.
𝐵𝐵𝐵𝐵𝐠= 𝐵ℎ𝐵𝐵 + 𝐵𝐵𝐵𝐵𝐵
𝐵𝐵𝐵𝐵𝐠= 2. 𝐵ℎ𝐵𝐵
𝐮 𝐵 cos 𝐠= 2. 𝐵 sin 𝐍
𝐠2
=
sin 𝐍
cos 𝐍
𝐠2
= tan 𝐍
𝐠= tan−1 𝐍
2 = tan−1 0.2 35 = 9.926°
The cherry picker’s maximum incline angle is 𝐠= 9.93° and the maximum output torque before
wheel slip is.
𝐍
𝐵𝐵𝐵 = 𝐵ℎ𝐵𝐵𝐠= 𝐮 𝐵 sin 𝐠= 0.4𝐠𝐠390𝐵 𝐠9.81𝐯𝐠𝐠sin 9.93° = 264𝐵P a g e | 14
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
The required torque at any angle may be calculated by 𝐵𝐵𝐵𝐵𝐠= 𝐮 𝐵 sin 𝐠and the torque for
wheel slip at any angle can be calculated by 𝐵𝐵𝐠= 𝐮 𝐵(𝐠cos 𝐠− sin 𝐩. Show in figure 6, is the
torque limit chart showing 𝐵𝐵𝐵𝐵𝐠and 𝐵𝐵𝐠against angle of incline (𝐩 for the cherry picker. The
intersection of lines at incline angle of 𝐠= 9.93°, shows the point of equilibrium for the cherry picker
and is the limit for incline travel.
Figure 6 Torque Limit Chart
2.5. Planetary Gearbox Ratio and Reactions.
2.5.1 Gear Ratio.
The gearbox will be a planetary gear set with input torque assumed to be 50.9Nm and output torque
264Nm with transfer efficiency of 99%.
𝐵𝐵𝐠=
𝐵𝐵
𝐵𝐠=
264𝐵
50.9𝐵 𝐠0.99 = 5.24 𝐵𝐵𝐵𝐵𝐍
To achieve 5.24 reduction with planetary gear set input will be sun gear, output will be carrier and the
ring gear will be fixed. Calculate number of gear teeth for the sun, planet and ring gears.
𝐵𝐵𝐠=
𝐵
+ 𝐵
𝐵
, 𝐵 = 1, 5.24 =
1 + 𝐵
1 , 𝐵 = 4.24𝐵
𝐵𝐵𝐵 𝐵 = 18 𝐵𝐵ℎ, 𝐵 = 4.24 𝐠18 = 76.32 = 76 𝐵𝐵ℎ
𝐵 =
𝐵 – 𝐵
2 =
76 − 18
2 = 29 𝐵𝐵ℎ
The final output ratio is
𝐵𝐵𝐠=
𝐵
+ 𝐵
𝐵
=
18 + 76
18 = 5.22 𝐵𝐵𝐵𝐵𝐍
0
100
200
300
400
500
600
0 2 4 6 8 10 12 14 16
Torque (Nm)
Angle (degrees)
Torque Limit Chart
Torque Required (Nm) Torque Slip (Nm)P a g e | 15
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.5.2. Number of Planet Gears.
First determine the number of planetary gears – first check if 3 planetary gears will mesh?
𝐵
+ 𝐵
𝐍
= 𝐬
18 + 76
3 = 31.33,
𝐠is not an integer so check if 2 planetary gears will mesh?
𝐵
+ 𝐵
𝐍
= 𝐬
18 + 76
2 = 47,
𝐠is odd so 2 planetary gears will mesh but 4 will not as 𝐠= 23.5 for 4 gears.
2.5.3. Planetary Gearbox Free Body Diagrams and Reactions.
Figure 7 Planetary Free Body Diagram
2.5.4. Gear Angular Velocities.
𝜇
𝐵𝐠= 𝜇𝐵𝐵𝐠= 239𝐵𝐍
𝜇
𝐵𝐵𝐵 = −
𝐍
𝐍
2𝐵 𝜇𝐵𝐠= − 0 0..018 058𝐠𝐠𝐠239𝐵𝐠= −74.2𝐵𝐍
𝜇
𝐵𝐵𝐵 =
𝐍
𝐍
2(𝐵 + 𝐵) 𝜇𝐵𝐠= 2(0.018 0.018 𝐠+ 𝐠0.029) 𝐠239𝐵𝐠= 45.8𝐵𝐍
𝜇
𝐵𝐵 = 0𝐵𝐬 ̇ 𝐵𝐵𝐠𝐵𝐵 𝐵𝐵
2.5.5. Gear Forces.
𝐵
𝐵 =
𝐵𝐍
2𝐍
𝐍
=
50.9𝐵
2 𝐠0.018𝐠= 1414𝐠= 1.414𝐵
𝐵
𝐵 = 𝐵𝐵 = 1.414𝐵
𝐵
= 𝐵
𝐵 + 𝐵𝐵 = 2𝐵𝐵 = 2 𝐠1.414𝐵 = 2.83𝐵P a g e | 16
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.6. Gear Sizing and Specifications.
The sun gear is the input and smallest gear of planetary gear set, assumed to have the highest bending
and surface contact stresses. The 18 teeth sun gear drives the 29 teeth planet gear with a loading of
𝐵 = 1414𝐮 The sun gear is cut or milled manufactured from 4140 grade 2 steel with 𝐵𝐠=
1020𝐵𝐬 𝐵 = 655𝐵𝐬 𝐵 = 302 and 𝐠= 200𝐵𝐮
2.6.1. Estimate Gear Size Table.
Table 3 Estimate Gear Sizing
Estimate Gear Sizing
Parameter Symbol Units Values
Module m mm 1 2 3
Pitch Diameter d mm 18 36 54
Pitch line Velocity V m/s2 0.225252 0.450504 0.675757
Load Ft kN 2.827778 1.413889 0.942593
Dynamic Factor Kv 1.036927 1.073853 1.11078
Face Width b mm 112.6036 29.1534 13.40262
Minimum Face Width 3p mm 9.424778 18.84956 28.27433
Maximum Face Width 5p mm 15.70796 31.41593 47.12389
2.6.2. Sun Gear AGMA Bending Stress.
Bending stress for sun gear with face width of 30mm.
𝐵𝐵ℎ 𝐵𝐵 𝐵𝐵𝐵𝐵 = 𝐠=
𝐵𝐍
60 =
𝐠𝐠0.036𝐠𝐠239𝐵𝐍
60 = 0.451𝑄𝐍
𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 =
6.1 + 𝐍
6.1 =
6.1 + 0.451𝑄𝐍
6.1 = 1.074
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 = 𝐠= 0.31, 𝐵𝐵𝐵 14.6 − 𝔎𝐵𝐵𝐲𝐍
𝐵𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 1, 𝐵𝐵𝐵𝐍
𝐵𝐵 𝐵𝐵𝐵 = 𝐍
𝐠= 1,
𝐵𝐠𝔎𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 1, 𝐵 =
𝐵
ℎ𝐠= 1.2,
𝐵 = 1.2ℎ𝐠= 1.2 𝐠2.25 𝐠2𝐵 = 5.4𝐵
𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 𝐵
𝐵
𝐵𝐠(𝐵𝐵𝐵𝐵)
𝐵 = 1.074 𝐍
1414𝐍
30𝐵 𝐠2𝐵 𝐠0.31 = 81.6𝐵𝐍
Safety factor for bending stress for sun gear manufactured from Nitrided (through hardened steel)
4140 grade 2 steel with hardness of 300𝐵.
𝔎𝐠𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 0.749𝐵 + 110𝐵𝐬 𝐵𝐵𝐵 14.3 − 𝔎𝐵𝐵𝐲𝐍
𝐵 = 0.749 𝐠302 + 110𝐵𝐠= 336𝐵𝑐 a g e | 17
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
𝐵𝐵𝐵 𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐠𝐠= 1, 107𝐵𝐵𝐵, 𝐵𝐵𝐵 14.14 − 𝔎𝐵𝐵𝐲𝐍
𝐵𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐠𝐠= 1, 99% 𝐵𝐵𝐵𝐵𝐵𝐬 𝐵𝐵𝐠14.10 − 𝔎𝐵𝐵𝐲𝐍
𝐵𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐠𝐠= 1, 𝐵𝐠𝐵𝐵𝐵𝐵𝐵𝐠≤ 120°, 𝐵𝐵𝐵𝐠14.15 − 𝔎𝐵𝐵𝐍
𝐵𝐵𝐠𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝔎 =
𝐵𝐠𝐍
𝐠𝐵 𝐠= 𝐵 = 336𝐵𝐍
𝐵𝐵𝐵 𝐵𝐵𝐵 = 𝐵𝐠=
𝐵𝐵𝐠𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝔎
𝐵𝐵𝐵𝐠𝐵𝐵𝐵 (𝐵) =
336𝐵𝐍
81.6𝐵𝐠= 4.12
2.6.3. Sun Gear AGMA Contact Stress.
Contact stress for sun gear with face width of 30mm.
𝐵𝐵ℎ 𝐵𝐵𝐵𝐵 = 𝐵 = 𝐵 = 2 𝐠18 = 36𝐵
𝐵𝐵ℎ 𝐵𝐵 𝐵𝐵𝐵𝐵 = 𝐠=
𝐵𝐍
60 =
𝐠𝐠0.036𝐠𝐠239𝐵𝐍
60 = 0.451𝑄𝐍
𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 𝐵 =
6.1 + 𝐍
6.1 =
6.1 + 0.452𝑄𝐍
6.1 = 1.074
𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐵𝐵𝐠= 𝐵 = √𝐠(1 − 𝐵𝐵 21 + 1 − 𝐵𝐵 2) = √𝐠(1 200000 − 0.321 + 1 200000 − 0.32) = 187
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 = 𝐠=
cos 20° sin 20°
2
1.611
1.611 + 1 = 0.0992
𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = −𝐵√𝐠𝐵 𝐵 𝐵 𝐠= −187√30𝐵 1.074 𝐠36𝐠𝐵 1414 𝐠0 𝐠.0992 = −704𝐵𝐍
Safety factor for contact stress for sun gear manufactured from Nitrided (through hardened steel)
4140 grade 2 steel with hardness of 300𝐵.
𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝔎, 𝐵 = 1123𝐵𝐬 𝐵𝐵𝐠14 − 6 𝐵𝐵 743 𝔎𝐵𝐵𝐵
𝐵𝐵𝐵 𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 1, 107𝐵𝐵𝐵, 𝐵𝐵𝐵 14.14 − 𝔎𝐵𝐵𝐲𝐍
𝐵𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐠𝐠= 1, 99% 𝐵𝐵𝐵𝐵𝐵𝐬 𝐵𝐵𝐠14.10 − 𝔎𝐵𝐵𝐲𝐍
𝐵𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐠𝐠= 1, 𝐵𝐠𝐵𝐵𝐵𝐵𝐵𝐠≤ 120°, 𝐵𝐵𝐵𝐠14.15 − 𝔎𝐵𝐵𝐍
ℎ𝐵𝐵𝐵𝐠𝐵𝐵𝐠𝐵𝐵𝐵 = 𝐵 = 1, 𝐵𝐵𝐵𝐠14.11 − 𝔎𝐵𝐵𝐵
𝐵𝐵𝐠𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝔎 =
𝐍
𝐵𝐵𝐍
𝐠𝐵 𝐠= 1123𝐵𝐍
𝐵𝐠= (𝐵𝐵𝐠𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵 𝐵𝐵𝐵𝐠(𝐵 𝐵𝐵𝐵𝐠) ℎ)2 = (− 1123 704𝐵𝐠𝐵𝐩2 = 2.54P a g e | 18
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.6.4. Gear Specification Table.
Gear specifications for the planet, sun and ring gear are calculated using excel spreadsheet and are
shown in table 4. Gears are cut or milled manufactured from 4140 grade 2 steel with pressure angle
𝐠= 20° and full tooth profile, with lowest safety factor of 2.54 for contact stress on the sun gear. The
dynamic factor for planet and ring gear is 1 as the pitch line velocity is zero, as the ring gear is fixed.
The ring gear rim thickness was reduced to allow for clearance with hub and is included in table in
application factor with a rim thickness factor 𝐵 = 1.3 and thickness 𝐵 = 4.5𝐵.
Table 4 Gear Specifications
Gear Specifications
Parameter Symbol Units Sun Planet Ring
Gear Specifications and Knowns
Module m mm 2 2 2
Number of Teeth N 18 29 76
Pitch Diameter d mm 36 58 152
Face Width b mm 30 30 30
Pressure Angle 20.00 20.00 20.00
Pitch Line Velocity Sun/Planet Vsp m/s 0.451 0.451
Pitch Line Velocity Planet/Ring Vpr m/s 0 0
Load Ft N 1414 1414 1414
Dynamic Factor Sun/Planet KVsp 1.074 1.074
Dynamic Factor Planet/Ring KVpr 1 1
Bending Stress
Application Factor Ka 1 1 1.3
Modified Lewis Sun/Planet Jsp 0.31 0.355
Modified Lewis Planet/Ring Jpr 0.385 0.43
Bending Stress Sun/Planet σb MPa 81.7 71.3
Bending Stress Planet/Ring σb MPa 61.3 71.3
Contact Stress
Geometry Factor Sun/Planet Isp 0.0992 0.0992
Geometry Factor Planet/Ring Ipr 0.1164 0.2599
Elastic Coefficient C
p 187 187 187
Contact Stress Sun/Planet σcsp MPa -705 -555
Contact Stress Planet/Ring σcpr MPa -495 -205
Material and Safety Factors
Material 4140 4140 4140
Ultimate Tensile Strength Sut MPa 1020 1020 1020
Yield Strength Sy MPa 655 655 655
Hardness HB Brinell 302 302 302
Modulus of Elasticity E Gpa 200 200 200
Corrected Bending Strength St MPa 336 336 336
Bending Safety Factor nBF 4.12 4.72 4.72
Corrected Contract Strength Sc MPa 1123 1123 1123
Contact Safety Factor nCF 2.54 4.1 30.01P a g e | 19
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.7. Input Shaft.
The input shaft design shown in figure 8, incorporates the sun gear and the shaft minimum diameter
is constrained by the sun gear pitch diameter, plus tooth addendum and must be 40mm. The input
shaft is manufactured from 4140 steel with 𝐵𝐠= 1020𝐵𝐬 𝐵 = 655𝐵𝐬 𝐵 = 302 and 𝐠=
200𝐵𝐮 The input shaft incorporates a hole boss for hydraulic motor input shaft of 25mm diameter
with 8 x 7mm keyway and is supported by a single roller ball bearing located against a shoulder and
retained by circlip.
Figure 8 Input Shaft Design
2.7.1. Input Shaft Fatigue Life.
The input shaft is subjected to variable torsional loading of ±50.9𝐵 from hydraulic motor and under
worst case conditions a radial load from the planet gear if only one gear is in contact with sun gear.
The critical location for stress is the bearing shoulder with hydraulic motor boss and keyway.
Cross sectional area of axle is.
𝐠=
𝐨𝐲 − 𝐲)
4 =
𝐨402 − 252)
4 = 765.8𝐵2
Moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
64 =
𝐨404 − 254)
64 = 106489𝐵4
Polar moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
32 =
𝐨404 − 254)
32 = 212978𝐵4
Stress concentration factors,
Bending stress concentration factor
𝐠= 0.855 𝐵𝐠1000𝐵𝐠𝐵𝐠1𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 20 𝐵𝐵 303 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.35 𝐠2.14 = 5.03
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐠7 − 1 𝐵𝐠𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 9
𝐍
𝐵 ≅ 1 + 𝐨𝐵𝐠− 1) = 1 + 0.855(5.03 – 1) = 4.45P a g e | 20
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Torsional shear concentration factor.
𝐵 = 0.873 𝐵𝐠1000𝐵𝐠𝐵𝐠1𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 21 𝐵𝐵 304 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 1.96 𝐠3 = 5.88
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐠7 − 1 𝐵𝐠𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 8
𝐍
𝐵 ≅ 1 + 𝐵(𝐵𝐠− 1) = 1 + 0.873(5.88 – 1) = 5.26
Radial gear loading,
𝐵 =
2𝐍
𝐠=
2 𝐠50.9𝐵
0.036𝐠= 2828𝐍
𝐵
= 𝐵 tan 𝐠= 2828𝐠𝐠tan 20° = 1029𝐍
Completely reversed bending moment.
𝐠= 𝐍
𝐵 = 1029𝐠𝐠0.1545𝐠= 159.0𝐵
Stress concentration corrected bending amplitude and mean stresses.
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 4.45 (159.0𝐵 − ( 2− 𝐠159 106489 .0𝐵𝐵 )) 𝐴10 3 𝐠20𝐵
𝐵𝐠= 132.9𝐵𝐍
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 4.45 (159.0𝐵 + ( 2− 𝐠159 106489 .0𝐵𝐵 )) 𝐴10 3 𝐠20𝐵
𝐵𝐠= 0𝐵𝐍
Variable torsional loading 𝐠= ±50.9,
Stress concentration corrected torsional amplitude and mean shear.
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 5.26
(50.9𝐵 − (−50.9𝐵)) 𝐠10 3𝐠20𝐵
2 𝐠212978𝐵4 = 25.1𝐵𝐍
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 5.26
(50.9𝐵 + (−50.9𝐵)) 𝐠10 3 𝐠20𝐵
2 𝐠212978𝐵4 = 0𝐵𝐍
Von Mises amplitude and mean stresses.
′𝐵
= {[𝐵𝐠+ 0 𝐠.𝐵 85]2 + 3𝐵2}
1 2
′𝐵
= {[132.9𝐵𝐠+ 00 𝐵𝐠.85 ]2 + 3(25.1𝐵𝐩2}
1 2
= 139.8𝐵𝐍
′𝐵
= {[𝐵𝐠+ 𝐵𝑝2 + 3𝐵2}
1 2
′𝐵
= {[0𝐵𝐠+ 0𝐵𝑝2 + 3(0𝐵𝐩2}
1 2
= 0𝐵𝐍
Estimating fatigue strength.
𝐵𝐵 𝐵𝐵 = 𝐠=
′𝐵 ′𝐵
=
139.8𝐵𝐍
0𝐵𝐠= 139.8, 𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝑐 a g e | 21
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Load line intersects with modified Goodman.
𝐵 𝐵
+
𝐵 𝐍
𝐵
=
1 𝐍
, ⇒
𝐵 𝐵
+
𝐵 𝐍
𝐵
=
1 𝐍
, ⇒ 𝐵 =
𝐵
1𝐍
−
𝐵𝐍
𝐵
=
139.8𝐵𝐍
11
−
0𝐵𝐍
1020𝐵𝐍
= 139.8𝐵𝐍
Endurance limiting strength.
Estimated endurance limit. (𝐵𝐠≤ 1400𝐵𝐩
𝐲
𝐠= 0.5𝐵𝐠= 0.5 𝐠1020𝐵𝐠= 510𝐵𝐍
Fatigue stress correction factors
I. Surface factor. (machined)
𝐍
𝐠= 𝐵𝐵𝐠= 4.51 𝐠(1020𝐵𝐩−0.265 = 0.719
II. Size factor. (40mm rotating shaft)
𝐵 = 1.24𝘒0.107 = 1.24 𝐠(40𝐵)−0.107 = 0.836
III. Loading factor. (bending)
𝐍
𝐠= 1
IV. Temperature factor. (20° 𝐵𝐵 𝐵𝐵𝐵𝐵𝐵𝐩
𝐵 = 1
V. Reliability factor (99% Confidence)
𝐍
𝐠= 0.814
Corrected endurance limit.
𝐍
𝐠= 𝐵𝐵𝐵𝐵𝐵𝐲𝐠= 0.719 𝐠0.836 𝐠1 𝐠1 𝐠0.814 𝐠510𝐵𝐠= 249.5𝐵𝐍
Estimating number of cycles to failure.
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐠= ∞, 𝐵 𝐵 = 139.8𝐵𝐠< 𝐵 = 249.5𝐵𝐍
The input shaft has a fatigue life of infinite cycles for worst case condition loadings with only one
planet gear in contact with the sun gear. Fatigue life calculations have also been performed for sun
gear joint, shoulder, and circlip with keyway sections in excel spreadsheet with infinite life for all load
conditions.
2.7.2. Input Shaft Bearing.
The input shaft is supported by one roller ball bearing at hydraulic motor end and by the planet gears
at the other end. The hydraulic motor rotates at 239rpm and applies a 50.9Nm torsional loading.
Under worst conditions were only one planet gear is in contact with the sun gear the input shaft is
subjected to a radial loading of 1029N and the roller ball bearing is selected for these load conditions
with an internal bore of 40mm.
Bearing dynamic load rating.
𝐵𝐵𝐵𝐵𝐵𝐠= 𝐵 = 1.2 (𝐵𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝐩, 𝐠= 3 (𝐵𝐵), 𝐵𝐵𝐵𝐵𝐵𝐠= 𝐠= 99%
𝐵𝐵𝐵 𝐵𝐵 = 𝐵 = 25000ℎ (8ℎ 𝔎𝐵𝐵 𝐵𝐵𝐠𝐵𝐵𝐵𝐵), 𝐵𝐵𝐵 𝐵𝐵𝐠= 𝐵 = 239𝐵𝐍
𝐱0 = 𝐵𝐠𝐍
(
𝐵𝐵60
𝐱0
0.02 + 4.91𝐠(ln 𝐠1)
1
1.4 )
1𝑐 a g e | 22
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
𝐱0 = 1.2 𝐠1029𝐍
(
25000ℎ 𝐠239𝐵𝐠𝐶0
106𝐵𝐵𝐵
0.02 + 4.91𝐠(ln 0.1 99)
1
1.4 )
13
= 14909𝐠= 14.9𝐵
SKF 6008 radial ball bearing, determine bearing life.
𝐱0 = 17.8𝐵, 𝐰 = 11𝐵, 𝐰 = 15, 𝐵 = 68𝐵, 𝐵 = 40𝐵, 𝐠= 15𝐵
𝐱0 = 𝐵𝐠𝐍
(
𝐵𝐵60
𝐱0
0.02 + 4.91𝐠(ln 𝐠1)
1
1.4 )
1𝐍
, ⟹ 𝐵 = (𝐠𝐠𝐠10 𝐠𝐩𝐠𝐠𝐱0 (0.02 + 𝐵 4.𝐠91 60 𝐠(ln 𝐠1)11 .4)
𝐵 = (1.2 17800 𝐠1029 𝐠𝐩3 𝐠106 (0.02239 + 4 𝐵𝐠.91 𝐠𝐨 60 ln 0.1 99)11 .4) = 42600ℎ
2.7.3. Input Shaft Keyway.
The input shaft of hydraulic motor is 25mm diameter with an 8 x 7 x 32mm keyway and must
transmit 50.9Nm of torque to gearbox. The key shear strength is determined from the normal yield
strength, were the selected key steel yield strength is 𝐵 = 455𝐵𝐬 lower than input shaft
strength.
𝐍
𝐵 = 0.577𝐵 = 0.577(455𝐵𝐩 = 262.5𝐵𝐍
Shear failure occurs along the width and length of the keyway, so,
𝐠=
𝐍
𝐵 =
2000𝐍
𝐵𝐠=
2000 𝐠50.9𝐵
8𝐵 𝐠32𝐵 𝐠25𝐵 = 15.9𝐵𝐍
𝐵𝐵𝐵𝐵 =
𝐍
𝐵
𝐍
, 𝐠=
𝐍
𝐵
𝐍
=
262.5𝐵𝐍
15.9𝐵𝐠= 16.5
Compression failure occurs using one half the contact face,
𝐠=
2𝐍
ℎ𝐠=
4000𝐍
ℎ𝐵 =
4000 𝐠50.9𝐵
7𝐵 𝐠32𝐵 𝐠25𝐵 = 36.4𝐵𝐍
𝐵𝐵𝐵𝐵 =
𝐵 𝐍
, 𝐠=
𝐵 𝐍
=
455𝐵𝐍
36.4𝐵𝐠= 12.5P a g e | 23
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.8. Hub.
The hub shown in figure 10, is used to connect the wheel to the gearbox and is the output of the
planetary gearbox system. The wheel is connected to the hub with 8 x M16 bolts on a P.C.D of 300mm,
with a wheel centre hole of 200mm. The hub is supported by two tapered roller bearings and torque
output is transmitted to the hub from planetary gear set via the hub cover and fasteners.
Figure 9 Hub
2.8.1. Hub Bearings.
The client has specified the hub bearings are tapered roller type, with loadings of cherry picker 365kg
and payload 25kg. The hub has a maximum rotational speed of 45.8rpm and the bearings must be
large enough to allow input shaft to pass through the internal bore. The bearings are pre-loaded with
a minimum axial loading of 2kN (SKF requirement for specific bearing) with adjustable shims and both
bearings are to be the same size. the load force is applied at distances of 82.1mm to bearing A and
133.9mm to bearing B.
Find the bearing radial loads by taking the sum of moments around bearing A to find the radial load
at bearing B and solve for bearing A.
𝐵𝐵𝐠= 390𝐵 𝐍
9.81𝐍
𝐍
= 3826𝐍
∑ 𝐵 = 0 = (133.9(10−3)𝐠− 82.1(10−3)𝐩𝐵 − (82.1(10−3)𝐩𝐵𝐵𝐍
𝐵 =
(82.1(10−3)𝐩𝐵𝐵𝐍
133.9(10−3)𝐠− 82.1(10−3)𝐠=
(82.1(10−3)𝐩 𝐠3826𝐍
133.9(10−3)𝐠− 82.1(10−3) = 6064𝐍
𝐠𝐠= 𝐵𝐵𝐠+ 𝐵 = 3826𝐠+ 6064𝐠= 9890𝐍
Equivalent radial bearing loads. 𝐠= 1.5, 𝐵 = 2𝐵
𝐵𝐠= 0.4𝐵𝐠+ 𝐵 (0.47 𝐵 𝐵𝐠+ 𝐵)
𝐵𝐠= 0.4 𝐠9.89𝐵 + 1.5 (0.47 𝐱 6 .5 .064𝐵 + 2𝐵) = 9.806𝐵P a g e | 24
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
𝐵𝐠= 0.4𝐵𝐠+ 𝐵 (0.47 𝐵 𝐵𝐠+ 𝐵)
𝐵𝐠= 0.4 𝐠6.064𝐵 + 1.5 (0.47 𝐠19 .5 .89𝐵 + 2𝐵) = 10.07𝐵
Bearing dynamic load rating. For bearing B with radial loading 10.07KN.
𝐵𝐵𝐵𝐵𝐵𝐠= 𝐵 = 1.2 (𝐵𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝐩, 𝐠= 3/10 (𝐵𝐵𝐵), 𝐵𝐵𝐵𝐵𝐵𝐠= 𝐠= 99%
𝐵𝐵𝐵 𝐵𝐵 = 𝐵 = 25000ℎ (8ℎ 𝔎𝐵𝐵 𝐵𝐵𝐠𝐵𝐵𝐵𝐵), 𝐵𝐵𝐵 𝐵𝐵𝐠= 𝐵 = 45.8𝐵𝐍
𝐱0 = 𝐵𝐠𝐍
(
𝐵𝐵60
𝐱0
0.02 + 4.91𝐠(ln 𝐠1)
1
1.4 )
1𝐍
𝐱0 = 1.2 𝐠10.07𝐍
(
25000ℎ 𝐠45.8𝐵𝐠𝐶0
106𝐵𝐵𝐵
0.02 + 4.91𝐠(ln 0.1 99)
1
1.4 )
3
10
= 69.28𝐵
Selecting taper roller bearings with 80mm internal bore to allow clearance for input shaft, selected
SKF 30216 taper roller bearing with 𝐱0 = 151𝐵, 𝐰 = 183𝐵 𝐵𝐠𝐠= 1.4. Internal bore 𝐵 =
80𝐵, outside diameter 𝐵 = 140𝐵 and thickness 𝐠= 28.25𝐵. determine bearing life.
𝐵𝐠= 0.4𝐵𝐠+ 𝐵 (0.47 𝐵 𝐵𝐠+ 𝐵)
𝐵𝐠= 0.4 𝐠9.89𝐵 + 1.4 (0.47 𝐱 6 .4 .064𝐵 + 2𝐵) = 9.606𝐵
𝐵𝐠= 0.4𝐵𝐠+ 𝐵 (0.47 𝐵 𝐵𝐠+ 𝐵)
𝐵𝐠= 0.4 𝐠6.064𝐵 + 1.4 (0.47 𝐠19 .4 .89𝐵 + 2𝐵) = 9.874𝐵
𝐱0 = 𝐵𝐠𝐍
(
𝐵𝐵60
𝐱0
0.02 + 4.91𝐠(ln 𝐠1)
1
1.4 )
1𝐍
, ⟹ 𝐵 = (𝐠𝐠𝐠10 𝐠𝐩𝐠𝐠𝐱0 (0.02 + 𝐵 4.𝐠91 60 𝐠(ln 𝐠1)11 .4)
𝐵 = (1.2 151 𝐠9.847 𝐵 𝐵)3 𝐠106 (0.0245 +.8 4 𝐵𝐠.91 𝐠𝐨60 ln 0.1 99)11 .4) = 362000ℎ
Bearings are oversized for bearing loads however the constraint of clearance for input shaft to pass
through the spindle requires tapered bearings to be 80mm internal bore at this stage and SKF 30216
bearings are one of the smallest bearings available that suits the design.P a g e | 25
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.8.2. Hub Ansys FEA.
Finite element analysis of the hub design was conducted using Ansys academic in workbench to
determine stress loadings and safety factor for gravity loadings from cherry picker and payload, and
torsional loadings of gearbox output. The hub is to be manufactured from 6061 aluminium alloy after
initial FEA simulations showed a high safety factor and a weight reduction of approximately 8kg is
achieve with the material change from steel while maintaining safety levels. Shown in figure 10, are
screen shots taking during Ansys FEA. The first screen shot shows boundary conditions for hub, where
boundary conditions were also applied for bearings with frictionless supports at bearing locations,
fixed supports for cover fastener hole locations, a force applied to wheel mounting bolt holes and
spigot in Z direction only for cherry picker and payload force loadings, and moment for gearbox torque
output. The FEA simulation was solved for total deformation, equivalent stress and safety factor.
Shown in second screenshot is total deformation solution with maximum deflection of 1.95µm shown
by red area around bolt holes. The max equivalent stress for hub was 5.68MPa however limitations
were experienced with meshing quality due to academic limitations of 32000 nodes or elements and
the hubs size and dimensions. The safety factor for the hub design is approximated at 15 for hub
shown in the third screenshot.
Figure 10 Ansys FEA for Hub showing boundary conditions, Deformation and Safety Factor screen shots.
2.8.3. Hub Cover Screws.
The hub is connected to the planetary gear set output via the hub cover by fasteners screwed into the
hub face. The fasteners are subjected to shear loads as the output torque to transmitted to the hub
from cover and planet gears. The cover is secured with 8 x grade 8.8 M8 x 1.25 screws with 𝐵𝐠=
800𝐵𝐬 𝐵 = 640𝐵𝐬 𝐵 = 590𝐵𝐬 fastened to 21.6Nm resulting in 19.1kN pre-load per screw
(Rapp, Fastener Black Book, 2007).
𝐵
=
2𝐍
𝐠=
2 𝐠264𝐵
0.185 = 2854𝐍
𝐍
𝐠=
𝐠4
(𝐠+ 2 𝐩2 = 𝐠4 (8𝐵 +2 6.75𝐵)2 = 42.7𝐵2
𝐠=
𝐠𝐍
=
2854𝐍
8 𝐠42.7𝐵2 = 8.36𝐵𝐍
𝐍
𝐠=
𝐍
𝐵
𝐍
=
0.577 𝐠640𝐵𝐍
8.36𝐵𝐠= 44P a g e | 26
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.8.4. Wheel Bolts.
Wheel bolts are specified by client as 8 x M16 on 300mm PCD, with the hub design is for bolts with
threaded holes, however wheel studs maybe used in final gearbox installed from rear of hub.
𝐵ℎ𝐵𝐵 = 𝐵(0.75𝐩𝐵𝐠= 𝐠𝐠16𝐵 (0.75 𝐠10𝐵) 𝐠0.577(374𝐵𝐩 = 81400𝐠= 81.4𝐵
𝐍
𝐵𝐵𝐵𝐠=
𝐵ℎ𝐵𝐵
𝐵
=
81.4𝐵
2
= 40.7𝐵
2.9. Ring Gear.
The ring gear shown in figure 11, is fixed in the planetary gear set, and located on the spindle with a
keyway and fastened with the hub nut. The outer hub tapered bearing is located on the ring gear, with
hub bearing pre-load set and adjustment by shims installed in between the ring gear and spindle. The
ring gear is manufactured from 4140 steel with 𝐵𝐠= 1020𝐵𝐬 𝐵 = 655𝐵𝐬 𝐵 = 302 and 𝐠=
200𝐵𝐮
Figure 11 Ring Gear
2.9.1. Ring Gear Fatigue life.
The ring gear is subjected to variable torsional load from gear tangential force and under worst case
conditions a radial load from planet gear if only one gear is in contact with the ring gear. The critical
location for stress concentration is the bearing shoulder for outer hub bearing, with keyway for ring
gear location on spindle.
Cross sectional area of axle is.
𝐠=
𝐨𝐲 − 𝐲)
4 =
𝐨802 − 602)
4 = 2199𝐵2
Moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
64 =
𝐨804 − 604)
64 = 1374447𝐵4
Polar moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
32 =
𝐨804 − 604)
32 = 2748894𝐵4P a g e | 27
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Stress concentration factors,
Bending stress concentration factor.
𝐠= 0.891 𝐵𝐠1000𝐵𝐠𝐵𝐠2𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 20 𝐵𝐵 303 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.45 𝐠2.14 = 5.24
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐠7 − 1 𝐵𝐠𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 9
𝐍
𝐵 ≅ 1 + 𝐨𝐵𝐠− 1) = 1 + 0.891(5.24 – 1) = 4.78
Torsional shear concentration factor
𝐵 = 0.909 𝐵𝐠1000𝐵𝐠𝐵𝐠2𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 21 𝐵𝐵 304 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 1.95 𝐠3 = 5.85
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐠7 − 1 𝐵𝐠𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 8
𝐍
𝐵 ≅ 1 + 𝐵(𝐵𝐠− 1) = 1 + 0.909(5.85 – 1) = 5.41
Radial gear loading,
𝐵 = 2828𝐬 𝐵𝐵 𝐵 𝐵𝐠𝐵𝐵 𝐵𝐵𝐵𝐍
𝐵
= 𝐵 tan 𝐠= 2828𝐠𝐠tan 20° = 1029𝐍
Bending moment.
𝐠= 𝐍
𝐵 = 1029𝐠𝐠0.0475𝐠= 48.9𝐵
Stress concentration corrected bending amplitude and mean stresses.
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 4.78
(48.9𝐵 − 48.9𝐵) 𝐠10 3 𝐠40𝐵
2 𝐠1374447𝐵4
𝐵𝐠= 0𝐵𝐍
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 4.78
(48.9𝐵 + 48.9𝐵) 𝐠10 3 𝐠40𝐵
2 𝐠1374447𝐵4
𝐵𝐠= 6.8𝐵𝐍
Variable torsional loading
𝐠= 𝐍
𝐵 = 2828𝐠𝐍
0.154𝐍
2 = ±218𝐵
Stress concentration corrected torsional amplitude and mean shear.
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 5.41 𝐍
(218𝐵 − (−218𝐵)) 𝐠10 3𝐠40𝐵
2 𝐠2748894𝐵4 = 17.16𝐵𝐍
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 5.41 𝐍
(218𝐵 + (−218𝐵)) 𝐠10 3 𝐠40𝐵
2 𝐠2748894𝐵4 = 0𝐵𝐍
Von Mises amplitude and mean stresses.
′𝐵
= {[𝐵𝐠+ 0 𝐠.𝐵 85]2 + 3𝐵2}
1 2
′𝐵
= {[0𝐵𝐠+ 00 𝐵𝐠.85 ]2 + 3(17.16𝐵𝐩2}
1 2
= 29.7𝐵𝑐 a g e | 28
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
′𝐵
= {[𝐵𝐠+ 𝐵𝑝2 + 3𝐵2}
1 2
′𝐵
= {[6.8𝐵𝐠+ 0𝐵𝑝2 + 3(0𝐵𝐩2}
1 2
= 6.8𝐵𝐍
Estimating fatigue strength.
𝐵𝐵 𝐵𝐵 = 𝐠=
′𝐵 ′𝐵
=
29.7𝐵𝐍
6.8𝐵𝐠= 4.37, 𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝐍
Load line intersects with modified Goodman.
𝐵 𝐵
+
𝐵 𝐍
𝐵
=
1 𝐍
, ⇒
𝐵 𝐵
+
𝐵 𝐍
𝐵
=
1 𝐍
, ⇒ 𝐵 =
𝐵
1𝐍
−
𝐵𝐍
𝐵
=
29.7𝐵𝐍
11
−
6.8𝐵𝐍
1020𝐵𝐍
= 29.9𝐵𝐍
Endurance limiting strength
Estimated endurance limit. (𝐵𝐠≤ 1400𝐵𝐩
𝐲
𝐠= 0.5𝐵𝐠= 0.5 𝐠1020𝐵𝐠= 510𝐵𝐍
Fatigue stress correction factors
I. Surface factor. (machined)
𝐍
𝐠= 𝐵𝐵𝐠= 4.51 𝐠(1020𝐵𝐩−0.265 = 0.719
II. Size factor. (40mm rotating shaft)
𝐵 = 1.51𝐵−0.157 = 1.51 𝐠(80𝐵 𝐠0.370)−0.157 = 0.887
III. Loading factor. (bending)
𝐍
𝐠= 1
IV. Temperature factor. (20° 𝐵𝐵 𝐵𝐵𝐵𝐵𝐵𝐩
𝐵 = 1
V. Reliability factor (99% Confidence)
𝐍
𝐠= 0.814
Corrected endurance limit.
𝐍
𝐠= 𝐵𝐵𝐵𝐵𝐵𝐲𝐠= 0.719 𝐠0.887 𝐠1 𝐠1 𝐠0.814 𝐠510𝐵𝐠= 264.8𝐵𝐍
Estimating number of cycles to failure.
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐠= ∞, 𝐵 𝐵 = 29.9𝐵𝐠< 𝐵 = 264.8𝐵𝐍
2.9.2. Ring Gear Keyway.
The ring gear is fixed on the spindle with a 10 x 8 x 36mm keyway and must transmit 218Nm of
torque to gearbox. The key shear strength is determined from the normal yield strength, were the
selected key steel yield strength is 𝐵 = 455𝐵𝐬 lower than ring gear and spindle strength.
𝐍
𝐵 = 0.577𝐵 = 0.577(455𝐵𝐩 = 262.5𝐵𝐍
Shear failure occurs along the width and length of the keyway, so,
𝐠=
𝐍
𝐵 =
2000𝐍
𝐵𝐠=
2000 𝐠218𝐵
10𝐵 𝐠36𝐵 𝐠55𝐵 = 22.0𝐵𝐍
𝐵𝐵𝐵𝐵 =
𝐍
𝐵
𝐍
, 𝐠=
𝐍
𝐵
𝐍
=
262.5𝐵𝐍
22.0𝐵𝐠= 11.93
Compression failure occurs using one half the contact face,
𝐠=
2𝐍
ℎ𝐠=
4000𝐍
ℎ𝐵 =
4000 𝐠218𝐵
8𝐵 𝐠36𝐵 𝐠55𝐵 = 55.0𝐵𝐍
𝐵𝐵𝐵𝐵 =
𝐵 𝐍
, 𝐠=
𝐵 𝐍
=
455𝐵𝐍
55.0𝐵𝐍
= 8.27P a g e | 29
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.10. Spindle.
The spindle shown in figure 12, mounts the gearbox to the cherry picker frame and supports the wheel
and planetary gear set. The hub bearings are pre-load with the hub nut on the end of the spindle and
the ring gear is fixed on spindle with a keyway, with the hub bearings protected by industrial radial
seal inside the hub against the spindle. The spindle is mounted to the cherry picker frame with
threaded bolt holes in rear of the spindle in circular pattern. The input shaft is located inside the
spindle by the roller ball bearing, retained by internal circlip with the input shaft sealed by industrial
radial seal. The spindle is machined manufactured from 1040 steel with 𝐵𝐠= 590𝐵𝐬 𝐵 =
374𝐵𝐬 𝐵 = 225 and 𝐠= 200𝐵𝐮
Figure 12 Spindle
2.10.1. Spindle Fatigue Life.
The spindle is subjected to bending load from cherry picker and payload acting on the wheel and a
variable torsional load from the ring gear and constant axial load from hub bearings pre-load. The
critical location for stress concentration is the bearing shoulder for inner hub bearing.
Cross sectional area of axle is.
𝐠=
𝐨𝐲 − 𝐲)
4 =
𝐨802 − 682)
4 = 1395𝐵2
Moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
64 =
𝐨804 − 684)
64 = 961063𝐵4
Polar moment of inertia.
𝐠=
𝐨𝐴 − 𝐴)
32 =
𝐨804 − 684)
32 = 1922127𝐵4
Stress concentration factors,
Bending stress concentration factor.
𝐠= 0.782 𝐵𝐠590𝐵𝐠𝐵𝐠2𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 20 𝐵𝐵 303 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.5, 𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 9
𝐍
𝐵 ≅ 1 + 𝐨𝐵𝐠− 1) = 1 + 0.782(2.5 – 1) = 2.17P a g e | 30
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Axial stress concentration factor.
𝐠= 0.782 𝐵𝐠590𝐵𝐠𝐵𝐠2𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 20 𝐵𝐵 303 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.4, 𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 9
𝐍
𝐵 ≅ 1 + 𝐨𝐵𝐠− 1) = 1 + 0.782(2.4 – 1) = 2.09
Torsional shear concentration factor
𝐵 = 0.809 𝐵𝐠590𝐵𝐠𝐵𝐠2𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 21 𝐵𝐵 304 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.15, 𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐵 𝐠− 15 − 8
𝐍
𝐵 ≅ 1 + 𝐵(𝐵𝐠− 1) = 1 + 0.809(2.15 – 1) = 1.93
Bending moment.
𝐠= 𝐠𝐵𝐠− 𝐵𝐵 = 9890𝐠𝐠0.0659𝐠− 6064𝐠𝐠0.0141𝐠= 566𝐵
Stress concentration corrected bending amplitude and mean stresses.
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 2.17
(566𝐵 − 566𝐵) 𝐠10 3 𝐠40𝐵
2 𝐠961063𝐵4
𝐵𝐠= 0𝐵𝐍
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 2.17
(566𝐵 + 566𝐵) 𝐠10 3 𝐠40𝐵
2 𝐠961063𝐵4
𝐵𝐠= 51.1𝐵𝐍
Axial loading.
𝐵𝐵𝐵 = 2000𝐬 𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐠− 𝐵𝐵
Stress concentration corrected axial amplitude and mean stresses.
𝐵𝐠= 𝐵𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)
2𝐠= 2.09
(2000𝐠− 2000𝐩
2 𝐠1395𝐵2 = 0𝐵𝐍
𝐵𝐠= 𝐵𝐍
𝐵 𝐍
= 𝐍
𝐵
(𝐵𝐵 + 𝐵𝐵)
2𝐠= 2.09
(2000𝐠+ 2000𝐩
2 𝐠1395𝐵2 = 3.00𝐵𝐍
Variable torsional loading
𝐠= 218𝐵, 𝐵𝐵 𝐵 𝐵𝐵 𝐵𝐵
Stress concentration corrected torsional amplitude and mean shear.
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 − 𝐵𝐵)𝐍
2𝐠= 193
(218𝐵 − (−218𝐵)) 𝐠10 3𝐠40𝐵
2 𝐠1922127𝐵4 = 8.76𝐵𝐍
𝐍
𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 𝐵𝐍
(𝐵𝐵 + 𝐵𝐵)𝐍
2𝐠= 1.93
(218𝐵 + (−218𝐵)) 𝐠10 3 𝐠40𝐵
2 𝐠1922127𝐵4 = 0𝐵𝐍
Von Mises amplitude and mean stresses.
′𝐵
= {[𝐵𝐠+ 0 𝐠.𝐵 85]2 + 3𝐵2}
1 2
′𝐵
= {[0𝐵𝐠+ 00 𝐵𝐠.85 ]2 + 3(8.76𝐵𝐩2}
1 2
= 15.17𝐵𝑐 a g e | 31
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
′𝐵
= {[𝐵𝐠+ 𝐵𝑝2 + 3𝐵2}
1 2
′𝐵
= {[51.1𝐵𝐠+ 3𝐵𝑝2 + 3(0𝐵𝐩2}
1 2
= 54.1𝐵𝐍
Estimating fatigue strength.
𝐵𝐵 𝐵𝐵 = 𝐠=
′𝐵 ′𝐵
=
15.17𝐵𝐍
54.1𝐵𝐠= 0.28, 𝐵𝐵𝐵
Load line intersects with Langer.
𝐵
+ 𝐍
𝐠=
𝐵 𝐍
, 15.17𝐵𝐠+ 54.1𝐵𝐠= 69.3𝐵𝐍
Endurance limiting strength
Estimated endurance limit. (𝐵𝐠≤ 1400𝐵𝐩
𝐲
𝐠= 0.5𝐵𝐠= 0.5 𝐠590𝐵𝐠= 295𝐵𝐍
Fatigue stress correction factors
I. Surface factor. (machined)
𝐍
𝐠= 𝐵𝐵𝐠= 4.51 𝐠(590𝐵𝐩−0.265 = 0.831
II. Size factor. (40mm rotating shaft)
𝐵 = 1.51𝐵−0.157 = 1.51 𝐠(80𝐵 𝐠0.370)−0.157 = 0.887
III. Loading factor. (bending)
𝐍
𝐠= 1
IV. Temperature factor. (20° 𝐵𝐵 𝐵𝐵𝐵𝐵𝐵𝐩
𝐵 = 1
V. Reliability factor (99% Confidence)
𝐍
𝐠= 0.814
Corrected endurance limit.
𝐍
𝐠= 𝐵𝐵𝐵𝐵𝐵𝐲𝐠= 0.831 𝐠0.887 𝐠1 𝐠1 𝐠0.814 𝐠295𝐵𝐠= 177.0𝐵𝐍
Estimating number of cycles to failure.
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐠= ∞, 𝐵 𝐵 = 69.3𝐵𝐠< 𝐵 = 177.0𝐵𝐍
The spindle has a fatigue life of infinite cycles for worst case condition loadings at the inner hub
bearing shoulder. Fatigue life calculations have also been performed for ring gear shoulder and flange
shoulder sections in excel spreadsheet with infinite life for all load conditions.
2.10.2. Hub Nut.
The hub and ring gear are located and secured on the spindle by the hub nut. The hub nut is M60 x
1.5 with nut thickness of 10mm manufactured from 1040 steel with 𝐵𝐠= 590𝐵𝐬 𝐵 = 374𝐵𝐬
𝐵 = 225 and 𝐠= 200𝐵𝐮 The nut must be sufficient to resists 2kN of thread stripping force.
𝐵𝐵 = 𝐵(0.75𝐩𝐵𝐠= 𝐠𝐠60𝐵 (0.75 𝐠10𝐵) 𝐠0.577(374𝐵𝐩 = 305000𝐠= 305𝐵
𝐍
𝐠=
𝐵𝐵
𝐵𝐵𝐠=
305𝐵
2𝐵 = 152.5
(Juvinall & Marshek, 2012)P a g e | 32
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.10.3. Gearbox Mounting Bolts.
The gearbox to mounted to the cherry picker frame using 8 x grade 8.8 M16 bolts on a 220mm PCD
same as the wheel. The bolts must resist joint separation force from bending moment from the cherry
picker and payload forces acting on the ground.
𝐠= 𝐵𝐵𝐵 = 390𝐵 𝐠9.81𝐯𝐠𝐠0.2𝐠= 765𝐵
𝐍
𝐵𝐵𝐠=
𝐠𝐍
=
765𝐵
0.11𝐠= 6.96𝐵
𝐵ℎ𝐵𝐵 = 𝐵(0.75𝐩𝐵𝐠= 𝐠𝐠16𝐵 (0.75 𝐠10𝐵) 𝐠0.577(374𝐵𝐩 = 81400𝐠= 81.4𝐵
𝐵𝐵𝐠= 0.75(𝐵𝐵) = 0.75 𝐠4 (𝐠+ 2 𝐩2 𝐵 = 0.75 𝐠𝐠4 (16𝐵 + 214.5𝐵)2 590𝐵𝐠= 80800𝐍
𝐵ℎ𝐵𝐵 ≅ 𝐵𝐵𝐬 𝐵 𝔎𝐵𝐠𝐵 𝐠𝔎𝐵𝐵 𝐵 𝔎𝐵𝐵 𝐵𝐵𝐵𝐠𝐵 𝐵𝐵𝐵𝐍
𝐵 𝐵𝐵𝐵𝐠𝐠𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵 4, 𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐠=
𝐵𝐵𝐍
𝐍
𝐍
=
80.8𝐵𝐍
4 = 20.2𝐵
Assuming worst case conditions, four bolts 𝐵𝐵𝐠the 𝐠𝐵𝐵𝐍
𝐍
𝐠=
𝐵𝐵𝐍
𝐵𝐵𝐠=
4 𝐠20.2𝐵
6.96𝐵 = 11.61
Safety factor against joint separation is approximately 11.61, with gearbox mounting bolts tightened
to 20.2kN, however due to gearbox clearance on spindle flange M16 threaded holes may be removed
and the gearbox fastened and secured with M16 bolts and nuts alternatively.P a g e | 33
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.11. Cover
The cover shown in figure 13, transmits the gear box output torque by connecting the planet gears to
the hub. The planet gears are mounted on the cover by pins pressed into cover and welded on cover
outside face. The cover is fastened to the hub by cap screws into the hub face, and seals the gearbox
by an O-ring seal against the inside diameter of the hub. A G1/2 BSP Threaded hole positioned on the
cover allows a plug to be fitted for gear oil filling and draining of gearbox. The cover is machined
manufactured from 1040 steel with 𝐵𝐠= 590𝐵𝐬 𝐵 = 374𝐵𝐬 𝐵 = 225 and 𝐠= 200𝐵𝐮
Figure 13 Cover
2.11.1. Cover Ansys FEA.
Finite element analysis of the cover design was conducted using Ansys academic in workbench to
determine stress loadings and safety factor torsional loading of gearbox output. Shown in figure 14,
are screen shots taking during Ansys FEA. In the first screen shot shows boundary conditions for cover,
with the fastener holes fixed and a torque output moment applied to planet gear pin bosses. The FEA
simulation was solved for total deformation, equivalent stress and safety factor. Shown in second
screenshot is total deformation solution with maximum deflection of 0.57µm shown by red area
around pin bosses. The max equivalent stress for hub was 4.48MPa however limitations were
experienced with meshing quality due to academic limitations of 32000 nodes or elements and the
hubs size. The safety factor for the cover design is approximated at 15 for hub shown in the third
screenshot, so material is removed from cover internal wall and a 10mm fillet applied.
Figure 14 Ansys FEA for Cover showing Boundary Conditions, Deformation and Safety Factor screen shotsP a g e | 34
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.11.2. Planet Gear Pins Stresses.
The planet gears are connected to the cover by pins shown in figure 15, pressed and welded into the
cover. The pins are subjected to shear stress and bending stress. The pins are machined manufactured
from 1040 steel with 𝐵𝐠= 590𝐵𝐬 𝐵 = 374𝐵𝐬 𝐵 = 225 and 𝐠= 200𝐵𝐮 Worst case
condition loadings for pin is when only one planet gear is in contact with the sun and ring gear.
Figure 15 Planet Gear Pins
Shear stress.
𝐍
𝐵 = 0.577𝐵 = 340𝐵𝐍
𝐠=
𝐠𝐍
=
2𝐵
𝐵2
4
=
8𝐵
𝐵2 =
8 𝐠2828𝐍
𝐨30𝐵)2 = 8𝐵𝐍
𝐍
𝐠=
𝐍
𝐵
𝐍
=
340𝐵𝐍
8𝐵𝐠= 42.5
Bending Stress.
Moment of inertia.
𝐠=
𝐨𝐴)
64 =
𝐨304)
64 = 39761𝐵4
Bending moment
𝐠= 𝐵 = 2828𝐠𝐠0.0175𝐠= 49.5𝐵
Stress Concentration Factor
𝐠= 0.5 𝐵𝐠590𝐵𝐠𝐵𝐠0𝐵 𝐵𝐵𝐵, 𝐵𝐵 𝐵𝐵𝐵 6 − 20 𝐵𝐵 303 𝔎𝐵𝐵𝐙𝐍
𝐵𝐠≅ 2.7, 𝔎𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵𝐵𝐠7 − 1
𝐍
𝐵 ≅ 1 + 𝐨𝐵𝐠− 1) = 1 + 0.5(2.7 – 1) = 1.85
Corrected Bending Stress
𝐵𝐠= 𝐵𝐍
𝐍
𝐵
𝐠= 1.85 49.5𝐵 39761 𝐠10 𝐵 3 𝐴15𝐵 = 34.5𝐵𝑐 a g e | 35
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
Endurance limiting strength
Estimated endurance limit. (𝐵𝐠≤ 1400𝐵𝐩
𝐲
𝐠= 0.5𝐵𝐠= 0.5 𝐠590𝐵𝐠= 295𝐵𝐍
Fatigue stress correction factors
VI. Surface factor. (machined)
𝐍
𝐠= 𝐵𝐵𝐠= 4.51 𝐠(590𝐵𝐩−0.265 = 0.831
VII. Size factor. (40mm rotating shaft)
𝐵 = 1.24𝐵−0.107 = 1.24 𝐠(30𝐵 𝐠0.370)−0.107 = 0.958
VIII. Loading factor. (bending)
𝐍
𝐠= 1
IX. Temperature factor. (20° 𝐵𝐵 𝐵𝐵𝐵𝐵𝐵𝐩
𝐵 = 1
X. Reliability factor (99% Confidence)
𝐍
𝐠= 0.814
Corrected endurance limit.
𝐍
𝐠= 𝐵𝐵𝐵𝐵𝐵𝐲𝐠= 0.831 𝐠0.958 𝐠1 𝐠1 𝐠0.814 𝐠295𝐵𝐠= 191.2𝐵𝐍
Estimating number of cycles to failure.
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐠= ∞, 𝐵 𝐵 = 34.5𝐵𝐠< 𝐵 = 191.2𝐵𝐍
Bearing contact stress, bronze bearing (𝐵 = 69𝐵𝐩 half contact area
𝐠=
2𝐍
𝐠=
2𝐍
𝐵 =
2 𝐠2828𝐍
(30𝐵)2 = 6.28𝐵𝐬 𝐵𝐵𝐵 𝐵 ℎ𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐮
𝐍
𝐠=
𝐵 𝐍
=
69𝐵𝐍
6.28𝐵𝐠= 10.99
2.11.3. Cover Fastener Screws.
The cover is fastened to the hub by screws into the hub face. The screw holes are subjected to
compression bearing loads by torque transmitted to the hub from hub cover and planet gears. The
cover is secured with 8 x grade 8.8 M8 x 1.25 screws with 𝐵𝐠= 800𝐵𝐬 𝐵 = 640𝐵𝐬 𝐵 =
590𝐵𝐬 fastened to 21.6Nm resulting in 19.1kN pre-load per screw (Rapp, Fastener Black Book,
2007).
𝐵
=
2𝐍
𝐠=
2 𝐠264𝐵
0.185 = 2854𝐍
𝐠= 𝐵 = 8𝐵 𝐠5𝐵 = 40𝐵2
𝐠=
2𝐍
𝐠=
2 𝐠2854𝐍
8 𝐠40𝐵2 = 17.8𝐵𝐬 𝐵𝐵𝐵 𝐵 ℎ𝐵𝐠𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐮
𝐍
𝐠=
𝐵 𝐍
=
620𝐵𝐍
17.8𝐵𝐠= 34.9P a g e | 36
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
2.12. Cherry Picker Travelling Clearance and Speed.
The orchard owner has requested travelling clearance for cherry picker to navigate between 5m
spaced rows on a 150 gradient. The gearbox design outputs 264Nm of torque and is limited to a
gradient of 9.930. It is recommended the cherry picker only be operated on gradients up to maximum
of 9.750.
The clearance required for cherry picker traveling in straight path.
𝐵𝐵𝐵𝐵𝐠𝐵𝐵 𝐵𝐠𝐵𝐠= 5𝐠𝐠sin 15° = 1.294𝐍
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝐵𝐠𝐵 𝐵𝐵𝐠=
1.294𝐍
sin 9.75° = 7.64𝐍
𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐠= √(7.64𝐩2 − (5𝐩2 = 5.78𝐍
If the cherry picker travels in a straight path between rows, the cherry picker requires 5.78m plus 2m
for cherry picker width, clearance equals to 7.78m and total distance travelled equals 15.42m. if the
cherry picker travels in a zig zag path between the rows the cherry picker requires to travel 6.5m up
the gradient, due to rolling down the slope to turn cherry picker so.
𝐵𝐵𝐵𝐵𝐠𝐵𝐵 𝐵𝐠𝐵𝐠= 6.5𝐠𝐠sin 15° = 1.682𝐍
𝐵𝐵𝐵𝐵 𝐵𝐵𝐵𝐵𝐠𝐵 𝐵𝐵𝐠=
1.682𝐍
sin 9.75° = 9.93𝐍
𝐵𝐵𝐵𝐵𝐠𝐵𝐵𝐵𝐵 𝐵 𝐵𝐵𝐵 𝐵 𝐵𝐵𝐠=
√(9.93𝐩2 − (6.5𝐩2
2 = 3.75𝐍
If the cherry picker travels up the slope in a zig zag path between the rows, the cherry picker requires
3.75m plus 2m for cherry picker width, clearance equals 5.75m and total distance travelled equals
11.5m less than straight path method.
The gearbox has a final design gear reduction of 5.22 with maximum output speed equal to 45.8rpm,
the maximum theoretical speed for cherry picker on level ground is.
𝐠=
60𝐵𝜇
𝐵𝐵𝐵
1000 =
60𝐠𝐠0.8𝐠𝐠45.8𝐵𝐍
1000 = 6.91𝐵/ℎP a g e | 37
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
3. References.
Australian/New Zealand Standards. (2016, May 28). AS/NZS 1418.10:2011 Cranes, Hoists and
Winches Part 10: Mobile Elevating Work Platform. Retrieved from www.saiglobal.com:
https://www-saiglobalcom.ezproxy.ecu.edu.au/online/Script/OpenPDF.asp?DocN=AS0733798603AT
Bunynas, R. G., & Nisbett, J. K. (2015). Shigley's Mechanical Engineering Design 10th Edition SI Units.
New York: McGraw Hill Education.
Juvinall, R. C., & Marshek, K. M. (2012). Fundamentals of Machine Component Design. New York:
John Wiley & Sons.
Parker Hannifin Corporation. (2016, May 16). Hydraulic Motor TB series catalog. Retrieved from
parker.com: http://www.parker.com/Literature/Hydraulic%20Pump%20&%20Motor/HY13-
1590-009-TB-Series_20140718.pdf
Rapp, P. (2004). Engineers Black Book 2nd Edition. Perth: Pat Rapp Enterprises.
Rapp, P. (2007). Fastener Black Book. Perth: Pat Rapp Enterprises .
Richard G.Budynas, J. N. (2011). Shigley's Mechanical Engineering Design. New York: The McGraw
Hill Companies, Inc.
SKF. (2016, 22 May). Industral Shaft Seals. Retrieved from SKF.com: http://www.skf.com/binary/101-
129139/Industrial-shaft-seals---10919_2-EN.pdf
SKF. (2016, 22 May). Rolling Bearing Cataloge. Retrieved from SKF.com:
http://www.skf.com/binary/101-121486/SKF-rolling-bearings-catalogue.pdf
Titan. (2016, 5 16). Agricultural Cataloge. Retrieved from titanaust.com.au:
http://titanaust.com.au/wp-content/uploads/2015/10/TITA0053-C1L3P2-AgriculturalCatalogue-COMPLETE_LR.pdfP a g e | 38
ENS5114 GROUP 4 CHERRY PICKER GEARBOX SEMESTER 1, 2016
4. Engineering Drawings.330
200
300
216.8 195
5
220
140
82.5
25
106.4 180
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PLANETARY GEARBOX
ASS-CPG01
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
VARIOUS WEIGHT: 20726.81 g
A3
SCALE:1:5 SHEET 1 OF 3
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOXA A
SECTION A-A
SCALE 1 : 2
4
13
21
14
19
16
15
2 1 5
18
17
8 20
11
6
9 3
10
7
12
ITEM NO. PartNo DESCRIPTION QTY.
1 P-CPG01 SPINDLE 1
2 P-CPG02 RING GEAR 1
3 P-CPG03 INPUT SHAFT 1
4 P-CPG04 HUB 1
5 P-CPG05 COVER 1
6 SKF 6008 INPUT SHAFT BEARING 1
7 SKF 30216 HUB BEARING 2
8 P-CPG06 SHIM 1
9 P-CPG07 40mm EXTERNAL CIRCLIP 1
10 P-CPG08 68mm INTERNAL CIRCLIP 1
11 SKF 40 x 68 x
10 SEAL INPUT SHAFT SEAL 1
12 SKF 110 x 130
x 12 SEAL HUB SEAL 1
13 10 x 8 x 36
KEY SPINDLE KEY 1
14 P-CPG09 LOCK WASHER 1
15 P-CPG10 HUB NUT 1
16 P-CPG11 PIN 2
17 P-CPG12 THRUST WASHER 4
18 P-CPG13 PLANET GEAR 2
19 P-CPG14 PLANET GEAR BEARING 2
20 P-CPG15 30mm EXTERNAL CIRCLIP 2
21 O-RING 1
22 M8 X 25mm COVER CAPSCREW 8
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PLANETARY GEARBOX
ASS-CPG01
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
VARIOUS WEIGHT: 20726.81 g
A3
SCALE:1:5 SHEET 2 OF 3
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX17
18
19
20
15
14
2
8
7
4
3
6
10
9
11
1
12
5
16
22
13
21
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PLANETARY GEARBOX
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
VARIOUS WEIGHT: 20728.83 g
A3
SCALE:1:5 SHEET 3 OF 3
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX220
130
80
110
180
A A
8 x M16 THRU
42 60 68 +0.030 0 82.5 106.4 140
R2
R2
R5 R1
60
60 45
17
157
5
10
15
40 45
15
SECTION A-A
SCALE 1 : 2
2 x 1/2 UNC x 25.4mm DEPTH
10mm CHAMFER
M60 x 1.5
20mm DEPTH
CIRCLIP GROOVE
2.6mm x 72.5mm Dia
KEYWAY
10 x 8 x 55mm
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
SPINDLE
P-CPG01
CHERRY PICKER GEAR
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
1040 STEEL WEIGHT: 7042.21 g
A3
SCALE:1:2 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
ENS5114 GROUP 4166
60
A A
GEAR 76T x 2mm MODULE
10 x 8 KEYWAY
57.5
52.5
92.5
80 105
30
5
R5
R2
SECTION A-A
2mm CHAMFER
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
RING GEAR
P-CPG02
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
4140 STEEL WEIGHT: 363.033 g
A3
SCALE:1:2 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX40 + +0.018 0.002 48
A A
GEAR 18T x 2mm MODULE
185
40
37.7
124.5 30 1.8 13.8
R1
25
50
SECTION A-A
SCALE 1 : 1
25mm x 50mm Depth
8 x 7mm KEYWAY
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
INPUT SHAFT
P-CPG03
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
4140 STEEL WEIGHT: 1645.086 g
A3
SCALE:1:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOXM8 x 16 DEPTH
M16 THRU
330
200
300
185
A A
140 +0.040 0 150 160
168.5
11.8
10
70
190
78
103 42
17
170 130
R5
R2 R2
R10
SECTION A-A
SCALE 1 : 2
13mm CHAMFER
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
HUB
P-CPG04
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
6061 Alloy WEIGHT: 4289.33 g
A3
SCALE:1:5 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX200
65
G1/2 THRU
2 x 30 THRU
185
A A
94 170
15
5
5
SECTION A-A
SCALE 1 : 2
3.5mm
O-RING GROOVE
R75
R25
MILL CUT 10mm DEPTH
10mm FILLET CORNERS
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
COVER
P-CPG05
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
1040 STEEL WEIGHT: 1865.12 g
A3
SCALE:1:5 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX60 80
+0.074
0
A A
5
SECTION A-A
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
SHIM
P-CPG06
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
1040 STEEL WEIGHT: 82.33 g
A3
SCALE:1:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOXR30
R37.5
25
45
10
30°
2
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
LOCK WASHER
P-CPG09
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
1040 STEEL WEIGHT: 39.82 g
A3
SCALE:1:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX75
M60 x1.5 THRU
10
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
HUB NUT
P-CPG10
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
174.11 WEIGHT: 174.11 g
A3
SCALE:1:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX60
28.4
1.4 3.6
2mm CHAMFER
30
++
0.028
0.015
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PIN
P-CPG11
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
1040 STEEL WEIGHT: 329.27 g
A3
SCALE:2:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX30 +0.052 0 50
A A
2.5
SECTION A-A
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
THRUST WASHER
P-CPG12
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
BRONZE WEIGHT: 25.43 g
A3
SCALE:1:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOXA A
GEAR 29T x 2mm MODULE
30
36
+0.025
0
8.5
SECTION A-A
SCALE 2 : 1
1mm CHAMFER
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PLANET GEAR
P-CPG13
ENS5114 GROUP 4
27/05/2016
19/05/2016
H.HIMANSHU
M.STAMPALIA
4140 STEEL WEIGHT: 367.712 g
A3
SCALE:2:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX30
+0.052
0 36
++
0.042
0.026
A A
30
SECTION A-A
NOTE:
1mm CHAMFER ALL SHARP EDGES
AND 1mm FILLET ALL CORNERS
C D E F
1 2 3 4
A B
1 2 3 5
C D
4 6 7 8
A B
0
PLANET GEAR BEARING
P-CPG14
ENS5114 GROUP 4
27/05/2016
22/05/2016
H.HIMANSHU
M.STAMPALIA
BRONZE WEIGHT: 80.28 g
A3
SCALE:2:1 SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
NAME SIGNATURE DATE
DEBUR AND BREAK SHARP EDGES
FINISH:
APPV'D
CHK'D
DRAWN
FABRICATION TOLERANCE: DIMENSIONS IN MILLIMETERS
LINEAR 1 U.N.O
ANGULAR 0.5 U.N.O
3RD ANGLE PROJECTION
MACHINING TOLERANCE:
0.15 U.N.O
MACHINING FINISH:
U.N.O
PROJECT:
CHERRY PICKER GEARBOX