• Journal of the Korean Society for Precision Engineering
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• v.23 no.9 s.186
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• pp.54-60
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• 2006

Fitting process carried out in automobile transmission assembly line is classified into three classes; heat fitting, press fitting, and their combined fitting. Heat fitting is a method that heats gear to a suitable range under the tempering temperature and squeezes it toward the outer diameter of shaft. Its stress depends on the yield strength of gear. Press fitting is a method that generally squeezes gear toward that of shaft at room temperature by press. Another method heats warmly gear and safely squeezes it toward that of shaft. Warm shrink fitting process for automobile transmission part is now gradually increased, but the parts (shaft/gear) assembled by this process produced dimensional changes of gear profile in both radial and circumferential directions. So that it may cause noise and vibration between gears. In order to solve these problems, we need an analysis of warm shrink fitting process, in which design parameters are involved; contact pressure according to fitting interference between outer diameter of shaft and inner diameter of gear, fitting temperature, and profile tolerance of gear. In this study, an closed form equation to predict contact pressure and fitting load was proposed in order to develop optimization technique of warm shrink fitting process and verified its reliability through the experimental results measured in the field and FEM, that is, thermal-structural coupled field analysis. Actual loads measured in the field have a good agreement with the results obtained by theoretical and finite element analysis and also the expanded amounts of the gear profile in both radial and circumferential directions are within the limit tolerances used in the field.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.2
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• pp.14-18
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• 2015

In recent years, world is faced with a transportation energy dilemma, and the transportation is almost dependent on a single fuel - petroleum. However, Hybrid Electric Vehicle (HEV) technology holds more advantages to reduce the demand for petroleum in the transportation by efficiency improvements of petroleum consumption. Therefore, there is a trend that lower gear noise levels are demanded in HEV for drivers to avoid annoyance and fatigue during operation. And meshing transmission error (T.E.) is the excitation that leads to the tonal noise known as gear whine, and radiated gear whine is also the dominant source of noise in the whole gearbox. In this paper, the analysis of gear tooth profile and lead modification is firstly presented, and then, the different transmission error of no mesh misalignment and mesh misalignment under one loaded torque for the 1st gear pair of HEV gearbox was investigated and compared. At last, the appropriate tooth modification was used to minimize and compare the transmission error of the gear pair with mesh misalignment under the loaded torque.

• Tribology and Lubricants
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• v.36 no.2
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• pp.96-104
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• 2020

The electric vehicle industry is rapidly developing because of enforced environmental regulations, and several studies have been conducted on the multispeed transmission to improve the fuel efficiency of electric vehicles. Among these studies, research on the power density improvement of electric vehicle transmission is critical. Thus, the optimal design of the gear train is necessary to enhance transmission efficiency. In this study, an optimal design methodology for the lightweight two-speed transmission of electric vehicles is proposed. Because a multispeed transmission has many operating conditions and equality and inequality constraints, a new gear design method that combines analytical and iterative methods is applied without using complex optimization algorithms. Sets of possible design variables are generated considering the operating conditions and various design variables. The modules and face width ratios of each stage gear that satisfy the corresponding operating conditions are analytically calculated. The volume of the gear train is calculated, evaluated, and arranged using these values to determine the optimal solution for minimizing the volume, and the proposed methodology is applied to the actual model to verify its effectiveness. The design of a two-speed transmission with multiple operating conditions and constraints without complicated optimization algorithms can be optimized.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2014.10a
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• pp.505-508
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• 2014

Transmission error (TE) is defined as "the angular difference between the ideal output shaft position and actual position". As TE is one of the major source of the noise and vibration of gears, it is originally studied with relation of the noise and vibration of the gears. However, recently, with the relation of mesh stiffness, TE has been studied for fault detection of spur gear sets. This paper presents a physics-based theory on fault diagnostics of a planetary gear using transmission error. After constructing the lumped parameter model using DAFUL, multi-body dynamics software, we developed a methodology to diagnose the faults of the planetary gear including phase calculation, signal processing. Using developed methodology, we could conclude that TE could be a good signal for fault diagnostics of a planetary gear.

• Tribology and Lubricants
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• v.34 no.6
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• pp.325-331
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• 2018

Automobiles and systems requiring high gear ratios and high power densities generally use worm gears. In particular, as worm gears have a small volume and self-locking function, home appliances such as refrigerators and washers consist of worm gears. We can classify worm gears into cylindrical worms and rectangular worms. According to the AGMA standard, there are four types of cylindrical worms, ZA, ZN, ZK and ZI, depending on the machining of the worm shaft. It is preferable to use a ZI-type worm shaft, which is a combination of a worm wheel having an involute helical tooth surface and a conjugate tooth surface. However, in many cases, industries mostly use ZK, ZN, and ZA worm shafts because of the ease of processing. This paper presents numerical approaches to produce ZI and ZA worm surfaces and worm wheel. For the analysis of the transmission error of a worm gear system, this study (1) generates surface profile functions of ZI profile worm gear and worm shaft based on the common rack theory, (2) adopts the Newton-Raphson method for the analysis of the gear surface contact condition, and (3) presents and compares the corresponding transmission errors of ZI and ZA worm gears.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.2
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• pp.237-243
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• 2010

This paper presents a study on the helical gear inspection system for application to vehicle transmission gear manufacturing lines. The special gear profile inspection system is not suitable for manufacturing lines due to the measuring time. The master gear method, which was used in this study and compared with the machined gear in the line, is more efficient and economical. In this paper, three helical gear inspection parameters were of concern: nick, run-out, and PCD (pitch circle diameter) error. To evaluate its influence on the accuracy, the gear measuring system was also studied. This system can be useful in practical vehicle transmission gear manufacturing lines, where imported equipment is currently being used.

• Journal of the Society of Naval Architects of Korea
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• v.50 no.3
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• pp.153-159
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• 2013

The power transmission system has always been considered critical for a human powered boat(or water bike) since it first showed up at Human Powered Vessel Festival. Mechanical problems, such as abrasions and other damages of the gear system for the power transmission, lead to poor durability and low efficiency of a boat. This paper described mechanical problems and a design process of power transmission system and then suggested the method to solve the problems. It is selected a module and a type of gears that are structurally stable thus can transmit the power durable. Especially the lower gear box is applied to CRP(contra rotating propeller) system for improving the structural stability and the propeller efficiency as well. As the results, the upper and lower gear box are designed and manufactured. And from the trial test, it is confirmed that the power transmission system is reliable.

• Journal of Biosystems Engineering
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• v.19 no.4
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• pp.291-300
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• 1994

It is desired to operate tractor engines at or near maximum torque much of the time in field operation to increase fuel efficiency. To do this it is necessary to reduce engine speed and to shift gears to higher ratios as frequently as possible. Because of load variations in most drawbar work and inconvenience in gear shift, however, gear-type transmission are usually set in one ratio at unnecessarily high engine speeds, and engine-torque variations are used to compensate for changes in drawbar load. As a result, the most of time the tractor is not operated efficiently in terms of fuel consumption and work output. The objective of this study was to develop an automatic control system which is able to operate a tractor equipped with gear transmission under the optimal condition in terms of fuel efficiency with automatic governor setting and gear shift. An indoor experimental test set which can be used to simulate tractor operation, control engine speed and transmission ratio was developed in the previous paper. In this paper, the performance of the optimal operation system is reported. Through a series of tests, it was found that the automatic control system for optimal operation of tractors with gear transmission had a satisfactory performance.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2002.11b
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• pp.31-36
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• 2002

Even through the problem of misalignment is of great importance, not much work has been reported in the literature on the effect of misalignment on the vibrations of the gear-bearing systems. Therefore, the nonlinear dynamic characteristics of the gear drive system due to misalignment are investigated in this work. Transmission error for helical gear and bearing nonlinear stiffness is calculated. The equation of motion of the gear drive system is modelled using the time-varying gear meshing stiffness, bearing nonlinear stiffness, and bearing pre-load due to the housing deformation. Numerical analysis lot the gear drive system show the result of misalignment effect - sub-harmonic component, bearing pre-load effect, and another nonlinear phenomenon. And the numerical analysis are verified by the experimental result.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.857-860
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• 1996

The area of gear dynamics has recently been the focus of many studies. A new tooth profile modification was proposed by author for reducing vibration and noise of involute gears. A comparative dynamic analysis of the gear drive with the involute tooth and the modified tooth profile(using cubic splines) is performed to the unuformal transmission error reduces the gear vibration and noise due to less dynamic tooth load variation during the meshing cycle. This work also include a gear design process by the meaning of a practical approach, such as Win95 based simulation program with all using basic geardesign variables. Especially this program enables gear designers to dynamic analysis based on G.U.I.