A Two-Stage Speed Reducer Design

TWO-STAGE SPEED REDUCER
Executive summary
In this research study, a detailed analysis and evaluation of a two-stage speed reduced are
presented. The two-stage speed reducer is powered by means of an electric motor which moves
the rotating shaft. The major aim of this design project is to fully utilize the safety and the
efficiency of the input power of the electric motor. Besides, other designs of the speed reducers
have also been looked at and then a choice out of the best made depending on the optimum
operating performance. The research further presents some factors which help in determining
the choice of the best type of speed reducer. Some of this factor include couplings, shafts, gear
drives, machine housing among others (Benson, 2013).
These factors are arrived at considering various calculations as in the specifications
document. The calculations give a direction on the right choice of the material and sizes that
need to be applied in order to come up with the best design of the speed reducer.in order to
determine the optimum efficiency of the system, the internal components are analyzed
independently with regards to the power from the electric motor in the mechanical industry.
Usually, the electric motor is used while indoors as a result of the carbon oxide emissions and
also to ensure that minimum noise is produced (Shigley, 2011).
Introduction
This report presents elaborately the design of a gadget that will be applied while changing
the position of heavy objects in the conveyor belt. The conveyor belts have been in the past used
mostly in the manufacturing industries to move materials which are heavy as well as those that
need some packaging. While the conveyor belts are used for moving of objects , sometimes it

tends to experience some shocks resulting from the heavy loads and objects that it
transfers .nevertheless, the design provided in this report is such that all the shock loads that are
experienced by the conveyor belt are eliminated such that despite there generation, they are
never felt (Ramani, 2010). The design is a straight cut gear system which applies the belt as its
output.it focuses specific areas such as the smooth operation, reliability, low operation and
maintenance cost as well as the criteria for safety and performance.
Background
Over the past years, there has been an up growth in the demand for the efficient
powertrain components thereby also calling for more products to be produced. Conversely, the
engineers, in an attempt to offer solutions to most of the challenges, have also tried to come up
with some resolutions and in most case have settled to the idea of investing more on the
hardware parts of the components. For the engineers to come up with appropriate solutions, they
need to critically understand the performance criteria as well as the consumer needs of the
products.
The main aim of the speed reducer is to minimize the speed of the rotating shaft driven
by the electric motor while attempting to achieve a greater torque, hence, it is applied in
lessening the velocity of rotation. There are various designs of the sped reducer which are all
aimed at achieving some specific output configuration ratio that is desirable. Some of the various
designs of the speed reducers include the parallel shaft, worm gear, helical offset shaft, and
helical shaft among other types. The price of these types of speed reducers ranges from $400 to
$2000 depending on the costumer’s choice.

In most case, most of the customers' needs are not fully addressed when one is need of a
speed reducer and thus there are some features which define the speed reduces including the
mounting options, output replacement, the component life as well as the output ratio. One
common practice of the speed reducer is in the production line where it is applied in the
conveyor belt as result of the high demands of the products. The high demand for the products
calls for a production line design which will offer lower maintenance costs, longer lifetime and a
good performance quality. Apparently, the advancements in the manufacturing industry have
resulted in better ways of ensuring that materials of higher quality are produced.
Aim
The main of this research project is to come up with a two-stage speed reducer which can
be applied in the production industry with increasing efficiency and minimum requirements. The
designed speed reducer has to attain some characteristics such as being able to rotate the shaft by
the aid of a powered electric motor and then transfer of the power to various machine elements
after which it be able to minimize the speed of the output shaft while increasing the torque
Objective
The main objective of the task is to come up with a gear system that acts as a two-stage
speed reducer and at the same time be in line with the demands and specifications of the
manufacturing company. Described below are some criteria which must be met by the speed
reducer design
o Ensure safety while the system is in operation
o Reduced cost
o Development of prototype

o Cheaper maintenance costs
o Reduced noise and vibration
o Highly reliable
Performance criteria
In order to effectively come up with a design that will be able to meet up the requirements
and the demands of the customers, there are some performance criteria which must be adhered
to. These conditions include
 Product lifetime service of 10 years with 5 days weekly and 16 hours daily, time of
operation, thereby totaling to 4000hours
 The conveyor belts speed of 0.5m/s with a torque of 14ooNm and diameter of 350 mm
 Accuracy range of +-5%.
 Mechanical efficiency that is greater than 95%
 Couplings that are flexible to ensure the shaft is tightly fixed on the roller (Ajukumar,
2010).
 The ratio of the speed reduction to be not more than 3.53 and less than 3.46 in each of the
stages
For the two-stage speed reducer, the criteria of selection that must be adhered to is as follows
 Safety – safety of both the workers and in general the working environment must be an
apriority of the speed reducer
 Smooth operation
 High reliability
 Longer service life