Assignment 2

Figure 1 Figure 2
You are required to design a gearbox for a two-wheel balancing robot like in Figure 1. Each
wheel will have its own gearbox to power the wheel. The components that make up the
gearbox are as shown in Figure 2.
The requirement is that the arrangement of the motor must be kept perpendicular to the
motor leg to save space, therefore bevel gears are needed to be used.
The DC motor used is the IG45-33K, and the spec sheet of the motor is provided.
To generate more torque from the DC motor a 2-stage gear train is needed. The first stage
(bevel gear) gear ratio needs to be 2.5:1, while the second stage (spur gear) gear ratio needs to
be 3:1.
Prepare a design report that answers the Questions (a) ~ (f) below.
If possible, additional machining modifications to the selected parts is to be avoided, if there
are any modifications that need to be done, please state it in question (e).
 (a) Using the provided catalogue, select the appropriate parts and fill in the details for each
part in the table below

Part Catalog No. of Bore Hole Mounting

Number Module Pitch Diameter
Name Teeth Size Distance
Gear 1
Gear 2

Part
Catalog Number Module No. of Teeth Bore Hole Size Pitch Diameter
Name
Gear 3
Gear 4

It is specified that single-row deep groove ball bearings with snap ring groove is used in the
design. From the provided catalogue, select the proper bearing for use in your design.

Part Name Bearing Number Inner Outside Load Rating Limiting Speed
(Catalogue No.) diameter, d diameter, D in Grease
Bearing 1
Bearing 2
Bearing 3
Bearing 4

The bore hole sizes of the gears need to match the diameter of the shafts, which will also affect
the size of the bearings to be used.
For the bevel gears, the arrangement needs to be done so the gear mounting distance line up
such as below:
(b) Based on the Figure 3 below, fill in the specifications regarding the measurements
required to assemble your gearbox that matches your selected components.

Figure 3

Measurement Length (mm)

Gear Mounting Distance
Pinion Mounting Distance
Center Distance
Shaft 1 Diameter
Shaft 2 Diameter
(c) We want to make the gear box to be as small as possible. Based on your design, what
are the minimum length of these measurements that you can get without any
interference on your design? Show your calculations

Measurement Length (mm)

Minimum Box Width
Minimum Box Height
Minimum Wheel Diameter

(d) What is the output shaft speed (Shaft 2) of the gearbox when the DC motor is used at
the rated speed? What is the output torque of the gearbox when the DC motor is used
at the rated load torque (include machine efficiency of the gears as 98%) ?
(e) Does your design require machining modifications on the factory catalogue
components?
(f) What is the maximum load that can be applied to the wheel before breakdown occurs in
your design? Show your calculations.