Design Project – 01

Worm Gearbox Design for Traction Type Elevator

1. Problem Statement
A worm gearbox is to be designed for a traction type elevator having a capacity of 7
persons and a lifting speed of 0.6 m/s.
• The gearbox should safely transmit power from the motor to the lifting
mechanism while ensuring smooth and reliable operation.

2. Assumptions and Design Considerations

In order to proceed with the design, certain standard assumptions are made as per
elevator design practice and PSG data handbook.
• The average weight of a person is taken as 75 kg, which is commonly used in
design calculations. Therefore, the total passenger load becomes:
W_pass = 7 × 75 = 525 kg
• The weight of the elevator car is assumed to be 400 kg, which is reasonable for a
small passenger lift.
• In traction elevators, a counterweight system is used to reduce the load on the
motor.
The counterweight is generally taken as the car weight plus 40–50% of the passenger
load. Here, we assume 50% for safe design:
Wc = 400 + 0.5 × 525 = 662.5 ≈ 660 kg

Load Calculations
The total load acting on the elevator car side is the sum of the car weight and
passenger load:
W_total = 400 + 525 = 925 kg
However, due to the presence of the counterweight, the motor does not need to lift the
entire load. Only the unbalanced load is lifted:
W_net = 925 - 660 = 265 kg
In practical systems, additional losses occur due to friction in pulleys, guide rails, and
bearings. These losses are generally taken as 10% of the load.
W_eff = 265 × 1.1 = 291.5 ≈ 295 kg
Converting Mass into Force
F = 292 × 9.81 = 2865 N

4. Power Requirement
The power required to lift the load is given by:
P = (F × V) / 1000
∴ P = (2865 × 0.6) / 1000 = 1.72 kW
Since worm gearboxes are not 100% efficient, we must consider transmission losses.
The efficiency of a worm gearbox is typically around 70–75%. Taking efficiency as 75%:
P_motor = 1.72 / 0.75 = 2.29 kW
From standard motor ratings, a 3 kW motor is selected.

5. Speed Determination of the Lifting Drum (Sheave)

In a traction elevator, the lifting motion is achieved through a traction sheave (pulley)
over which the rope passes. The linear speed of the rope is equal to the lifting speed of
the elevator.
Given: V = 0.6 m/s
Assumption of Sheave Diameter
The diameter of the traction sheave is selected based on practical considerations such
as rope life, bending stress, and space constraints.
For small elevators, a typical value is:
D = 400 mm = 0.4 m
Relation between Linear and Rotational Motion
The relationship between linear velocity and rotational speed is given by:
V = (π × D × N) / 60
∴ 0.6 = (π × 0.4 × N) / 60
∴ 0.6 = (1.256 × N) / 60
∴ 0.6 × 60 = 1.256 N
∴ 36 = 1.256 N
∴ N = 36 / 1.256 = 28.66 rpm
∴ N₂ ≈ 30 rpm
Thus, the output shaft of the gearbox (connected to the sheave) should rotate at
approximately 30 rpm.
6. Selection of Gear Ratio
The motor selected earlier runs at:
N₁ = 1440 rpm
The required output speed is:
N₂ = 30 rpm
Gear Ratio
Gear Ratio = N₁ / N₂ = 1440 / 30 = 48
Standard Selection
Since the exact ratios are not always available, we select the nearest standard value:
Gear Ratio = 50 : 1

7. Selection of Worm and Worm Wheel

According to standard design practices and referring to PSG Design Data Book, the
worm and worm wheel are selected based on:
• Gear Ratio
• Centre distance
• Power capacity
Selection of Number of Starts and Teeth
For a gear ratio of approximately 50:
• Number of starts on worm: Z₁ = 1
• Number of teeth on worm wheel: Z₂ = 52
Thus, actual ratio = Z₂ / Z₁ = 52 / 1 = 52
This is close to the required ratio and is acceptable.
Selection of Module and Diameter Factor
From PSG tables (based on centre distance and power) selecting m & q:
Centre Distance — q
A commonly used empirical relation is:
a = C · ∛P
where P = Power in kW, C = constant (depends on material & duty)
Given: P = 1.72 kW
Assuming C for medium duty: 100
∴ a = 100 · ∛1.72
 ∴ a = 100 × 1.2 = 120 mm
∴ a = 120 ≈ 125 mm
From PSG Data book:
m = 4 mm
q = 10 mm (taken to be adequate)

8. Calculation of Principal Dimensions

Pitch Circle Diameter of Worm
d₁ = q × m = 10 × 4 = 40 mm
Pitch Circle Diameter of Worm Wheel
d₂ = m × Z₂ = 4 × 52 = 208 mm
Centre Distance
a = (d₁ + d₂) / 2 = (40 + 208) / 2 = 124 mm ≈ 125 mm
Addendum and Dedendum
For worm gearing (standard):
Addendum = m = 4 mm
Dedendum = 1.2m = 1.2 × 4 = 4.8 mm
Outside (Outer) Diameter
Worm:
do₁ = d₁ + 2m = 40 + 2×4 = 48 mm
Worm wheel:
do₂ = d₂ + 2m = 208 + 2×4 = 216 mm
Root Diameter
Worm:
df₁ = d₁ - 2×1.2m = 40 - 2×4.8 = 30.4 mm
Worm wheel:
df₂ = d₂ - 2×1.2m = 208 - 2×4.8 = 198.4 mm
Face Width
b = 8m to 12m
∴ b = 10m = 10×4 = 40 mm
Circular Pitch
pc = π·m = π × 4 = 12.57 mm
Axial Pitch (Worm)
pa = pc = 12.57 mm
Lead of Worm
L = π·d₁ × Z₁ = π × 40 × 1 = 125.66 mm
Lead Angle
tan γ = Z₁ / q = 1 / 10
∴ γ = tan⁻¹(1/10) = 5.71°
Tooth Thickness
t = pc / 2 = 12.57 / 2 = 6.28 mm
Hub Diameter and Length
d_h = 1.6d
l_h = 1.5d

9. Force Analysis on Worm and Worm Wheel

When power is transmitted through a worm gear set, three main forces act on the teeth:
• Tangential force
• Axial force
• Radial force
These forces are essential for shaft, bearing, and housing design.
Velocity of Worm
The pitch line velocity of the worm is given by:
V = (π × d₁ × N₁) / 60
∴ v = (π × 0.04 × 1440) / 60
∴ v = 180.96 / 60 = 3.02 m/s
Tangential Force (Pt)
The tangential force is responsible for transmitting power:
Pt = (1000 × P) / V
∴ Pt = (1000 × 1.72) / 3.02 = 569 N
Design Tangential Force: To account for shock and service conditions, a service factor
is applied:
Pt = 569 × 1.5 = 853.5 ≈ 850 N
Axial Force (Pa)
The axial force on the worm is given by:
 Pa = Pt / tan γ
∴ Pa = 850 / tan(5.71°) = 8500 N
Radial Force (Pr)
The radial force is given by:
Pr = Pt × tan α
Taking pressure angle α = 20°:
∴ Pr = 850 × tan(20°)
∴ Pr = 309 N

10. Torque Transmitted

Torque on Worm Shaft
P = (2π · N₁ · T₁) / 60000
∴ T₁ = (9550 × P) / N₁
∴ T₁ = (9550 × 1.72) / 1440 = 11.4 Nm = 11400 Nmm
Torque on Worm Wheel Shaft
T₂ = (9550 × P) / N₂
∴ T₂ = (9550 × 1.72) / 30 = 548 Nm = 548000 Nmm

11. Efficiency of Worm Gear

Efficiency depends on lead angle and friction. The formula is:
η = tan γ / (tan γ + μ)
Assuming μ = 0.04:
∴ η = tan(5.71°) / (tan(5.71°) + 0.04) = 0.7142
∴ η = 0.7142 × 100 = 71.42%

12. Selection of Materials

Material selection is carried out based on strength, wear resistance, and working
conditions.
1. Material for Worm
• Case Hardened alloy steel (EN353)
• Surface Hardness = 58 HRC
• σ_b = 180 MPa
 • High surface hardness – resists wear
• Tough core – absorbs shock
• Suitable for high-speed sliding
2. Material for Worm Wheel
• Phospher Bronze
• Allowable bending stress: σ_b = 55 MPa
• Wear factor: K = 0.7 N/mm²
• Low friction
• Good wear resistance
• Prevents seizure
3. Material for Worm Wheel Shaft
• Mild Steel (C45)
• τ = 40 MPa
• Adequate strength
• Good machinability
• Economical
4. Material for Key
• Mild Steel (C45)
• σ_c = 80 MPa
• Same as shaft for uniform strength
• Safe for torque transmission
5. Material for Housing
• Cast Iron (FG 200)
• σ_c = 600 MPa
• High compressive strength
• Good damping
• Good heat dissipation

13. Design of Worm Shaft

The worm shaft is subjected to:
• Torque due to power transmission
• Bending due to radial force
• Axial thrust (handled by bearings)
Forces acting on worm shaft
• Tangential force, Pt = 850 N
• Radial force, Pr = 309 N
• Axial force, Pa = 8500 N
For shaft bending, we consider:
• Pt → Vertical plane
 • Pr → Horizontal plane
Assumptions of Shaft Layout
As per standard design:
• Worm is located between two bearings
• Distance between bearings: L = 150 mm
• Worm is centrally placed
Reaction Forces (Vertical Plane)
In vertical plane, tangential force Pt acts downward.
Let reactions at bearing be R_A and R_B.
Taking moments about A:
ΣM_A = 0
R_B × 150 = 850 × 75
∴ R_B = (850 × 75) / 150 = 425 N
Now sum of vertical forces:
R_A + R_B = 850
∴ R_A = 850 - 425 = 425 N
Reaction Forces (Horizontal Plane)
Radial force: Pr = 309 N
Taking moments about A:
R_B × 150 = 309 × 75
∴ R_B = 154.5 N
Sum of forces:
R_A = 309 - 154.5 = 154.5 N
Maximum Bending Moment
Vertical plane:
M_v = (Pt × L) / 4 = (850 × 150) / 4 = 31875 Nmm
Horizontal plane:
M_h = (Pr × L) / 4 = (309 × 150) / 4 = 11587 Nmm
Resultant Bending Moment
M = √(M_v² + M_h²)
∴ M = √((31875)² + (11587)²)
∴ M ≈ 33900 Nmm
Equivalent Torque
Considering Shock Factors: K_t = 1.5, K_b = 1.5
 T_e = √((K_t·T)² + (K_b·M)²)
∴ T_e = √((1.5 × 11400)² + (1.5 × 33900)²)
∴ T_e = 53600 Nmm
Shaft Diameter
Using Torsion equation:
T_e = (π/16) × τ × d³
∴ 53600 = (π/16) × 40 × d³
∴ d = 19 mm ≈ 20 mm

14. Design of Worm Wheel Shaft

This shaft carries much higher torque so it will be larger.
Torque
T = 548000 Nmm
Bending Moment
Assuming Span: L = 200 mm
M = (850 × 200) / 4 = 42500 Nmm
Equivalent Torque
T_e = √((1.5T)² + (1.5M)²)
∴ T_e = √((1.5 × 548000)² + (1.5 × 42500)²)
∴ T_e ≈ 825000 Nmm
Shaft Diameter
T_e = (π/16) × τ × d³
∴ 825000 = (π/16) × 40 × d³
∴ d = 47 mm ≈ 50 mm

15. Design of Key

Selection of type of key
A rectangular sunk key is selected because:
• It is simple and widely used
• It is suitable for moderate to high torque
• Easy to manufacture and assemble
Dimension of Key
For shaft diameter, d = 50 mm, from standard tables:
b = 16 mm, h = 10 mm
Length of Key
The length of key is generally taken equal to the hub length or face width of gear.
∴ l = 40 mm
Check for Shear Failure
The shear stress induced in the key is:
τ = 2T / (d·b·l)
∴ τ = (2 × 548000) / (50 × 16 × 40)
∴ τ = 1096000 / 32000 = 34.25 MPa
As τ < τ_allow i.e. 34.25 < 40 MPa
∴ Safe in shear
Check for Crushing Failure
The crushing stress is given by:
σ_c = 4T / (d·h·l)
∴ σ_c = (4 × 548000) / (50 × 10 × 40)
∴ σ_c = 109.6 MPa > σ_c_allow = 80 MPa
∴ Not safe in crushing
Modification of Design
To reduce stress, increasing key length:
l = 60 mm
Recheck crushing stress:
∴ σ_c = (4 × 548000) / (50 × 10 × 60)
∴ σ_c = 73 MPa < σ_c_allow = 80 MPa
∴ Safe in crushing

∴ Dimensions of Key are: 16 × 10 × 60 mm