SCIENTIFIC PROCEEDINGS XIII INTERNATIONAL CONGRESS "MACHINES. TECHNOLОGIES. MATERIALS.

" 2016 - WINTER SESSION ISSN 1310-3946

ANALYSIS OF COMPLEX PLANETARY CHANGE-GEARS THROUGH THE

TORQUE METHOD
Assoc. Prof. Karaivanov D. PhD., Petrova A., Ilchovska S., Konstantinov M.
Department of Applied Mechanics – University of Chemical Technology and Metallurgy, Sofia, Bulgaria
dipekabg@[Link]
Abstract: An alternative method for kinematic and power analysis of compound gear train is presented, which uses the torques and lever
analogy of a given gear train. The method combines the accuracy of the Willis analytical method with the clarity of the graphic method of
Kutzbach. Unlike these methods, the torque method allows determining not only the gear ratio, but the magnitude and direction of power
flows, and hence the determination of efficiency of a given compound planetary gear train. The application of the method is illustrated with
example of complex change-gear (gear-box).
Keywords: KINEMATIC ANALYSIS, POWER ANALYSIS, RATIO, EFFICIENCY, PLANETARY GEAR TRAINS, CHANGE-
GEARS

a.) Equilibrium of ideal (with no account of losses) external

1. Introduction torques acting on the three shafts
There are various methods for analysis of planetary gear trains
(PGT) at all. Two, however, are most commonly used. One is the
∑ T=i TD min + TD max + TΣ= 0 (1)
where
analytical method of Willis, the other is a graphical method of
Kutzbach. Both methods have proved their worth over many years. TD min and TD max are the unidirectional external ideal torques (with
The method of Willis (1841) [19] is used for almost two centuries different sizes), therefore are indicated by single lines on the figure,
and the method of Kutzbach (1927) [12] is there nearly a century. but with different thickness, according to their size;
The main advantage of analytical method is the accuracy. TΣ is the largest torque, in absolute value equal to the sum of other
Moreover it is universal. However, it lacks any clarity, the volume two torques TD min and TD max , and therefore is marked with a double
of calculations, especially for the complex compound PGTs, is not line.
small, which allows and there is no simple way to check the results,
but the most careful repeating of the calculations. ТΣ
Т D max FΣ
Undoubtedly the main advantage of the graphical method is the
clarity. However, it is lost for complex compound planetary gear
trains because of the tangle of lines obtained. Frankly in graphical
1 t
methods we cannot speak for high accuracy.
Т D min FD min
The importance of accurate analysis of all gear trains is FD max
determined by the fact that errors in defining the correct transmit
ratio or in the direction of rotation of the output shaft of the train in Fig. 1 Planetary gear train with three external shafts, their torques
some cases may be fatal. and the lever analogy

The two main methods at use have advantages and b.) Equilibrium of the real (considering the losses) external
disadvantages. This determined the need of proposed another torques
method – torque method – more suitable for the practice that
combine their advantages and avoid the disadvantages [1, 3, 4, 5, 6,
∑ T=
i
′ TD′ min + TD′ max + TΣ=
′ 0 (2)
where
7, 8, 9, 10 ]. The following properties are desired:
- accuracy; TD′ min , TD′ max and TΣ′ are the same external torques as above, but
- simplicity; real now considering the losses in the gear train.
- maximum clarity;
c) Sum of ideal (not considering the losses) powers
- easy usability (relevance);
For the simpler case, when the gear train is with one fixed shaft, i.e.
- easy check of the results;
working with F = 1 degree of freedom, the condition is
- generally the opportunity to achieve more goals than with
previous methods, namely - not only determining the gear ∑ Pi = PA + PB = TA ⋅ ω A + TB ⋅ ωB = 0 (3)
ratio, but the presence or absence of internal division or where
circulation of power, determining the efficiency and, in PA , TA and ω A are the input power, torque and angular velocity;
particular in gearboxes, determining the load spectrum of
the elements of gear train (wheels, shafts, bearings), as a PB , TB and ωB - the output power, torque and angular velocity;
prerequisite for their reliable load capacity calculation; The above condition is used to determine the speed ratio
ωA T
The aim of this paper is illustrate the advantages of torque i= = − B (4)
method in analysis of complex planetary change-gears (gear-boxes). ωB TA

2. Essence of the Torque Method d) Sum of real (considering the losses) powers

Unlike the methods of Willis and Kutzbach using angular

∑ Pi′ =η ⋅ PA′ + PB′ =η ⋅ TA′ ⋅ ω A + TB′ ⋅ ωB =0 (5)
where
velocity ω (or rotational speed n ) and the peripheral velocities v ,
at the presented here method the torques T are used. The method is PA′ , TA′ and ω A are the input power, torque and angular velocity;
based on the following well-known principles of mechanics, PB′ , TB′ and ωB - the output power, torque and angular velocity;
illustrated with the simplest case of elementary (single-carrier) gear From this follows the formula for the efficiency
train with three external shafts that has a very good lever analogy
T′ T′ i
(Fig. 1): η=
− B A = − T (6)
ω A ωB ik

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 SCIENTIFIC PROCEEDINGS XIII INTERNATIONAL CONGRESS "MACHINES. TECHNOLОGIES. MATERIALS." 2016 - WINTER SESSION ISSN 1310-3946

In this formula iT means the ratio of the real external torques TB′ - What is the direction of power flow, respectively does the gear
train works as a reducer or a multiplier at F = 1 degree of freedom,
and TA′ at the input A and output B of gear train, as signified more
respectively such as a collecting or as a separating gear at F = 2
as dynamic [11], as a power ratio or torque transformation [14, 18]. degrees of freedom, i.e. as a differential;
The other ratio ik is the usual speed ratio and unlike the above, if - Does the gear works as a single or as a component train along
necessary, the index k - from the "kinematic” can be used. with others in a compound planetary gear train.
To determine the real external torques Ti ′ it is necessary that the
3. Application of the Torque Method
directions of relative (rolling) powers Prel i are identified in each
The application of the torque method is best illustrated in [6, 7].
gear train according to the respective carrier, and each gear train has
Main points as determination of relative power direction in
its own internal efficiency [11, 14, 18].
component planetary gear trains, circulation or division of power,
In most cases the direction of relative (rolling) power Prel in one
etc. are presented and explained.
planetary gear train (from the sun gear 1 to the ring gear 3 and vice
versa) can be determined, proceeding from the direction of the Coefficient of efficiency of the PGTs is in direct proportion of
torque on the sun gear and its relative angular velocity toward the the coefficient of internal losses ψ 0 and the basic (internal)
carrier ω1rel= ω1 − ωH , by the following simple criteria: coefficient of efficiency η0 . This is the coefficient of efficiency of
- when the directions of the torque T1 and the relative angular the PGT at immovable carrier H ( ωH = 0 ), i.e. gear as normal,
velocity ω1rel coincide i.e. ω1rel ⋅ T1 > 0 - the relative power is nonplanetary. When losses in the meshing prevail, the basic
coefficient of efficiency η0 is calculated starting from the
transmitted from the sun gear 1 through the planets 2 to the
ring gear 3, or in other words, the sun gear appears to be the coefficients of overlapping ε α of the two meshings - external and
driving one in the relative motion; internal, and the coefficient of friction µ z of the meshing [30, 34,
- when ω1rel ⋅ T1 < 0 - the relative power is passed from the ring
35, 36 and 37]. There is also a simplified formula for determining
gear 3 to the sun gear 1; the basic (internal) coefficient of efficiency [14 and 32]
In relatively rare cases this situation is not that clear. Then it is
1 1 1 1
appropriate for determining the direction of the relative power to η0 = 1 −ψ 0 ≈ 1 − 0,15  +  + 0, 2  −  . (10)
use the method of the samples [17].  z1 z3   z2 z3 
For the coefficient of efficiency determination of the PGT
Along with the foregoing known principles of mechanics, the
according to the torque method the real external torques
following two small but very useful innovations are made:
(considering losses) must be determined, for which you need to
e) For the greatest possible illustration of the method the know the direction of power transmission with respect to the carrier
known symbol of the Wolf [20] (Fig. 2) is used, but modified [1, 3, H, i. e. the relative power Prel . There are two options – it is
4, 5, 6, 7, 8, 9, 10 ]. The each elementary (single-carrier) gear train, transmitted from the sun gear 1 through the planets 2 of the ring
which has three external shafts is depicted with a circle, from which gear 3 or vice versa. Using basic (internal) coefficient of efficiency
the three shafts are coming out, marked differently from the original
– i.e. not with numbers, letters or inscriptions, but by the thickness
η0 for these two cases, the following relations are obtained for the
of the lines corresponding to the size of the external torque, as real external torques
already mentioned above. This little innovation concerning the T3′= η0 ⋅ t ⋅ T1′ - when the relative power is transmitted from 1
manner of marking the shafts makes the method very clear and to 3;
useful. T3′ - when the relative power is transmitted from 3 to 1.
T1′ = η0
Т D max t
The very direction of the relative power Prel transmission is
ТΣ
t > +1 defined by the following criteria - a match or mismatch of the
direction of the torque T1 of the sun gear 1 with the direction of the
Т D min relative angular velocity ω1rel= ω1 − ωH with respect to the carrier
Fig. 2 Modified symbol of Wolf with three external shafts and their H.
torques
Problems of the power circulation are explained in [2].
f) Besides using the modified symbol of Wolf, where
appropriate another innovation is made. A new torque ratio is 4. Analysis of the Four Stage Planetary Change-
defined – the one of the unidirectional external torques [1, 3, 8] Gear Train through the Torque Method
TD max (7)
=t > +1 Figure 3 presents a four-carrier planetary change-gear train
TD min
(kinematic scheme).
because TD max > TD min (fig. 1).
Ideal torques, real torques, check their values by formulae (3)
This innovation is especially important. It is connected to the lever and (5), speed and torque ratios and efficiency for all ways of
analogy. operating are determined (Figs. 4, 5, 6 and 7). The basic efficiency
g) Ideal external torques are always in a certain ratio, of all stages are chosen equal each other
expressed with the torque ratio t η=0I η=0 II η =
0 III η =
0 IV 0,97 .
TD min : TD max : TΣ = T1 : +t ⋅ T1 : − (1 + t ) T1 = 1: +t : − (1 + t ) (8)
Figure 8 shows how to determine the load spectrum of an
in which always element of the change-gear while working with different gear-ratio
TD min < TD max < TΣ (9) steps (speeds).
however:
- How many degrees of freedom F (F = 1 or F = 2) the gear train is
running with;
- Which shaft is fixed at F = 1 degree of freedom;

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SCIENTIFIC PROCEEDINGS XIII INTERNATIONAL CONGRESS "MACHINES. TECHNOLОGIES. MATERIALS." 2016 - WINTER SESSION ISSN 1310-3946

PA PB

I II III IV
Fig. 3. A four-carrier planetary change-gear with four gear-ratio steps (speeds)

PA
2
∑T = i TA + TB + TC = 4, 2 − 27, 04 + (1 + 21,84 ) = 0 PA

∑T ′= TA′ + TB′ + TC′ = 4,33 − 27, 044 + (1 + 21, 714 ) = 0

2
TA = +4, 2 i T′A = +4,33
Prel
1 1
+ T −27, 04 tI = 4, 2 tII = 4, 2 +1
tI = 4, 2 tII = 4, 2 1 i=
− B =
− =
+6, 438
TA +4, 2 η0 I = 0,97 η0 II = 0,97

T1( IV ) +5, 2
−5, 2 3 = = 1, 238 ≈ 1, 24 −5,33 3
TA +4, 2
+5, 2 4 +5,33 4
T ′ −27, 044
iT = B = = −6, 2457 PB
PB TA′ +4,33 tIII = 4, 2 tIV = 4, 2
tIII = 4, 2 tIV = 4, 2 Prel η = 0,97
η0 III = 0,97 0 IV
TB = −27,04 i −6, 2457 T′B = −27,044
η=− T =− =0,9701
6 ik +6, 438 +21,714 5
6
+21,84
5

Fig. 4. Ideal and real torques, speed and torque ratios and efficiency of “first speed” of the planetary change-gear from Fig.3

3
PA ∑ T =T + T + T =−5, 2 + 21,84 + (1 − 17, 64 ) =0
i A B C
3
PA
TA = −5, 2 ∑ T ′ =T ′ + T ′ + T ′ =−5, 074 + 20, 671 + (1 − 16,597 ) =0
i A B C
T′A = −5,074

1 T +21,84 1
+1 i=
− B =
− =
+4, 2 + 1 tI = 4, 2 tII = 4, 2
tI = 4, 2 tII = 4, 2 TA −5, 2 η0 I = 0,97 η0 II = 0,97
Prel
T1( IV ) −4, 2
2 +4, 2 = = 0,8077 ≈ 0,81 2 +4,074
TA −5, 2
−4, 2 4 −4,074 4
T ′ +20, 671
iT = B = = −4, 0739
PB TA′ −5, 074 tIII = 4, 2 PB
tIII = 4, 2 Prel tIV = 4, 2
tIV = 4, 2 η0 III = 0,97 η0 IV = 0,97
TB = +21,84 i −4, 0739 T′B = +20,671
η=− T =− =
0,970
6 ik +4, 2 −16,597
6
−17,64
5 5

Fig. 5. Ideal and real torques, speed and torque ratios and efficiency of “second speed” of the planetary change-gear from Fig.3

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SCIENTIFIC PROCEEDINGS XIII INTERNATIONAL CONGRESS "MACHINES. TECHNOLОGIES. MATERIALS." 2016 - WINTER SESSION ISSN 1310-3946

PA
∑T = T
i A + TB + TC = 1,808 − 6, 438 + ( 0, 43 + 4, 2 ) = 0 PA
10 TA = +1,808 10 TA = +1,824
9 9
+0, 430 ∑ Ti′ = TA′ + TB′ + TC′ = 1,824 − 6,319 + ( 0, 421 + 4, 074 ) = 0 Prel +0, 421

TB −6, 438 tI = 4, 2 tII = 4, 2

tI = 4, 2 tII = 4, 2 i=− =− ≈ +3,561 η0 II = 0,97
TA +1,808 η0 I = 0,97

−2, 238 8 T1( IV ) +1, 238 −2, 245 8

= = 0, 6847 ≈ 0, 68
+2, 238 7 TA +1,808 +2, 245 7
1 +1 +1, 238 5 1 +1 +1, 245 5
T ′ −6,319 Prel
PB iT = B = = −3, 4644 tIII = 4, 2 tIV = 4, 2 PB
tIII = 4, 2 tIV = 4, 2 TA′ +1,824 η0 III = 0,97 Prel η = 0,97
TB = −6, 438 T′B = −6,319
0 IV

+4, 2 +4,074
+5, 2 6 i −3, 4644 +5,074 6
2 −5, 2 η=− T =− =0,9729 2 −5,074
3 4 ik +3,561 3 4

Fig. 6. Ideal and real torques, speed and torque ratios and efficiency of “third speed” of the planetary change-gear from Fig.3

PA ∑T = i TA + TB + TC = 2, 771 − 6, 438 + ( −0,533 + 4, 2 )= 0 PA

9
TA = +2,771 10 ∑ T ′=i TA′ + TB′ + TC′ = 2, 796 − 6,319 + ( −0,551 + 4, 074 )= 0 TA = +2,796 10
9
−0,533 −0,551
TB −6, 438
i=− =− ≈ +2,323 tI = 4, 2 tII = 4, 2
tI = 4, 2 tII = 4, 2 TA +2, 771 η0 I = 0,97 η II = 0,97
Prel
T1( IV ) +1, 238
= = 0, 4469 ≈ 0, 45 8 −2, 245
8 −2, 238 TA +2, 77
+2, 238 7 +2, 245 7
1 +1 +1, 238 5 TB′ −6,319 1 +1 +1, 245 5
iT = = = −2, 260
TA′ +2, 796 Prel
PB tIII = 4, 2 tIV = 4, 2 PB
tIII = 4, 2 tIV = 4, 2 η0 III = 0,97
i −2, 26 Prel η0 IV = 0,97
TB = −6, 438 η=− T =− ≈ 0,9729 TB = −6,319
+4, 2 ik +2,323 +4, 074
+5, 2 6 +5,074 6
2 −5, 2 2 −5,074
3 4 3 4

Fig. 7. Ideal and real torques, speed and torque ratios and efficiency of “fourth speed” of the planetary change-gear from Fig.3

TI NI
= 1, 24 ϕI
= = 0, 05
TA NΣ
N II 9
TII
= 0,81 ϕ
= = 0,10 T  IV
 Tj 
TA
II
NΣ =
  ∑
=
9
  ϕj
 TA  Eq j = I  TA 
TIII N III
= 0, 68 ϕ
= = 0, 20 1

TA
III
NΣ = (1, 24 .0, 05 + 0,81 .0,1 + 0, 68 .0, 2 + 0, 45 .0, 65) =
9 9 9 9 9

TIV ϕ
=
N IV
= 0, 65 = 0,895 ≈ 0,9
= 0, 45 IV
NΣ
TA

Relative loading Relative duration

Tj T 
TA   = f ( NΣ )
 TA lim
1, 24
T  T 
 =  0,895 ≈ 0,9
  = f (N)
 TA  Eq  TA lim N
0,81
b.) Safety factor
0, 45 T  T 
  = const
 TA lim b   = f ( NΣ )
S  A lim
T
= >1
T 
NI N II N III N IV N  
NΣ  TA  Eq
N limb

Fig. 8. Determination of load spectrum of an element (sun gear of the fourth stage) of four-carrier change-gear while working with different gear-ratio steps
(speeds)

54 YEAR XXIV, VOLUME 3, P.P. 51-55 (2016)

SCIENTIFIC PROCEEDINGS XIII INTERNATIONAL CONGRESS "MACHINES. TECHNOLОGIES. MATERIALS." 2016 - WINTER SESSION ISSN 1310-3946

When the change-gear from Fig. 3 works at “first speed” (Fig. 3. ARNAUDOW, K. and D. KARAIVANOV. r. Systematik,
4) power pass through II and IV stage which operated with F = 1 Eigenschaften und Möglichkeiten von zusammengesetzten
degrees of freedom as in series connected planetary gear train. At Mehrsteg-Planetengetrieben. Antriebstechnik. 2005, Nr. 5, S.
“second speed” (Fig. 5) power pass through I and IV stage which 58-65.
operated with F = 1 degrees of freedom as in series connected 4. ARNAUDOV, K. and D. KARAIVANOV. Higher compound
planetary gear train too. In the other two cases (Figs. 6 and 7) the IV planetary gear trains. VDI-Berichte 1904-1, 2005, pp. 327-344.
stage works with F = 2 degrees of freedom and power pass through ISSN 0083-5560
the loop (III and IV stage) with division. 5. ARNAUDOV, K. and D. KARAIVANOV. The complex
compound multi-carrier planetary gear trains – a simple study.
All four simple planetary gear trains operate with movable VDI–Berichte 2108 – 2, 2010, pp. 673-684. ISSN 0083-5560
carrier and their relative powers are less then relevant absolute
powers. Because this the efficiency of change-gear η is practically
6. ARNAUDOV, K. and D. KARAIVANOV. Alternative method
for analysis of complex compound planetary gear trains:
equal (a little bit bigger) to basic efficiency η0 of the connected Essence and possibilities. Mechanisms and Machine Science, 13
(2013), Power Transmissions, Proceedings of the 4th
simple planetary gear trains. International Conference, Sinaia, Romania, June 20-23, 2012,
Editor Georg Dobre, Springer Dordrecht Heidelberg New York
5. Conclusion London, p. 3-20 (Plenary Paper). ISSN 2211-0984.
Unlike the most commonly used methods of Willis and 7. ARNAUDOV, K. and D. KARAIVANOV. The torque method
Kutzbach-Smirnov that use the angular and peripheral velocities, at used for studying coupled two-carrier planetary gear trains.
the presented torque method here another parameter of mechanics is Transactions of FAMENA. 2013, 37 (1), No. 1, pp. 49-61. ISSN
used – the torque. This alternative method is characterized with the 1333-1124.
following: 8. KARAIVANOV, D. Theoretical and experimental studies of the
influence of the structure of coupled two-carrier planetary gear
1. The method is characterized by simplicity, maximum trains on its basic parameters. Dissertation. Sofia: Univ. of
clarity and ease of usability (relevance), combining in Chemical Technology and Metallurgy, 2000. (in Bulgarian)
itself, accuracy and clarity, existing separately in the 9. KARAIVANOV, D. Structural analysis of the coupled
Willis and Kutzbach-Smirnov’s methods. planetary gears with considering the efficiency of the coupling
gears. Proceedings of the 2th Int. Conf. on Manufacturing
2. The method allows achieving more goals than is possible
Engineering (ICMEN), Kallithea of Chalkidiki [Greece],
with the methods of Willis and Kutzbach-Smirnov -
October 5 – 7, 2005, pp. 381-387. ISBN 960-243-615-8.
determining not only the speed ratio, but also the internal
10. KARAIVANOV, D. Structural Analysis of Compound
power flows by size and direction, as a prerequisite for
Planetary Gear Trains. Balkan Journal of Mechanical
the determination of the efficiency. Also the determining
Transmissions, 2011, 1 (1), pp. 33-45. ISSN 2069-5497.
of the load spectra of elements of the compound change-
11. KUDRYAVTSEV, V. N. and Y. N. KIRDYASHEV. Planetary
gears – gear-wheels, shafts and bearings, while working
trains. Handbook. Leningrad: Mashinostroenie, 1977.
with different gear-ratio steps (speeds) as a prerequisite
12. KUTZBACH, K. Mehrgliedrige Radgetriebe und ihre Gesetze.
for their reliable load capacity calculation.
Maschinenbau. 1927, Nr. 22, S. 1080.
3. The dependence of the designer on a particular literary 13. LEISTNER, F., G. LÖRSCH and O. WILHELM.
source is avoided, so he may act independently. Umlaufrädergetriebe. 3. Auflage. Berlin: VEB Verlag Technik,
1987.
4. The method allows easy verification of calculations by the 14. LOOMAN, J. Zahnradgetriebe – Grundlagen, Konstruktion,
conditions of equilibrium of the ideal and real external Anwendung in Fahrzeugen. 3. Auflage, Berlin: Springer-Verlag,
torques. 1996.
5. Because of the clarity and ease applicability, the method 15. MÜLLER, H. W. Epicyclic drive trains. Detroit: Wayne State
is suitable either for industry - for engineers, or for University Press, 1992.
learning process - for students. 16. NIEMANN, G. and H. WINTER. Maschinenelemente. Band 2.
Zahnradgetriebe – Grundlagen, Stirnradgetriebe. 2. Auflage.
Considering all these possibilities and the current acceptance of Berlin: Springer-Verlag, 1995.
the torque method in different countries (Giger 2007, Müller 1998, 17. SEELIGER, K. Das einfache Planetengetriebe. Antriebstechnik.
Troha 2011), there is reason to believe that the torque method can 1964, S. 216-221.
successfully compete with those of Willis and Kutzbach-Smirnov, 18. VDI-Richtlinie 2157 Planetengetriebe – Begriffe, Symbole,
especially in the analysis of complex compound planetary gear Berechnungsgrundlagen, Entwurf. 2010
trains. 19. WILLIS, R. Principles of Mechanism. London: John W. Parker,
1841.
Acknowledgments 20. WOLF, A. Die Grundgesetze der Umlaufgetriebe.
The authors would like to express their deepest gratitude to the Braunschweig: Friedr. Vieweg und Sohn, 1958.
governing body of University of Chemical Technology and
Metallurgy – Sofia for support in the research within the scientific
grant 11432/2015 of the Research-Development Sector of UCTM

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55 YEAR XXIV, VOLUME 3, P.P. 51-55 (2016)