Means of transmitting linear force and motion from cylinder output to the

lever input

1. RACK AND PINION

Rack and pinion is one way of transmitting linear motion. Although the
racks moment is converted to angular rotation of the gear we can
reconvert it to linear motion with the use of a meshed another rack and
pinion
Thus we will design a gear box containing 2 racks and 2 pinions to
connect the shaft to the lever. The first rack is connected alongside the
cylinder shaft through welding and roller supports. This rack has a pinion
names gear 1meshed to it. The pinion is connected to another gear
(gear2)and both are perfectly meshed together. At the other end gear 2is
meshed with rack 2 which translates back and forth on support rail.
Attached to this rail is the slider which slides along the slot of the lever
operating the machine.

Things to consider while designing a rack and pinion mechanism for the
BBTM

Proper support for guided motion

Space allocation
Velocity and torque transfer
Lubrication and heating
Locationing
Supports for the gear box
Wear and other fatigues
Permissible stress
Power and load values

Load for calculations

FH

Hydraulic force

Pmax

max hydraulic pressure available

Dc

Hydraulic cylinder diameter

stroke of the hydraulic cylinder

VH

Hydraulic linear velocity

Flow rate Hydraulic oil

Pload

load pressure

Ac

cross sectional area

Energy per unit

Since any fluid exerts pressure, which is force per unit area with a 200psi
max internal gear pump
Pmax =200 psi

Pmax =1378951.46 pa
Since
P=

F
A

Pmax =

PASCAL LAW
FH
AC

1378951.46=

FH
dC
4

0.05

F
1378951.46= H
F H =2707.64 N
F H =2.7 N
From brake band yield stress calculations, the amount of force accepted
and hence readily controlled by the relief valve was 1.3 KN.
Even so the rack pinion is designed for the worst case scenario, that the
hydraulic unit achieves its maximum pressure.
FU =Load force that rack pinion has sustain
FU =2.7 KN
By rack and pinion drive calculation and selection manual

FU =

F U tab
K A . f n . LKHB . S B

FU tab =Table provide relation gear dim ension the allowed load force
K A =Load factor
Load driven and the drive operational mode for the hydraulic cylinder in
BBTM, light shocks are experienced. However the driven lever employers
smooth operation.
K A =1.25

Hence

S B =Safety coefficient
Considering hydraulic high force values and closeness of the gear box to
the operator we select the maximum possible value of this coefficient
S B =1.4
Life time factor

fn

Tangential linear velocity of the pinion, which is intact, the shafts linear
velocity.
V H =0.08 m/ s
V H <0.5

m
s

And considering monthly lubrication

f n=3
LKHB =linear load distribution factor

State in which mode is the load distributed between the meshing gear,
weather it is pre-loaded or not. For that case considering the preloaded
lever and and the roller support
LKHB =1.2
Hence
FU =K A f N LKHB S B FU
FU =(1.25)(3) (1.4)(1.2)(2.7)
FU =17.01 KN
Hence tangential load at maximum possible hydraulic load is to be 17.01
kN. Since the system would be in equilibrium, this would be the same
amount of force that Rack 2,1 and pinion 1 and 2 would have to sustain

GEAOMATRICAL AND VELOCITY CALCULATIONS

DRAWINGSSSSSSSSSSSSSSSSSSSSSSS
Critically designed for perfect mesh
p=distance shaft center weld center

q=slider clearence
w=width of rack

d 1=Gear 1 pitch diameter

d 2=Gear 2 pitch diameter

D=space for gear box placement
Distance left for gears pinion= D-2p-q
=D-6
Since D= 200mm from the placement of the cylinder to the stand. We
readjust the boxs placement so that D=206mm and distance left for
gears Dp=200mm
In order for two pinion gears to be spatially meshed
d 1 +d 2=D p
d 1 +d 2=200 m

eq 1

Testing results once the hydraulic system was installed proved to be slow.
Expected theoretical and motor RPM promised and should have had a
velocity of Vi >1.5m/s as per design criteria
Owing to the motor capacitor over heating or any other intricate issue in
the unit the shaft extends at a speed of Vi=0.05m/s only. While the design
criteria for levers linesar velocity is VI=0.124m/s preferably VI=0.25 m/s
We can hence design the gear ratio as such to provide a higher linear
velocity at the levers end, which can be achieved by modifying and
selecting proper gear ratio.
d 2 2 v2
= =
d 1 1 v1
where 12 are angularv 1v 2 are linear velocities of the piston

Since from the shaft side we have a velocity 0.05 m/s and we want a
velocity of 0.15 m/s at the levers end.

Therefore
d1 v2
=
d2 v1
d 1 0.15
=
d 2 0.05
d 1=3 d 2

eq 2

solvind eq 12 simulteneously
3 d 2+ d 2=200 mm
4 d 2=0.2 m
d 2=0.05 m
d 1=3 d 2
d 1=50(3)
d 1=150 mm
Cautionary measure , the space has to be perfectly maintained otherwise
shift the hydraulic unit idf required.
Thus the two pinion gears and their respected racks have the following
requirement
d 1=150 mm
F perm =17 kN
d 1=150 mm
F perm=17 kN

d 1=50 mm
F perm=17 kN

Cost cheap
Easy to use

Cost cheap
Easy to use

NOTE:
Circular pitch for all the gears and racks should be the same otherwise
would start to ware of, overheat and cause other problems
From ATLANAT HANDBOOK tables selected pinions and their respected racks
are
GEAR 2
d 2=56 mm

GEAR 1
d 1=144 mm

Rack PR
Quality-8
Rack material C45
Rack heat treatment- hand hardened

Rack RR
Quality- 8
Rack material 42CrM04
Rack heat treatment- Quenched and
tempered
Pinion material- 16MnCr5
Pinion material- C45
Pinion heat treatment- case hardened Pinion heat treatment- ind. Hardened
Number of pinion teeth-14
Number of pinion teeth
For the rack to work the entire stroke and still have part of it near the
cylinder side. Also the racks length should be less than that of the
hydraulic unit box. Thus
ra ck length=stroke+clearance
rack length=450+50

rack length=500 mm
rack length=0.5 m

Rack 1 and 2 are of equal length

Relations of the pinions to complete the racks stroke length

2 rn=s
2 (150)n=450

2 rn=s
2 (50)n=450

SETTING PRESSURE ANGLE

There are two possible options 20 and 14.5 pressure angle gears. The
lower limits for the number of teeth on the 20 set is 13 while that of the
14.5 PA has the lowest limit of 16. Lower number of teeth can cause one
great tooth to touch and wear out the lower portion of the matching pair.
This is referred to as undercut and is an undesirable phenomenon. We
hence select the gear with a PA of 20 since gear 1 has 14 teeth on it
=20 BOSTON GEAR

FACE WIDTH BY

THEORY

From Atlanta catalogue, the selected rack and pinion set has predefines
face width from the gear tooth. However BOSTON GEAR HANDBOOK
recommends use of the ----------- theory to determine the face width of the
gear.
W=

SFY
600

P
600+ v

Where:
W= Max load
S=
F=
Y=

p= Diametrical pitch=

1
module

v = Linear velocity of gear

All variables involved in the equation are developed with the MKS metric
standard

W=

SFY
600

P
600+ v

For GEAR 1
W=

SFY
600

P
600+ v

S=
W=2707
Y=
p= 250
v = 0.05

For GEAR 2
W=

SFY
600

P
600+ v

S=
W=2707

Y=
p=250
v = 0.15
For GEAR 3/RACK 1
W=

SFY
600

P
600+ v

S=
W=2707
Y=
p=250
v = 0.05

For GEAR 4 / RACK 2

W=

SFY
600

P
600+ v

S=
W=2707
Y=
p=250
v = 0.15
LEWS FORMULA
S=static safe stress
The amount of stress the material can withstand in static condition
Selected steel ------ 20 carbon case hardened
S=2500 psi

S=172,368,932 pa
S=172,368.932 kpa

F =Face width
The face width of the teeth viewed from the pitch circle
Y= Form factor
For GEAR1
Number of teeth=36
=20

F=0.377
p=diametrical pitch

GEAR 1=

N 36
=
=250
D 0.44

GEAR 2=

N 14
=
=250
D 0.60

D= Pitch diameter
GEAR 1= 56mm
GEAR 2 = 144mm
v = 0.05 m/s

v =0.15m/s