MECH11311 Mechanical Engineering Systems

Mechanical Power Transmission

Section 1: Mechanical Power Transmission Failure 

In a digitalized and optimized world where industries try to minimize downtime and costs, identifying the basic failures of a gearbox can assist in saving money and time so as to enable the service and the repair shop become the main part of the process of optimization.

The Causes Of Mechanical Power Transmission Failure 

The gearbox alignment on the application is one of the mechanical power transmission failure causes. Failing of a gearbox in totally mechanical, the design of gears done in a way that they can operate in a particular configuration and react back to settings for every tooth of the gear, which once it is misaligned can lead to loads concentrating on a section of the gear, bearings, housing or other weaker section and lead to premature failure (Bell, 2016, p. 221).

Another cause of mechanical failure is the overloading and operational mistakes. Usually bare to harsh conditions of working, the gearbox equally suffer from operating and overloading mistakes. Gearbox are originally supplied with the right service factor and configuration to offer ideal working and improved performance.

A real-life illustration of gearbox failure is in the case of reducers being pushed to the limits and even above. The setting of conveyors is done to speed up and heavier loads are being applied to the existing outputs ad emergency stops or even cold starts might add the loads of shock to the reducers above their design limits. The gearbox failure in a rapid manner upon the critical limit being reached.

Steps to Take in Correcting the Failure Problem

Many gearboxes are provided with a high quality of lubricant oil whose adaption is done to the type of application, mounting configuration and the environment. The manufacturer analyses the right quantity and outlines the right type of oil to make sure a perfect for both the gearbox and oil. The splash and bath lubrication configuration ensure the right amount of oil is spread in the gearbox, allowing the creation of a thin film by the oil on the gears.  

During the cases of overloading and operational mistakes, heavy loads can be applied to the torque arms, output shafts and backstop devices. Conveyor, shredder or mixer that is fully loaded usually demands an extra effort to the geared motors up to the level it gets to the speed of operation requested. Adapted automation and soft start devices can minimize the overload and ease the efforts made by the gearbox (the University of Michigan, 2017, p. 113).

The main steps taken in the above cases so as to correct the identified problems of failure include;

• Define the failure problem
• Collect the information regarding the failure problem
• Analyse the information   
• Propose a solution if there is sufficient information; if the information is not sufficient, go back to the first step
• Test the solution proposed
• Implementation of the solution

Changes Made To The Design  

The type of materials applied in the design of mechanical transmission has got a significant effect on the consumption of fuel and weight of vehicles. For every minimization of about 10 percent in the weight of the vehicle, there is a reduction of fuel consumption by around 5 to 7 percent. Therefore, manufacturers spend more time to search for materials that contain lightweight and have the ability of withstanding the required load. Thus, reduction of weight is more practical in terms of the fuel consumed (South, 2017, p. 174).

Searching for materials that have the components of the transmission such as bearing, gear and transmission casing forms an important scenario since materials matters the life of components of transmission particularly and the vehicle at large. With an expected life of vehicle between 10 to 20 years, the property of the material can increase the life through avoiding any mechanical deterioration in properties whereas extensive research has been conducted on aluminium and steels of ultra-high strengths (Zhang & Mi, 2017, p. 284).

Section 2: Devices That Store Mechanical Energy 

Mechanical energy storage devices may be found in pure mechanical or even in combination with electrical devices. The key difference between the two is found in the way the store energy is used be it directly or if it has to be transmitted through an electronic motor generator. Electrical mechanical energy storage devices are applied in supplying electricity to the grid even as pure mechanical energy storage devices can provide mechanical work for instance smoothing rotation for a given rotating mass as is the situation of a flywheel. The major mechanical energy storage devices include pumped hydro energy storage, flywheel energy device systems as well as compressed air energy systems.

Flywheel energy storage devices operate on the basis of storage of energy for a short while through the use of a rotating mass in the form of kinetic energy. These devices are applicable in hybrid vehicle, space, marine as well as wind power alongside railway. Flywheels tend to be the most effective with regard to swiftness in response. Flywheels are often made up of bearings, frequency inverter, motor-generator and rotating mass with the design of every component being the major determinant of its efficiency.

Pumped hydro energy storage is often characterized by the long-life cycle, low cost of maintenance as well as flexibility. The system is made up of three key component including pumping system, upper reservoir and hydro turbine. The operation of the system is such that pumping of water is done from to the upper reservoir from the lower reservoir in case of excess energy to allow its usage when required. The system relies on the potential gravitational energy such that the upper container can offer positive difference in pressure in relation to the lower reservoir and as a result generate power with the aid of the hydro turbine.

Section 3: Connected Shafts (Requirements For a Constant Velocity Ratio Between Two Shafts) 

Generally, a universal joint is a mechanical coupling that exists between two rotating shafts, applied in transmitting motion, power or both. The shafts ’axes always are interconnecting and the bending angle between them is tolerable to changes during the operation. The Cardan joint, also referred to as Hooke’s joint, is an example of a universal joint. Notably, the cardan joint transmits rotary motion even though it does not make sure that the shafts’ angular velocities at all times are equal. On the other hand, a constant velocity universal joint defines a universal joint that carries out the transmission of a rotary motion while ensuring the shafts’ angular velocities are equal at all times.

Factual constancy of angular velocity transmission is attained by a widely applied arrangement of two cardan joints in sequence, the first joint’s output member include the input member to the second joint. However, it is noted that the constancy is maintained only under geometrical requirements that are strict; both output and input shafts must stay in one plane and both bending angles of the two cardan joints at all times must be equal (Parker, 2017, p. 215).

References 

Bell, P. C., 2016. Mechanical Power Transmission. 3rd ed. London: Macmillan.

Parker, F. E., 2017. Safety Code for Mechanical Power-transmission Apparatus. 3rd ed. London: U S Government Printing Office.

South, D. W., 2017. Mechanical Power Transmission Components. 3rd ed. Texas: Taylor & Francis.

the University of Michigan, 2017. Power Transmission: Mechanical, Hydraulic, Pneumatic, and Electrical. 4th ed. London: Prentice Hall.

Timings, R., 214. Mechanical Engineer's Pocket Book. 4th ed. Texas: Elsevier.

Zhang, Y. & Mi, C., 2017. Automotive Power Transmission Systems. 4th ed. Texas: John Wiley & Sons.

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