Research Papers

An Automated Design Search for Single and Double-Planet Planetary Gear Sets

[+] Author and Article Information
H. S. Kwon

Department of Mechanical and Aerospace
The Ohio State University,
201 W. 19th Avenue, Columbus,
Columbus, OH 43210
e-mail: kwon.166@osu.edu

A. Kahraman

Department of Mechanical and Aerospace
The Ohio State University,
Columbus, OH 43210
e-mail: kahraman.1@osu.edu

H. K. Lee

Hyundai Motor Company,
Gyeonggi-Do 445-706, South Korea
e-mail: hk-lee@hyundai-motor.com

H. S. Suh

Hyundai Motor Company,
Gyeonggi-Do 445-706, South Korea
e-mail: hssuh@hyundai.com

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received August 20, 2013; final manuscript received February 7, 2014; published online April 11, 2014. Assoc. Editor: Qi Fan.

J. Mech. Des 136(6), 061004 (Apr 11, 2014) (13 pages) Paper No: MD-13-1368; doi: 10.1115/1.4026871 History: Received August 20, 2013; Revised February 07, 2014

Design of planetary gear sets is more involved than the design of their counter-shaft counterparts as it involves simultaneous design of a set of internal and external gear meshes while complying with a large number of systems and gear mesh related requirements for assembly, durability, noise, and efficiency. A manual iterative design process often results in suboptimal designs that fail to meet all these requirements simultaneously. In this paper, a methodology for an automated design search of single and double-planet planetary gear sets is proposed. With the input of a number of system-level constraints associated with the spacing and phasing of the planets, and acceptable ranges of basic geometric design parameters, this methodology defines a large design space in that a large number of geometric design concepts are identified and checked for any interferences. The external and internal meshes of these concepts are evaluated by using computationally efficient loaded gear tooth contact analysis model to predict their performance metrics such as transmission error amplitudes and contact and root stresses. They are then rank-ordered based on their performance metrics to identify balanced planetary gear set designs meeting all requirements equally well. At the end, results of an example design search were presented to demonstrate the effectiveness of the proposed methodology in defining a balanced solution that is acceptable in terms of all of its requirements.

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Fig. 1

(a) A SP planetary gear set and (b) a DP planetary gear set

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Fig. 2

Flowchart of the process to generate candidate sets of tooth count combinations

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Fig. 3

A double-planet branch (a) with maximum planet sizes, (b) with theoretical minimum planet sizes for Zp1≥Zp2, and (c) with practical minimum planet sizes

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Fig. 4

The limiting case of tip interference between two adjacent planet branches of (a) a SP gear set and (b) a DP gear set. Solid circles denote major circles and dashed circles denote pitch circles.

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Fig. 5

Distributions of (a) profile, (b) face, and (c) total contact ratios versus operating normal module of s-p gear meshes of the 91,298 candidate SP designs

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Fig. 6

Respective values of design A marked on the distributions of maximum contact stress versus the first harmonic amplitude of transmission error of (a) external and (b) internal gear meshes

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Fig. 7

Respective values of design B marked on the distributions of (a) maximum planet root stress and (b) maximum sun and ring root stresses versus the first harmonic amplitude of transmission error of external and internal gear meshes

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Fig. 8

Overall and branch views of (a) SP gear set design A and (b) DP gear set design B specified in Table 7




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