Automatic Generation of Gearbox Layouts

The primary objective of this thesis is to develop an automated system for generating a gearbox layout, focusing on the precise calculation and design of key components such as bevel gears, cylindrical gears, shafts, and bearings. This system integrates advanced computational tools to ensure precision and efficiency throughout the design process. The initial phase involves detailed calculations for bevel and cylindrical gears using MATLAB. These calculations determine the dimensions and forces acting on the gears based on user inputs like input torque, desired output torque, material properties, and working condition of the gearbox. Parametric modeling in MATLAB is crucial as it allows quick adjustments and rapid design iterations, significantly reducing design time. Users input critical values, and MATLAB processes these inputs to design the gears, ensuring they meet performance and durability criteria. Following the gear design, the shafts undergo static analysis using the finite element method (FEM) to determine optimal diameters and lengths. This analysis ensures the shafts can withstand the forces generated by the gears, providing a detailed understanding of stress distributions and potential failure points. After determining the shaft dimensions, the system selects suitable bearings based on the forces derived from the FEM analysis. This process is automated using a custom code that references the SKF catalogue, ensuring the bearings can handle the loads and conditions. The code considers load ratings, lubrication, and maintenance requirements to select the most appropriate bearings. The calculated data is exported to Excel files, which serve as the foundation for the parametric design process in NX Siemens, a leading CAD software. CAD is crucial in the industry for creating precise and detailed models that facilitate visualization, simulation, and optimization before manufacturing. The parametric design in NX Siemens allows for flexible adjustments and easy modifications, ensuring the gearbox design can adapt to various specifications. In NX Siemens, the parameters are imported to create a detailed CAD model of the gearbox, including all designed components—gears, shafts, and bearings—arranged in an accurate layout. This automated approach accelerates the engineering process and enhances the accuracy and reliability of gearbox designs. By leveraging MATLAB for calculations, combined with the powerful design capabilities of NX Siemens, the system provides a versatile and efficient tool for gearbox development. This methodology is suitable for various industrial applications, offering significant improvements in design time, cost efficiency, and overall product quality. The contributions of this thesis include a fully automated design workflow that integrates computational analysis and CAD modeling, marking a significant advancement in gearbox engineering. This system will benefit industries requiring precise and efficient gearbox designs, providing a foundation for future innovations in mechanical design automation.