Problem Statement: Design of a Gearbox for a Conveyor System

Your team is tasked with designing a gearbox for an industrial conveyor system. The conveyor system needs to transport materials at a speed of $2$ m$/$s with a capacity of $500$ kg per hour. The motor driving the conveyor system operates at $1500$ RPM$.$ The design should include:

$1.$ Selection of an appropriate gear ratio to achieve the desired conveyor speed.

$2.$ Determination of the type of gears to be used $($spur$,$ helical, bevel, etc.$),$ considering factors like load, noise, efficiency, and cost.

$3.$ Calculation of forces acting on the gears, including tangential$,$ radial, and axial forces.

$4.$ Selection of materials for gears and shafts based on strength, fatigue, and wear resistance.

$5.$ Design of shafts to support the gears, including bearings, keyways, and stress analysis.

$6.$ Detailed CAD model of the gearbox, showing the assembly of gears, shafts, bearings, and housing.

$7.$ Consideration of lubrication methods to ensure smooth operation and longevity of the gearbox.

$8.$ Cost analysis for manufacturing the gearbox, including material costs and machining.

Specifications:

$-$ Conveyor speed: $2$ m$/$s

$-$ Load capacity: $500$ kg$/$hr

$-$ Motor speed: $1500$ RPM

$-$ Transmission efficiency: $90\%$

$-$ Gearbox life expectancy: $5$ years under continuous operation Deliverables:

$-$ A detailed report outlining the design process, calculations, material selection, and CAD drawings.

$-$ A CAD model and assembly drawings of the gearbox.

$-$ A presentation summarizing the design choices and demonstrating the operation of the gearbox