Requirements

Analysis

This project is directed towards making a more automated procedure for delaminating the carbon fiber boards. The initial proposed design consists of a gear train to help deliver the power needed for crushing the boards.     (Appendix A. fig 9-10)

The electric motor is mounted below the frame of the machine directly underneath gear box number 1. To accommodate an additional gearbox, the motor needed to be rotated 90 degrees within the existing frame. (Appendix A. fig 13-14)

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The connection is made by a sprocket on the output shaft of the motor, and the input shaft of the gear box. These two components are connected by a roller chain. (Appendix A. fig 5)

Following the power flow, the output shaft of gearbox number 1 is coupled to gearbox number 2. This coupling connection is made by using a flexible roller chain coupling.

Afterwards the power is transmitted through gearbox number 3 to a spur gear that is attached to the output shaft. The spur gear meshes with the bottom spur gear of the roller crusher shaft. This shaft in turn meshes and synchronizes with the upper roller crusher shaft. (Appendix A. fig 7-8 , 12)

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Using the calculated output torque, force analysis (Appx A. fig 7) was conducted on the gearbox number 2 output shaft spur gear. The analysis showed that the tangential force, the driving force for the gear, would be approximately 9542.7 lbs. Following this calculation, a spreadsheet (Appx A. fig 8) was used to determine the bending and contact stress of the gears on the crusher shaft would experience. It was found that the force far exceeded the yield strength of any material for the gears at 4,746,173 psi bending stress.

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The spur gears were redesigned to handle the maximum torque of the system. A spreadsheet (Appx A. fig 12) was used to calculate the dimensions and stresses in the spur gears. The analysis shows that the maximum contact stress on the spur gear teeth would be 165,352 psi.

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