# Gearbox design-Is this design possible to make the output shaft thin?

• a61098417
In summary, the conversation discusses different design options for supporting an output shaft in a belt drive system. The importance of proper alignment and bearing placement is emphasized, as well as the need to consider factors such as power, RPM, torque, and belt tension. Various solutions, such as using a flexible coupling or additional support pulleys, are suggested to address potential issues with shaft diameter. Careful alignment is stressed as a crucial factor in maximizing the lifespan of the system.
a61098417
TL;DR Summary
The output shaft of the gearbox undergoes torque and bending force(tensile force of the belt)(I use belt after gearbox). If I mount/fix the pulley on other things instead of the output shaft, the belt won't bend the shaft. Thus, the output shaft gets torque only. Is my design correct?
Is this design correct?

Welcome to PhysicsForums. Can you post a drawing or picture of your arrangement, and comment on what kind of bearings you are using at each joint? You can use the "Attach files" link below the Edit window to upload PDF or JPEG files.

Lnewqban and Dr.D
a61098417 said:
Is this design correct?
There are many solutions. There is no one correct design.

Where an additional bearing is provided, it must be positioned and aligned correctly, or it will not carry the required forces without increasing stresses in the shaft. Will you have a flexible coupling between the gearbox and the pulley shaft?

The problem with supporting the output shaft on both sides of the belt pulley is that you are restricted to a mounting that enables you to change the belts quickly, without special tools.

What does the belt drive? A compression strut, floating in spherical self-aligning bearings, between two shafts, can counter the belt tension, while making it possible to change the belt quickly.

Specify the power to be transmitted.
Specify the RPM of the output shaft.
Compute the torque in the shaft.
Specify the pulley diameter and the tension in the belt.

The minimum possible shaft diameter to consider must satisfy that torque requirement.
Now analyse the bending due to belt tension with one or two support pulleys.

Lnewqban and berkeman

## 1. Can a thin output shaft be designed for a gearbox?

Yes, it is possible to design a gearbox with a thin output shaft. However, the feasibility of this design will depend on various factors such as the torque and speed requirements, material selection, and manufacturing capabilities.

## 2. What are the advantages of having a thin output shaft in a gearbox?

A thin output shaft can reduce the overall weight and size of the gearbox, making it more compact and efficient. It can also improve the performance and reduce the cost of the gearbox.

## 3. Are there any limitations to designing a thin output shaft for a gearbox?

Yes, there are some limitations to consider when designing a thin output shaft for a gearbox. These include the torque and speed limitations, material strength, and potential vibrations or deflections that may affect the performance of the gearbox.

## 4. What materials are suitable for a thin output shaft in a gearbox?

The material selection for a thin output shaft in a gearbox will depend on the specific requirements and limitations of the design. Some commonly used materials include high-strength steel, aluminum, and carbon fiber composites.

## 5. How does the design of a thin output shaft affect the overall performance of a gearbox?

The design of a thin output shaft can significantly impact the overall performance of a gearbox. A thinner shaft can reduce the weight and inertia, leading to faster acceleration and improved efficiency. However, it can also affect the strength and durability of the gearbox, so careful consideration must be given to the design and material selection.

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