A new and generalized methodology to design multi-stage gear drives by integrating the dimensional and the configuration design process

This paper proposes a new and generalized design methodology to support the designer at the preliminary design phase of multi-stage gear drives. The proposed design methodology automates the design process by integrating the dimensional design and the configuration design processes in a formalized algorithm. The algorithm consists of four steps. In the first step, the user provisionally sets the number of reduction stages. In the second step, gear ratios of every stage are chosen by using the random search method within the specified ratio range, and the ratios are used as the basic input for the dimensional design of gears in the next step. In the third step, the values of the basic design parameters of a gear are chosen by using the generate and test method. Then the values of other design parameters, such as pitch diameter and outer diameter, are calculated for the configuration design in the final step. In the final step, the configuration design is carried out by using the simulated annealing algorithm. The positions of gears and shafts are determined to minimize the geometrical volume of a gearbox while satisfying spatial constraints. These steps are carried out iteratively until a desirable solution is acquired.