Optimizing Gear Engineering Boosts Accessibility for Agricultural Vehicles
- Significant cost reduction achieved by updating the gear train through gear engineering without replacing the gearbox
A leading agricultural vehicle manufacturer turned to Srushty for gear engineering solutions to improve accessibility. Their existing product required power control adjustments to enhance ease of use, particularly for older users. To make the vehicle more accessible for everyone, these critical adjustments were necessary.
Objective
Srushty ES was tasked with utilizing gear engineering to enhance user accessibility, reduce speed, and minimize the weight of a specific gear in a machine part, with power control adjustments implemented. The primary objective is to redesign the gear for agricultural equipment to achieve a speed of 8-10 km/ph. This approach aims to facilitate easy usage while concurrently pursuing a cost-effective design and development of the products.
Solution
To address the challenges, a meticulous approach was taken to optimize the 3D model. This involved using specialized software to reduce polygon counts while preserving the integrity of the shapes. The final model was then converted to GLB format, ensuring efficient storage and loading.
Our Process
- Created a detailed specification outlining the attributes of gears, shafts, outer casing, and clutches, providing clear design guidance using gear engineering principles.
- Developed a user-friendly gearbox design focused on optimal performance and easy control, especially for older users, prioritizing simplicity and accessibility.
- Performed calculations and analysis on various outputs, with a focus on achieving the correct RPM.
- Determined the necessary torque for different tasks in the paddy cycle and built a high-quality prototype to ensure smooth functionality.
Key Challenges in Gear Engineering
Performing gear calculations, optimizing vendor selection for cost reduction, and designing castings are integral aspects of the overall process, ensuring efficiency and cost-effectiveness in production. These tasks contribute to streamlined operations and enhanced product design.
Implementation & Solution
The team at Srushty ES, examined various outputs to choose the necessary RPM and torque for progression. We employed JIS B 0401 standards for fitting and tolerance, followed by machining a prototype to assess the mechanism.
Impact
Significant cost reduction was achieved by updating the gear train without replacing the gearbox
Designed for small farms, this product ensures viability with minimal fuel dependence and empowers farmers with self-maintenance, offering an intuitive user experience