Alexandria Engineering Journal (2022) 61, 4067–4079

H O S T E D BY
Alexandria University

Alexandria Engineering Journal

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Graphical method for the analysis of planetary gear

trains
Adam Marciniec *, Mariusz Sobolak, Piotr Połowniak

Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, al. Powstańców Warszawy 8,
35-959 Rzeszów, Poland

Received 7 September 2020; revised 31 August 2021; accepted 13 September 2021

Available online 23 September 2021

KEYWORD Abstract The main purpose of this paper is to propose a new graphical method for a planetary
Planetary gear train; gear train (PGT) analysis. This is a fully graphical method that determines the rotational speeds
Velocity diagram; of all transmission components, as well as the torque, power flow, power losses, and efficiency of
Torque balance; any PGT. With this method, a sketcher workbench available in any modern computer-aided design
Power flow; (CAD) system can be used. This provides an interactive way to work. Both the construction of the
Efficiency; geometric model and the interpretation of the results are intuitive, which facilitates error identifica-
Idle circulating power tion. Observing the impact of the selected input data or model parameters on the model behavior is
extremely easy and can even be animated. It is believed that the presented method can streamline
the PGT design process.
Ó 2021 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria
University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/
licenses/by-nc-nd/4.0/).

1. Introduction ance; meshing and bearing losses; power flow including the
losses; and the efficiency are determined. These quantities form
Planetary gear trains (PGTs) possess the advantages of com- the basis for initiating the design and performing strength
pact size, low weight, high reduction speed ratio, high effi- calculations.
ciency, and differential drive capability. With these Both the synthesis and analysis of PGTs, characterized by
advantages, PGTs are widely used in the automobile, aero- the presence of the moving axes, are much more difficult than
space, and engineering industries. PGTs have recently been those of ordinary gears, whose axes are all stationary. For this
applied to wind-power generation, safe robotic manipulation, reason, numerous specialized synthesis and analysis methods
and hybrid vehicles. dedicated to PGTs have been developed.
During the process of synthesis and analysis, such quanti- Buchsbaum and Freudenstein [1] introduced graph theory
ties as the transmission ratio; shaft torque; loss-free power bal- into the synthesis process of geared kinematic chains, which
has become an extremely popular tool for the synthesis and
analysis of PGTs. Freudenstein [2] proposed the concepts of
* Corresponding author.
rotation and displacement graphs for use in PGTs. Ravisankar
E-mail addresses: [email protected] (A. Marciniec), msobolak@prz. and Mruthyunjaya [3] redefined closed rotation and displace-
edu.pl (M. Sobolak), [email protected] (P. Połowniak).
ment graphs, presented a computerized method based on
Peer review under responsibility of Faculty of Engineering, Alexandria
graph theory, and used a matrix representation to derive the
University.
https://doi.org/10.1016/j.aej.2021.09.036
1110-0168 Ó 2021 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
4068 A. Marciniec et al.

PGTs. Tsai at al. developed a generation method to synthesize ing at individual gear stages are appropriately assembled to
one degree-of-freedom (1DOF) and 2DOF PGTs [4–7] and form multi-node levers representing a multi-stage gear. Such
applied the idea of fundamental geared entities to analyze a representation allows for an intuitive way of working and
and sketch the PGTs [8,9]. Kim and Kwak [10] applied edge an easy interpretation of existing relationships [40]. However,
permutations to identify non-isomorphic graphs of PGTs. it requires the formulation of analytical systems of equations
Olson et al. [11] defined a coincident-joint graph for topologi- and their solutions.
cal analysis of 1DOF PGTs. In addition, Shin and Krishna- Similarly, Esmail [41,42] applied nomographs of PGTs to
murthy [12] developed an algorithm and a program for visualize the angular speed, torque, power, and power flow
structural synthesis of PGTs. Hsu and Lam proposed a graph direction. And here again, to obtain a solution, it is necessary
representation using polygons to denote multiple joints [13,14], to formulate analytical equations.
which enables the automatic analysis of the kinematic struc- Summarizing this review, numerous specialized synthesis
ture of PGTs and the detection of the structural isomorphism and analysis methods dedicated to PGTs have been developed,
[15–19]. Liu and Chen [20] and Liu and coworkers [21] intro- some of which cover only a part of the problem; e.g., the kine-
duced the idea of a kinematic unit to the topological and kine- matics. The vast majority are difficult to use, requiring the
matic analysis of geared mechanisms. Rao at al. [22–24] application of a complicated mathematical apparatus, being
applied the genetic algorithm and a Hamming string to inves- deprived of an intuitive approach in the model building and
tigate the isomorphism and generate PGTs. Del Castillo [25] causing difficulties in interpreting the results. As PGTs become
and Salgado and Del Castillo [26] developed new methods increasingly complex; e.g., those used in the multi-speed auto-
for the detection of degenerate structures and a graph repre- matic transmissions of modern cars, there is a need for simpler
sentation having three rows to synthesize PGTs without idle tools during the design process.
links. Ding and Yang et al. [27–29] proposed the use of unified This paper proposes a new method for a planetary gear
graph representations for planar kinematic chains, including analysis. The method is fully graphical and determines the
simple joints, multiple joints, and PGTs. Xie et al. [30] synthe- rotational speeds of all transmission components as well as
sized seven-speed PGTs with a high reduction speed ratio torque, power flow, power losses, and efficiency of any PGT.
based on six-speed PGTs. Ngo and Yan [31] presented an With this method, it is used a sketcher workbench available
approach to synthesize parallel hybrid transmissions consisting in any modern computer-aided design (CAD) system. In this
of two PGTs. Currently, it can be noticed that the dominant way, a gear train model in the form of a geometric apparatus
part of the research papers focuses on the issues of synthesis is built from basic geometric objects with combined geometric
[32–34] and analysis [35,36] of complex multi-stage multi- constraints and dimensions as well as equations expressing the
DOF PGT transmissions for hybrid electric vehicles or electric relationships among parameters. The aforementioned geomet-
vehicles. ric apparatus is a set of interrelated flat mechanisms with
A literature survey revealed that the representation of defined degrees of freedom, input data, and unknowns, in
PGTs employing graph theory has been a common utility for which most of the relationships are formulated using triangle
a systematic structure and kinematics analysis. The result is similarity. From the perspective of a mathematical model,
a system of equations that are solved by numerical methods. the stated geometric apparatus represents a system of nonlin-
Numerical methods by their nature have a specified accuracy ear equations in which the dimensions are variables; the equa-
to the solutions and a need for proper interpretation of the tions are those of geometric objects, such as a line segment and
results. This is not always an easy task because numerical relations expressed by means of geometric constraints; the
methods do not provide insight into the essence of occurring input data are the driving dimensions; and unknowns are the
phenomena and their existing relationships. However, once driven dimensions. The sketcher is simply a solver of this sys-
created, the system of equations can be repeatedly used for tem of equations applied in real-time, and presents a solution
various input data. on the computer screen in the form of the current geometric
By contrast, other methods are more intuitive and illustra- arrangement. This provides an interactive way of working.
tive and give insight into the relationships that exist in a gear The accuracy of the model and the results are extremely high
train. These methods include graphical and graphical- and virtually independent of the size and complexity of the
analytical approaches, each of which has its advantages and PGT model. Both the construction of the geometric model
disadvantages as well as a limited range of use. and the interpretation of the results are intuitive, allowing easy
For example, the very illustrative and clear method devel- identification of errors. Observing the impact of the selected
oped by Kutzbach [37] is only used to determine the speed input data or the model parameters on the model behavior is
of the individual components and thus, the transmission ratios. extremely easy and can even be animated.
Its accuracy is also limited and decreases with an increase in The remainder of this paper is structured as follows. In Sec-
the gear complexity. In the case of multi-stage gearboxes, the tion 2 introductory information on how to use CAD sketcher
method implemented through a conventional paper-and- to create geometric apparatus for determining kinematic and
pencil approach is virtually useless. In addition, a new velocity static relationships in a gear pair is provided. In Section 3,
diagram should be drawn up for each case. basic objects in the form of fundamental gear pairs (FGP)
Helfer’s lever model method [38,39] is particularly useful are presented, from which the PGTs are constructed, and the
during the synthesis process and is a graphical-analytical geometrically defined relations describing the speed, torque,
method. The relationships between the speed and torque are and power flow are defined.
expressed using an analogy to a lever and are represented Section 4 presents a simple PGT with a negative base trans-
graphically, whereas the results are obtained through analyti- mission ratio and its relationships. This is the basic object for
cal equations derived from these relationships; e.g., equations the construction of multi-stage planetary gears. Section 5
of static equilibrium. Levers representing simple gears appear- describes a simple PGT with a positive base transmission ratio
Graphical method for the analysis of planetary gear trains 4069

and investigates some of its special use cases that illustrate the values are of opposite signs when the segments are directed
occurrence of the circulating power. Section 6 provides two to the opposite sides of the lever. The geometric construction
examples of the proposed method application. One is an anal- in Fig. 1a implements Eq. (3). Here, the parameters r1 and r2
ysis of an aviation transmission with a power split and a veri- are represented by the segment lengths: 2–3 and 1–3, respec-
fication of the value of the determined efficiency, based on the tively. The angular velocity at node 2 is read as a driven dimen-
results of a matrix method available in the literature. The other sion for a given value at node 1. Geometric constraint symbols
is the synthesis and kinematic analysis of Simpson gear train. are shown: fix, horizontal, vertical, equal. The small squares
indicate the endpoints coincidence constraints. The geometric
2. Basic information about creating CAD sketches construction in Fig. 1b implements Eq. (4). Here, the parame-
ters r1 and r2 are represented by the segment lengths: 1-X3 and
The sketcher workbench is a CAD tool for creating two- X3-2, respectively. The torque at node 2 is read as a driven
dimensional sketches on planes. A sketch is created by drawing dimension for a given value at node 1. That construction is
geometric elements such as points, lines, circles, arcs and for the value only, not for the sign. Correct direction of the
applying constraints to control them. There are geometric con- segment 2-T2 is shown in Fig. 1c in which both Eqs. (4) and
straints and dimensional constraints. Geometric constraints (6) are implemented. The following applies: the torque in the
affect the orientation of the geometry (horizontal, vertical) inner node is equal to the sum of the torques in the extreme
or the relationship between sketch geometry (e.g. parallel, per- nodes. The summation operation is performed by means of
pendicular, coincident, equal). Normal dimensional constraint an additional diagonal line hooked at point 1 and parallel to
are parametric dimensions that determine the size of sketch the existing one. The torque value at node 1 is transferred
geometry – they ‘‘drive” the geometry. Driven dimensions, along these two parallel lines to the right side to node 2 where
conversely, are nonparametric dimensions that show the cur- it is added to the torque at that node. Eq. (7) expressing the
rent value of geometry. Driven dimensions, which appear power balance with no losses is realized by means of the geo-
enclosed in parentheses in the graphics window, allow sketch metrical apparatus shown in Fig. 1d. The value of the power at
geometry to dynamically respond to associated changes. node 1 is the product of the segments: 1-W1 and 1-T1 dimen-
Below, some simple examples of geometrical constructions pre- sions divided by the scale length of 5 mm for uniformity of
pared with the sketcher of Inventor CAD system are shown. In units. Correspondingly for node 2. At node 1 the power is pos-
Fig. 1 there are presented four geometrical constructions rep- itive (input) because the directions of the segments 1-W1 and
resenting four mathematical relationships which apply for an 1-T1 are consistent. At node 2 the directions are opposite,
external gear pair EGP (Fig. 2b). In each case, EGP is modeled therefore the power is negative (output). It is a good idea to
as a horizontal, 3-node lever, where the nodes represent respec- adopt a color system to mark the segments, e.g. green - input,
tively: 1- an input gear, 2 - an output gear, 3 - an arm. The red -output, black - reaction (T3). If this is not possible, the
lengths of vertical segments express the values of the following arrows can be used.
quantities: angular velocity -w, torque -T, and power -P. The This is only introductory information on how to use CAD
sketcher to create geometric apparatus for determining kine-

Fig. 1 Geometrical constructions representing four mathematical relationships which apply for an external gear pair EGP: (a) Eq. (3),
(b) Eq. (4), (c) Eq. (4) and (6), (d) Eq. (7).
4070 A. Marciniec et al.

Fig. 2 Fundamental gear pairs: (a) external and (b) internal gear pairs.

matic and static relationships in a gear pair. A similar principle k ¼ ji0 j: ð2Þ
can be used to build geometric apparatus for the synthesis and From Fig. 2, for meshing point C, the following relation-
analysis of complex PGTs or the application of the Kutzbach ships can be written as follows for the angular speeds and
method. torque:
x1 x2 x1 x2
vC ¼ x1 r1 ¼ x2 r2 ; ¼ ; ¼ ; ð3Þ
3. Fundamental gear pairs r2 r1 k 1

T1 T2 T1 T2
In the construction of gears, basic objects called fundamental F¼ ¼ ; ¼ : ð4Þ
r1 r2 1 k
gear pairs (FGP) can be distinguished and can take the form
of an external gear pair (EGP) or an internal gear pair (IGP) Furthermore, for each FGP, three equations apply:
depending on the type of meshing, as shown in Fig. 2. They
consist of gear 1, gear 2, and arm 3, ensuring a constant dis- (a) kinematic equation (Willis equation [43]),
tance between the axes of the mating gears. When the arm is
fixed, it refers to an ordinary gear pair (OGP). If the axis of x1  x3
i0 ¼ i12 ¼ ; ð5Þ
rotation is defined for the arm at point A or B, then we have x2  x3
a mechanism consisting of three links connected by three rota-
tional joints and one meshing type joint. If all three links are (b) torque balance condition,
movable, the mechanism has 2 degrees of freedom (2 DOF).
There can then be two inputs and one output creating a sum- T1 þ T2 þ T3 ¼ 0; ð6Þ
mation mechanism, or one input and two outputs creating a
differential. When one of these members is immobilized, the
mechanism has 1 DOF. Further, in this paper, only mecha- (c) power balance (without losses),
nisms with 1 DOF will be considered. Each of the members
may be the input or output providing all six cases with six P1 þ P2 þ P3 ¼ T1 x1 þ T2 x2 þ T3 x3 ¼ 0: ð7Þ
transmission ratios. If the direction of the angular velocity and the torque are
The basic characteristic of a gear pair is the base transmis- the same, then the power has a positive sign and is the input
sion ratio defined as the kinematic gear ratio with arm 3 fixed: power, whereas if they are opposite, then the power has a neg-
x1 r2 d2 z2 ative sign and is the output power.
i0 ¼ i12 ¼ ¼ ¼ ¼ ; ð1Þ Fig. 3aa presents a geometric way to implement the princi-
x2 r1 d1 z1
ple expressed in Eq. (4) in the context of the torque of gears
where with EGP and IGP meshing.
Similarly, Fig. 3a shows a geometric approach to imple-
x is the angular speed, ment the principle expressed in Eq. (3) when the arm is station-
d and r are the diameter and radius of the reference circle, ary; i.e., x3 ¼ 0, with respect to the rotational velocities of the
respectively, and EGP and IGP.
z is the number of teeth. In Fig. 3b and c, Eq. (5) has been analogously considered
for the cases in which x2 ¼ 0; i13 ¼ 1  i0 and
For an internal gear, the number of teeth and diameters are x1 ¼ 0; andi23 ¼ 1  1=i0 . The corresponding support in point
taken as negative. A (Fig. 2) is released. Considering that ikj ¼ 1=ijk , six FGP
Thus, the EGP provides negative basic transmission ratios work cases are provided.
i0 ðÞ, whereas IGP provides positive base transmission ratios The case shown in Fig. 3d is unique. By blocking any two
i0 ðþÞ. components, the mechanism is no longer a transmission but
To build a geometric model, where the dimensions cannot operates like a coupling in which the input and output veloci-
be negative, the characteristic factor of the gear pair is defined ties are the same, and the torques have equal values but in
as follows: opposite directions.
Graphical method for the analysis of planetary gear trains 4071

Fig. 4 Power flow diagrams for EGP and IGP when fixing (a)
link 3, (b) link 2, and (c) link 1, and (d) when any two components
are permanently connected; i.e., in coupling operating mode.
Fig. 3 Diagrams (aa) for determining the torques for EGP (left
side) and IGP (right side) and diagrams of angular velocities when
fixing (a) member 3, (b) member 2, or (c) member 1 and when (d)
any two members are permanently connected; i.e., coupling A distinction is made between different types of power in
operation mode. the gear pair. Case (a) shows an OGP in which all power flows
through the meshing, and thus all three elements are involved.
Torque balance systems (Eq. (6)) for the EGP and IGP Therefore, the flow of power is marked with a polyline 1–3-2,
gears shown in Fig. 3aa are independent of the kinematics. thus distinguishing the meshing power. In case (b), ring gear 2 is
For the EGP, the summing member is arm member 3, and fixed, and the power flow is from 1 to 3. For the EGP, this case
the torque value is as follows: can be considered as a superposition of two transmission
T3 ¼ T1 þ T2 ¼ ð1 þ kÞT1 ; ð8Þ modes: coupling and meshing modes. In coupling mode, all
three elements rotate at the same speed x3 and the coupling
whereas for IGP, the summing member is member 2; i.e., an power flows from 1 to 3.
internal gear, where
P1c ¼ T1 x3 ¼ P3c ð10Þ
T2 ¼ T1 þ T3 ¼ T1 þ ðk  1ÞT1 ¼ kT1 ð9Þ
In meshing mode, there is a relative movement between
Fig. 3aa also shows the geometric method of adding tor- gears 1 and 2 and the meshing power flows through members
ques. As the principle is adopted in the diagrams, the upward 1–2–3.
vector is positive and downward negative. In the sketcher, the
sizes x; T; and k are represented as line segments with the P1m ¼ T1 ðx1  x3 Þ ¼ T2 ðx2  x3 Þ ¼ P2m ¼ P3m ð11Þ
appropriate dimension dx [mm] determined using the assumed
scale factor k; e.g., T1 ¼ kT dT1 , x1 ¼ kx dx1 ; and; k ¼ kk dk . P1 ¼ P1c þ P1m ¼ ðP3c þ P3m Þ ¼ P3 ð12Þ
Similarly, the power P1 ¼ kP dP1 can be represented using One important thing should be noted. In this case, the
dP1 ¼ ðdx1 dT1 Þ=1mm. meshing power is lower than the input power, so the rest of
Based on the dimensions of x and T and their product, the the power flows in the same direction to the output node in
power at each lever node can be determined based on the prin- the form of coupling power. The meshing power at node 2 is
ciple that, with consistent directions, the power is positive (in- a strictly internal power that flows only through node 2 from
put), and with opposite directions, the power is negative node 1 to node 3 in the 1–2–3 loop. This power is not mani-
(output). One can then determine the power flow diagram in fested on the outside of the gear pair - link 2 is fixed.
the gear pair. Fig. 4 shows diagrams corresponding to the For the IGP case b), the angular velocity of arm 3 is direc-
velocity diagrams in Fig. 3. ted opposite the input speed of gear 1. Therefore, the meshing
4072 A. Marciniec et al.

power P1m ¼ T1 ðx1  x3 Þ will be greater than the input power lever EGT and IGT based on the fact that nodes 3 and p are
P1 , which is equal to the output power P3 . common. The application of Thales’ theorem for given k1
The surplus power is as follows: and k2 makes it possible to determine the lengths of 3 segments
P1m  P1 ¼ Pid ð13Þ between 4 nodes of the lever.
The advantage of this representation is the ability to deter-
This is called idle power or circulating power because it flows mine the angular velocities (Fig. 6b) of all members, including
in a closed loop between the members 1–3–2–1. The appear- the planet’s velocity. Knowing this velocity is important when
ance of circulating power is unfavorable because it causes determining the planetary bearing losses that affect the
overloading, an increase in losses, and a decrease in efficiency. amount of planetary gear loss.
The circulating power is a strictly internal power flowing The node p is a free node. It is the only node that is not
through the inner loop and is not manifested on the outside attached to the shaft and therefore cannot transmit torque out-
of the gear pair or PGT. ward. So the sum of the torques applied in the node p is zero.
The case shown in Fig. 3c for EGP is analogous to the pre- Hence, in Fig. 6d, the segments Tp in the p nodes belonging to
vious one except that the power flow is between members 2 and EGP and IGP are equal but directed in opposite directions. In
3 with stationary gear 1. In the IGP unit, the power flows from practice, the three-node lever shown in Fig. 6e is most often
3 to 2 in coupling mode. The surplus power appearing in gear 2 used.
creates a 2–1-3–2 circulating power loop in meshing mode. The torque is determined similar to that of the EGP
P2c  P2 ¼ Pid ð14Þ (Fig. 6e). The p node is omitted as an intermediate element,
and it is irrelevant to the external equilibrium conditions of
Case Fig. 3d represents the coupling mode ði0 ¼ 1Þ. There is the transmission with three external shafts. The equilibrium
no relative movement and thus, no loss. conditions occurring inside are shown in Fig. 6d, as are the
The above FGPs are presented as theoretical units for kinematic relationships (Fig. 6c). Carrier 3 plays a role of
building more complex transmission systems. One should be the summation shaft. The torque value on this shaft is as
aware that not all of these cases can be implemented practi- follows:
cally. This applies particularly to cases with moving gear axes.
T3 ¼ T3e þ T3i ¼ T1 þ T2 : ð16Þ
4. Planetary gear train with a negative base transmission ratio For this reason, no circulating power will occur in the PGT
(). The power flow diagram is analogous to that of the EGP
PGTs allow the practical realization of a transmission in which (Fig. 3a). The power flow is better illustrated in the form of a
at least one gear axis is movable relative to the gearbox hous- triangle diagram (Fig. 6h). Although the figure shows a gear-
ing. There are numerous types of planetary gears and methods box working in a multi-path gear mode, it does not diminish
for their classification. To begin, the case presented in Fig. 5 the generality of the considerations regarding the planetary
will be considered. By assembling the two fundamental EGP gearbox.
and IGP gears, a PGT is created, the base transmission ratio
of which is a negative value PGT(). 5. Planetary gear train with a positive base transmission ratio
  
x1 zp z2 z2
i0 ¼ i12 ¼ ¼   ¼ ð15Þ By assembling the two external gear pairs EGP1 and EGP2, a
x2 z1 zp z1
PGT(+) is created, whose base transmission ratio has a posi-
The parts of this gear transmission are named as follows: 1, tive value.
sun gear; 2, ring gear; 3, carrier; and p, planet. For structural   
x1 zp1 z2 z2 zp1
and technological reasons, the transmission ratio for the PGT i0 ¼ i12 ¼ ¼   ¼  ð17Þ
x2 z1 zp2 z1 zp2
() is within 7  i0  1:6.
Fig. 6a shows the geometric construction of a four-node Fig. 7 shows the construction used to create a PGT(+)
lever representing a PGT() composed from two three-node transmission and its structural diagram along with the velocity
diagram created according to the Kutzbach method. This is
also a geometric model created in a sketcher, which allows
observation of the existing kinematic relationships in a
dynamic way. Any changes in the dimensions of the model
are immediately visible on the velocity diagram. This helps in
understanding the essence of such changes.
The content of Fig. 8 is analogous to that in Fig. 6. The
operating principle is analogous to that of the IGP. Fig. 8e
shows a system with an external torque balance of the gear
train, which results in the following torque values:
T2 ¼ T1 þ T3 ¼ T1 þ ðk  1ÞT1 ¼ kT1 : ð18Þ
In addition, the power flow is as shown in Fig. 8g.
However, as indicated in Fig. 8d, when considering that the
output torque is T2 ¼ kT1 , inside the EGP1 unit, a surplus of
torque DT3 occurs that creates an idle circulating power loop
Fig. 5 Scheme for creating a PGT() with a negative base Pid (Fig. 8f). The triangle-shaped diagram (Fig. 8h) better illus-
transmission ratio i0() as an EGP and IGP assembly.
Graphical method for the analysis of planetary gear trains 4073

Fig. 6 Velocity, torque, and power flow diagrams for PGT().

Fig. 7 Scheme for creating a PGT(+) with a positive base transmission ratio i0(+) as an EGP1 and EGP2 assembly and Kutzbach
velocity diagram.

trates the flow of power in the transmission. Fig. 8i shows the mined based on the loss factor related to the efficiency
power flow even more precisely. w ¼ 1  g , the losses generated in the first pair of EGP1 are
Both active and idle power is transferred in the meshing as follows:
mode. The relative movement in the meshing will result in a 00 0
L1 ¼ wPm ¼ wP1 þ wPid ¼ L1 þ Lid ð19Þ
loss. If the amount of loss in the external meshing is deter-
4074 A. Marciniec et al.

Fig. 8 Velocity, torque, and power flow diagrams for PGT(+).

The losses in the second pair EGP2 are as follows: The idle circulating power, composed of the coupling power
0 and the meshing power Pid ¼ Pc þ Pm , is much higher than the
L2 ¼ wP p ¼ wðP1  L1 Þ ð20Þ
active useful power P3In ¼ P1 . This transmission operates
In addition, the efficiency of the entire gear PGT(+) is the with a significant overload and will generate large losses. This
following: transmission will become self-locking when the loss power is
0 greater than the input power.
P2 P1  L P1  ðL1 þ L2 Þ
g¼ ¼ ¼ ð21Þ
P1 P1 P1
6. Examples of application
The geometrical method for determining the efficiency in a
sketcher is shown in Fig. 9. To verify the proposed geometric method of a planetary gear
Fig. 10 shows the application of the proposed geometric analysis, it is useful to determine the efficiency of the aircraft
method for a PGT(+) gearbox analysis with 1DOF, with gear engine power split planetary gear reducer (AEPR). This effi-
2 fixed and the input on carrier 3 and the output on sun gear 1. ciency was calculated in [44] using the method presented
The following ratios were assumed: therein, which consists mainly of a numerical solution of the
   formulated systems of equations. A structural diagram of the
28 28
i0 ¼ k ¼   ¼ 0:7656 transmission is shown in Fig. 11 along with the Kutzbach
32 32
velocity diagram. The gearbox consists of two simple PGTs,
1
i31 ¼ ¼ 4:2666: ð22Þ both PGT(), that form two stages connected according to
1  i0 the topology diagram shown in Fig. 11a.
Graphical method for the analysis of planetary gear trains 4075

Fig. 9 Determination of efficiency for PGT(+).

Fig. 10 Velocity, torque, and power flow diagrams for PGT(+) and i0 < 1.

Ring gear 2 is permanently connected to sun gear 7, and nodes 2 and 7 represent a free node of the assembled PGT
carrier 3 is permanently connected to ring gear 5. Carrier 6 where T7 ¼ T2 and that TT54 ¼ i45
is fixed. The input is to sun gear 4, and the output is from ring On the basis of the dimensions specified in the sketch and
gear 5. The numbers of gear teeth are as follows: recorded with an accuracy of 8 decimal places, the necessary
z2 ¼ z5 ¼ 97; z4 ¼ z7 ¼ 35. Hence, k1 ¼ k2 ¼ ji0 j ¼ 2:771. quantities can be calculated; e.g., the total ratio with the same
The diagram for determining the speed is shown in Fig. 12a. precision is as follows:
The dimensions in the diagram result from the adoption of
the following scale factors, kk ¼ 1=10mm, such that k ¼ kk dk . dx4 20mm
i45 ¼ ¼ ¼ 11:45224490 ¼ 11:452: ð23Þ
The quantities x; T; and P are scaled such that the dimension dx5 1:746mm
dx ¼ 20mm corresponds to 100% of the value of xandP at The input rotational speed is n4 ¼ 12300 rpm. From the
the input and T at the output. It should be remembered that speed diagram, it is easy to calculate that n3 ¼ n5 ¼ 1074 rpm
the dimension of the power P ¼ kP dP for a particular node andn2 ¼ n7 ¼ 2976:58 rpm. These results are consistent with
results from the product of the appropriate dimensions x the results from the Kutzbach speed diagram (Fig. 11c) as well
and T, where dP ¼ ðdx dT Þ=1mm. It is worth noticing that as those published in [39]. Similarly, the values obtained from
4076 A. Marciniec et al.

Fig. 11 Aircraft engine power split planetary gear reducer (AEPR): (a) topology diagram, (b) structural diagram, and (c) Kutzbach
velocity diagram.

Fig. 12 AEPR power flow.

Graphical method for the analysis of planetary gear trains 4077

Fig. 13 Synthesis of Simpson PGT.

Table 1 Gear changing sequence.

Speed Ratio Gear C1 C2 B1 B2
2.837 G1 X X
1.508 G2 X X
1.0 G3 - direct X X
2.619 Reverse X X

the diagrams in Fig. 12b and c. The values are necessary to set the clutch and brake engagement sequence and determine
determine the power flow (Fig. 12d), considering the losses in the speed ratios for each gear (Table 1). The opposite can also
meshing mode and finally the AEPR efficiency, and assuming be applied. Assuming two speed ratios of the three gears, Rev-
that the efficiency of a simple PGT() constituting one trans- erse, G1, and G2, one can determine the values of k1 and k2
mission stage is gI ¼ gII ¼ 0:980. and thus the base transmission ratios. To do this, one need
The overall gear train efficiency is g = 0.93773857, which is to convert two output values of gear ratios to input and two
in accordance with the result given in [44]; i.e., g = 0.938. values of k1 and k2 to be set as output. In the sketcher environ-
Another example of the application of the proposed ment, an appropriate attribute should be set for the dimen-
method is shown in Fig. 13, which concerns a Simpson auto- sions of the respective sections: normal for input, driven for
matic transmission used in passenger cars. Two simple PGTs, output. The analytical formulas for G2 and reverse gear ratios
both PGT(), are connected according to the topological dia- are very simple – these are the ratios of the corresponding sin-
gram shown in Fig. 13a. Two C1 and C2 clutches and two B1 gle planetary gear ratio: 1-st stage PGT (2–3-4)
and B2 brakes are used to change gears. Three forward gears iG2 ¼ 1 þ k11 ¼ 1:529 for the 2-nd gear G2 and 2nd stage PGT
and one reverse gear are available. The basic transmission (5–6–7) iRev ¼ k 2 ¼ 1:889 for Reverse. Deriving the gear ratio
ratios of simple PGTs at stages 1 and 2 provide the following formula for G1 is more difficult because both PGT stages are
characteristic factors: k1 ¼ 68=36 and k2 ¼ 76=32. Fig. 13b coupled. This task is all the more difficult the more PGT stages
shows the mechanism for composing a four-node lever; i.e., are included in the gear unit. In [45] Simpson Gear Train is
2–(3 = 5)–6–(4 = 7), representing the simple PGT of two analyzed and the gear ratio formula for G1 is given as Eq.
levers; i.e., 2–3–4 and 5–6–7. With this lever, one can easily (9). The G1 gear ratio value iG1 ¼ 2:787 obtained here by the
4078 A. Marciniec et al.

graphical method is fully consistent with the value obtained [10] J.U. Kim, B.M. Kwak, Application of edge permutation group
using this equation. Moreover, using the geometric construc- to structural synthesis of epicyclic gear trains, Mech. Mach.
tions for lever G1 from Fig. 13, it is easy to derive the analyt- Theory 25 (5) (1990) 563–574.
ical formula using Thales’s theorem. [11] D.G. Olson, A.G. Erdman, D.R. Riley, Topological analysis of
single-degree-of-freedom planetary gear trains, ASME J. Mech.
1 þ k1 þ k2 i01 þ i02  1 Des. 113 (1) (1991) 10–16.
iG1 ¼ ¼ : ð24Þ
k1 i01 [12] J. Kyun Shin, S. Krishnamurty, Standard code technique in the
enumeration of epicyclic gear trains, Mech. Mach. Theory 28 (3)
This example proves the usefulness of the proposed (1993) 347–355.
method, not only for an analysis of PGTs but also for synthe- [13] C.H. Hsu, K.T. Lam, A new graph representation for the
sizing such gearboxes with a complex structure. automatic kinematic analysis of planetary spur-gear trains,
ASME J. Mech. Des. 114 (1) (1992) 196–200.
[14] C.H. Hsu, K.T. Lam, Automatic analysis of kinematic structure
7. Conclusions of planetary gear trains, ASME J. Mech. Des. 115 (3) (1993)
631–638.
[15] C.-H. Hsu, Displacement isomorphism of planetary gear trains,
This paper presented a new planetary gear train analysis
Mech. Mach. Theory 29 (4) (1994) 513–523.
method. The method is fully graphical and based on the geo- [16] C.-H. Hsu, K.-T. Lam, Y.-L. Lin, Automatic synthesis of
metrical rules, which facilitates determining the rotational displacement graphs for planetary gear trains, J. Math. Comput.
speeds of all transmission components as well as the torque, Modell. Int. J. 19 (11) (1994) 67–81.
power flow, power losses, and the efficiency of any PGT. Using [17] C.H. Hsu, Y.C. Wu, Automatic detection of embedded structure
this method, a sketcher workbench available in any modern in planetary gear trains, ASME J. Mech. Des. 119 (2) (1997)
CAD system can be used. This provides an interactive way 315–318.
of working. The accuracy of the model is extremely high and [18] C.-H. Hsu, J.-J. Hsu, An efficient methodology for the structural
the results are virtually independent of the size and complexity synthesis of geared kinematic chains, Mech. Mach. Theory 32
(8) (1997) 957–973.
of the PGT model. Both the construction of a geometric model
[19] C.H. Hsu, An analytic methodology for the kinematic synthesis
and the interpretation of the results are intuitive, facilitating
of epicyclic gear mechanisms, ASME J. Mech. Des. 124 (3)
the identification of errors. The presented graphical method (2002) 574–576.
was shown to be an effective tool for analyzing 1 DOF PGTs. [20] C.P. Liu, D.Z. Chen, On the application of kinematic units to
the topological analysis of geared mechanisms, ASME J. Mech.
Des. 123 (2) (2001) 240–246.
Declaration of Competing Interest [21] C.-P. Liu, D.-Z. Chen, Y.-T. Chang, Kinematic analysis of
geared mechanisms using the concept of kinematic
The authors declare that they have no known competing fractionation, Mech. Mach. Theory 39 (11) (2004) 1207–1221.
financial interests or personal relationships that could have [22] V.V. Prasad Raju Pathapati, A.C. Rao, A new technique based
appeared to influence the work reported in this paper. on loops to investigate displacement isomorphism in planetary
gear trains, J. Mech. Des. 124 (4) (2002) 662–675.
[23] A.C. Rao, A genetic algorithm for epicyclic gear trains, Mech.
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