Gearbox Design for Train Engine Upgrade

Train engines with rated speed of 900 rpm are being replaced with modern engines with rated speeds up to 1800 rpm for improved emissions and fuel economy. The train is propelled by a diesel/electric power system with a diesel engine driving an alternator or generator. An electric motor at each of the multiple wheels provides power as needed for different loads and grades. Trains may stretch a mile long and may weigh 10 million to 20 million pounds so propulsion force varies greatly with grade. A gearbox may be placed between the new 1800 rpm engine and the old 900 rpm generator to maintain the generator/alternator speed. The new engines are smaller than the old 900 rpm engines, which will allow space to install this new gearbox. Full details of this project are provided in the DP2: Gearbox Design folder in Canvas.

You will be responsible for two submissions in this project, and you will submit each to the same assignment here in Canvas.

Submission 1
You will need to complete the gear design sheet (pg. 3 in SoW) and have it approved before you can move on to the second part of this project. Your group should have Submission 1 completed no later than July 27.

Submission 2
The remainder of the design process upon approval of your gear design entails determining (iteratively) the forces on the bearings so you can select the correct bearings (using hours of life) then size your components for the shaft (shaft size, key size, etc.). An example of Submission 2Download example of Submission 2 is provided in the project files; you are not limited to the format of this example, but your submission should provide clear sections on the requested information.