Challenge

Design a large rotating powertrain for an industrial product in which the main shaft (∅150mm) was subjected to demanding combinations of torque, bending and cyclic loading. The design also required integration of the shaft with the transmission, bearing system, supporting structure and geared electric drive.

Engineering Approach

The main shaft and surrounding powertrain were developed as an integrated mechanical system. Work included shaft sizing and detailed geometry, bearing selection and arrangement, gearing, structural interfaces and coupling systems. Particular attention was given to load paths, stress concentrations, fatigue life, bearing loads, shaft deflection and the interaction between the shaft and surrounding components. Stress and fatigue analysis, supported by FEA where appropriate, was used to develop and verify the shaft and critical structural interfaces. Bearing arrangements and lubrication requirements were developed to provide reliable operation under the combined operating loads.

Outcome

The completed powertrain was manufactured and tested before being released into production, where it performed successfully in service.