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This paper presents an approach that provides optimization of both gearbox kinematic arrangement and gear tooth geometry to achieve a high-density gear transmission. It introduces dimensionless gearbox volume functions that can be minimized by the internal gear ratio optimization. Different gearbox arrangements are analyzed to define a minimum of the volume functions. Application of asymmetric gear tooth profiles for power density maximization is also considered.
When a gear set is to be designed for a new application, the minimum size gears with the required capacity are desired. These gears must be capable of meeting the power, speed, ratio, life, and reliability requirements.