Design and Analysis of a Shaft Mounted Speed Reducer for Efficient Variable Speed Transmission

Nilam Baburao Pawar; S S Patil

Design and Analysis of a Shaft Mounted Speed Reducer for Efficient Variable Speed Transmission

Author(s)	Ms. Nilam Baburao Pawar, Prof. Dr. S S Patil
Country	India
Abstract	Conventional worm gear speed reducers are widely used for obtaining high reduction ratios; however, their performance is often limited by low transmission efficiency, excessive frictional losses, and heat generation under self-locking operating conditions. This study presents the design, structural analysis, fabrication, and experimental validation of a shaft-mounted speed reducer (SMSR) based on an eccentric internal–external gear mechanism for efficient variable-speed transmission. The proposed mechanism enables speed variation through modification of eccentricity while maintaining a compact and directly mountable configuration. Mechanical design of critical components, including shafts, sleeves, and gear elements, was carried out using ASME design standards and validated through finite element analysis (FEA). Stress and deformation results obtained from ANSYS confirmed that all components operated within permissible material limits under the prescribed loading conditions. A prototype of the SMSR was fabricated and experimentally evaluated using a rope brake dynamometer. The experimental investigation verified stable torque transmission, effective speed reduction, and satisfactory operational performance under varying load conditions. The analytical, numerical, and experimental results showed close agreement, confirming the reliability of the proposed design methodology. Compared with conventional worm gear arrangements, the developed SMSR demonstrated improved transmission efficiency, lower power losses, reduced installation space, and enhanced flexibility in speed-ratio modification. The proposed design offers a practical and energy-efficient solution for low- and medium-power industrial applications requiring compact and adaptable speed reduction systems. The developed prototype achieved a maximum transmission efficiency of 87.4%, while the maximum equivalent stress and deformation were limited to 42.6 MPa and 0.031 mm, respectively. Experimental results showed a 28% improvement in efficiency compared with conventional worm gear reducers.
Keywords	Shaft-mounted speed reducer, eccentric gear mechanism, variable-speed transmission, finite element analysis, transmission efficiency, power transmission.
Field	Physics > Mechanical Engineering
Published In	Volume 8, Issue 3, May-June 2026
Published On	2026-06-13

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CrossRef DOI prefix of IJFMR is 10.36948/ijfmr

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Design and Analysis of a Shaft Mounted Speed Reducer for Efficient Variable Speed Transmission

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