Designed a production-ready conveyor gearbox utilizing a compact 8:1 compound spur gear train for efficient power transmission in industrial applications. The project focused on complete gear train design, mechanism analysis, and development of a fully enclosed housing system. All components were modeled in Autodesk Fusion 360, incorporating GD&T and ISO fit standards to ensure precision, interchangeability, and manufacturability.
Executed the full mechanical design cycle, including shaft design, bearing selection, and detailed fatigue and deflection analysis to meet a targeted five-year service life. Performed bearing load evaluation and bolt preload calculations to ensure structural integrity under operating conditions. Designed CNC-machined shafts and housing components while prioritizing stock parts to optimize manufacturing efficiency. Applied DFM/DFA principles to simplify machining, streamline assembly, and support maintenance. Conducted finite element analysis (FEA) to validate housing performance, confirming minimal deflection under load, and produced comprehensive engineering drawings, tolerance schemes, and cost analysis for large-scale production.
Delivered a fully validated gearbox design meeting all performance, durability, and geometric constraints, achieving extremely low shaft deflection and reliable structural performance. The design demonstrated scalability for a 5000-unit production run, with detailed cost analysis identifying opportunities for further optimization through component selection. The final outcome highlights strong competency in gear train design, FEA, GD&T, and DFM/DFA, along with the ability to balance performance, manufacturability, and cost in industrial mechanical systems.
