The multi-speed internal gear hub of a bicycle is a well-closed gear shifting system that works perfectly under any challenging riding environment, and is developed specifically to improve fragile chain-drive derailleur using planetary gear trains. In recent years, bicycle internal hub gears have been developed toward multi-speed transmission, and in the development process of internal gear hubs, the structure of speed changing mechanism has changed from a single planetary gear train to multiple planetary gear trains, and is becoming more complex. The primary purpose of this Study aims to establish a systemized and efficient design process, and develop an effective theory and method for designing multiple-speed internal gear hubs with the design concept and common features of multiple-speed internal gear hub products developed in recent years, to favor the innovation and development of internal gear hubs. First, existing multiple speed internal hub products are analyzed and summarized for their basic features, limitations, and demands as the reference for the design of multiple speed internal gear hubs, and a catalog of usable planetary structures is systematically established with the coupling and connection of basic high and low ratio speed changing modules. Secondly, usable planetary structures that offer best performance of geometric progression speed ratio distribution of gear hub are matched with gear positions, and a table of gear sequence is confirmed; third, based on the maximum external diameter required by design, tooth numbers for every gear in a hub are defined according to the relationship between tooth number and speed ratio, as well as the gear sequences; and finally, the systematic design process above is applied to the development of an easy-to-use computer aided design software with the lowest possible number of variables using Visual Basic 6.0 for designers, in order to favor the innovation and development of internal gear hubs.

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The subject of this study is a proposal to streamline the production process of gear with internal gear. At the beginning of the thesis are described some types of gearing. The second chapter is focused on the analysis of manufactured part and workplaces for production. The third chapter contains description of technological methods of gearing production by conventional and unconventional methods. The main point of this work is a proposal of innovation of the production process of gearing production. In conclusion, technical-economic evaluation including a comparison of existing and newly designed solutions.

<p dir="ltr">This research developed a lumped volume-based coupled simulation model for gear pumps and motors, which is employed to analyze a reference machine of a compensated crescent- type internal gear pump. The model is composed of simultaneous simulations of the pump fluid domain pressure, lubricating films, and dynamics of the moving components.</p><p dir="ltr">The simulation model developed includes four major novel contributions.</p><p dir="ltr">1. A coupled simulation model was developed for the reference machine which provides (a) a lumped parameter simulation of the fluid pressure within the inter-teeth volumes, (b) CFD simulations of the lubricating interfaces, and (c) a simulation of the micromotion of the pressure compensating components and gear bodies. The simulation tool is developed in C++ and constitutes the simulation core of Multics for internal gear pumps. The model achieved volumetric and mechanical predictions for the reference type of machine, which are validated via experimental investigations.</p><p dir="ltr">2. A flexible pressure solver was established to solve the pressure transience in the fluid domain in gear pumps with general CV geometry exemplified in the reference machine. The approach allows for ample freedom in defining control volumes, including possible volume discontinuities. The new formulation, derived from mass conservation, avoids the numerical evaluation of the volume derivatives so that it allows for simulating a control volume layout with sudden shape changes. The new formulation also considers the sliding motion from volume boundaries when evaluating internal flows, which improves the accuracy of the control volume pressure solutions. The effectiveness of the proposed formulation was examined by applying the method to the simulation of the reference machine. Compared with the state-of-the-art simulations, several improvements in the pressure simulation were observed : (i) the proposed formulation provides free-of-spike fluid pressure simulations, even for discontinuous volumes; (ii) the proposed formulation properly captures the flow component between volumes that is caused by the volume boundary motions, a term previously neglected, which affects the pressure evaluation accuracy, especially in gear meshing zone.</p><p dir="ltr">3. The swift film coupling algorithm proposes a novel artificial inertia damping-based method (AIDM) to simulate this coupling. The proposed method considers modifying the physical body dynamics with artificial inertia and damping values that could achieve significant numerical solver accelerations while maintaining extremely low errors. The artificial inertia and damping are determined based on the instantaneous physical system’s Jacobian so that the first-order dynamics in the solution can be conserved from the original dynamic system. The solver acceleration capability is quantified in time-discretization-based derivations, where additional guidelines for determining the artificial inertia and damping values are found. The proposed approach is used to simulate two model problems for a 1-D slider pad under periodic loading conditions, where one pad is fixed inclined and the other free to move vertically and rotate about its center. Simulation results reported an error lower than 0.01 μm in the gap height geometry prediction by the proposed AIDM approach compared to the state-of-the-art Reynolds film damping-based method (RDM). Meanwhile, the numerical solver speed improved 1000 times for the fixed incline pad problem and one hundred thousand times for the free-to-float pad problem. Derivations showed that additional acceleration potential can be achieved in realistic mechanical systems where a higher degree of freedom is present in the body motions. The error behavior of the proposed AIDM approach is discussed, showing the error is positively related to the absolute magnitude of the modification parameter ϕ used for calculating the artificial inertia and damping, and the error is related to the validity of the linearization assumption on the system dynamics.</p><p dir="ltr">4. Based on a novel experimental set-up to measure the filling characteristics of an internal gear pump under induced gaseous cavitation. An integrated simulation approach was proposed to study the incomplete filling behavior in positive displacement machines. The approach consists of (a) a 1st order predictive model for evaluating the amount of undissolved gas at the pump inlet from the circuit pressure loss, (b) a gas-equilibrium-based cavitation model for predicting the pressure transience in the pump fluid domain, (c) a lumped volume based pump flow evaluation. Experiments performed over a wide range of operating conditions validated the deployment of the first-order gas release prediction (with 8 s time constant for fluid with 6 % total air). The complete simulation approach was validated via a good match with the measured volumetric efficiency for both low-speed and high-speed conditions.</p><p dir="ltr">The reference compensated crescent-type internal gear pump (CCIGP) unit was simulated with the full scope coupled simulation model, with which the methods proposed in this thesis research were validated with experiments. Simulation results matched with volumetric efficiency as well as mechanical efficiency. The model also reports a breakdown of the energy consumption within the reference CCIGP, which promotes the understanding of the operation of the reference machine.</p>

In recent years, additive manufacturing (AM) has become one of the most revolutionary and promising technologies in manufacturing. The process of making a product layer by layer is also often referred to as 3D printing. Once employed purely for prototyping, AM is now increasingly used for small series production, for example in aerospace applications. The paper starts with a motivation for AM in hydraulic applications and the development of an AM internal gear pump. For a better understanding of the manufacturing process, a brief introduction to AM highlighting the advantages and challenges is given. The AM internal gear pump is part of an electrohydraulic power pack, which is used to power an electrohydraulic actuator (EHA). The power pack contains all necessary peripherals to realise the hydraulic system of the EHA. The AM process allows for new design possibilities, but the process differs strongly compared to subtractive manufacturing processes and therefore is outlined here. The paper concludes by presenting measurement results of the AM internal gear pump.

Oil lubrication film plays an important role in analysis of dynamic behavior of the internal gear motors and pumps. During operation, the oil film is considered as the spring and damping system. Therefore, calculation of the dynamic stiffness and damping coefficients is necessary to build the mathematical model for studying of dynamic problem. In order to calculate these coefficients, the dynamic pressure and perturbing pressure distribution must be determined firstly. In this paper, the infinitesimal perturbation method (IFP) is used to calculate the dynamic pressure distribution. Based on that the dynamic stiffness and damping coefficients can be computed. The calculation results point out that the dynamic stiffness and damping coefficients are much dependent on the eccentricity ratio.