Our team designed a PTO (Power Take-Off) speed reduction unit to bring a 45kW diesel engine’s speed from a whirlwind 2800 rpm to a steady 1300 rpm, making it perfect for powering hydraulic systems. The goal? Reliable performance with durability and easy upkeep.
Maintenance? Piece of Cake. With this PTO unit, maintenance isn’t something you dread—it’s part of the fun! We designed the unit with user-friendliness in mind, so there's no need for complicated tools or an engineering degree to keep it running smoothly. A simple oil change every 2500 hours, a bit of greasing here and there, and this unit will keep humming along happily. It's like the car maintenance version of “set it and forget it,” but for industrial machinery.
And of course, here is why you'll love our PTO:
This PTO speed reduction unit offers reliable power transfer, long-lasting durability and easy maintenance—all while making your life a little easier.
My team focused on understanding the project requirements and defining the specifications for the PTO speed reduction unit. This included setting performance goals to reduce the engine speed from 2800 rpm to 1300 rpm using a gear ratio of 2.15, and selecting durable materials like EN24 and EN8 steel for the gears.
The gear design took center stage. My team calculated gear ratios and torque requirements, utilising GP100 software to ensure the gears were designed for optimal performance and longevity. An analysis of power transfer efficiency and load distribution was also conducted.
Attention shifted to the shafts and bearings. Medium-carbon steel was selected for the shafts due to its strength, and a comprehensive fatigue and stress analysis was performed to ensure they could withstand dynamic loads. Bearings were also carefully chosen based on their load capacity to ensure smooth, long-term operation.
The validation phase began, where calculations were finalised to confirm that the PTO unit met all performance goals. Additionally, we focused on the ease of assembly, minimising the need for special tools to keep the process user-friendly.
My team then began producing the assembly drawings, detailing key components such as the gears, shafts and casing. We worked on ensuring that the layout and arrangement of parts would allow for seamless assembly.
The drawings were completed with detailed exploded views, showing the arrangement of all internal components. These final drawings included material specifications, tolerances and assembly instructions, all aligned with industry manufacturing standards.
Now that we’ve cruised through the timeline, let’s dive into the design report—where the gears start turning, and the engineering brilliance really kicks into high gear.
When it comes to gear design, it's all about turning that engine power from a 2800 rpm sprint into a smooth, manageable 1300 rpm jog—thanks to our perfectly calculated 2.15:1 gear ratio.
We didn’t just grab any old gears off the shelf. These are made from EN24 steel for the pinion and EN8 steel for the wheel, because durability is key when you’re dealing with the kind of power that could easily turn metal into mush.
Using GP100 software (and a few cups of coffee), we crunched the numbers on everything from the number of teeth to the perfect tooth size. The result? Gears that are tough enough to handle anything, while staying cool under pressure. And they’ll keep turning smoothly for up to 20,000 hours.
Connecting the engine, PTO unit and pump wasn’t just about bolting things together—it was all about precision.
Standard dimensions and bolt threads ensured the parts fit together, reducing any chance of a misstep.
The interface design made it easy for maintenance and replacement, while ensuring perfect alignment so everything runs smoothly, without any awkward wobbles or breakdowns.
When it comes to putting the PTO unit together, simplicity was key. We designed everything to fit like a puzzle—fewer parts, standardised shapes and easy access for tools meant less frustration and faster assembly.
Our modular sub-assemblies slotted together perfectly, with colour-coded components to keep even the most distracted assembler on track.
By focusing on tool accessibility and self-aligning features, we made sure that anyone could assemble (and disassemble) the unit without needing a PhD in mechanical engineering—or a magic wrench.
With the design all mapped out, it’s time to see how it comes together—welcome to the assembly drawings, where every nut and bolt finds its perfect place.
And there you have it—from initial sketches to fully assembled precision. We’ve tackled every challenge, and now, this PTO unit is ready to keep the wheels of industry turning smoothly!