Gearbox Design and Fabrication

Introduction

This report outlines the design, technical specifications, and future work recommendations for a gearbox, which is a continuation of Phase 1, Phase 2, and Phase 3 of the project. The objectives of this report are divided into three main sections, which are based on lectures 18, 19, and 20. Phase 1 concluded with gear ratios of 0.63 and 2.86 for the speed and hill climb, respectively, and the pitch diameter of both the pinion and gear were calculated to be 36 mm and 22.5 mm for pinions and 52 mm and 61.5 mm for gears, respectively. Phase 2 and Phase 3 concluded with a factor of safety for all gears and pinions much larger than the benchmark of 1.5 and determining the factor of safety at each critical point identified.

Description

The overall gearbox design is optimized for performance in two tests, the hill climb event and the top speed event, and was designed to be more effective than alternative designs by possessing high energy-efficiency and the ability to switch between maximizing operating torque and maximizing operating speed. To achieve this, the gearbox has a single stage shifting spur gear design with only an input and an output shaft. The input shaft can support two spur gears around the central hub on the left-hand side, and the sprocket on the right-hand side. The output shaft can support a single shifter gear, which is comprised of two gears that attach to form a dual stage. The single stage setup of this design, which is relatively simple and contains only two shafts, allowed for a reduction in material costs and the time required to 3D print.

The technical specifications section provides assembly instructions for the gearbox, which are designed to be simple and easy to follow, requiring only a screwdriver and allowing for easy disassembly. The complete parts list for the gearbox assembly is provided, and the instructions for assembling the input and output shafts, the side walls, and the end walls are given. The assembly process is straightforward, and the gearbox can be 3D-printed in approximately 5 hours and 45 minutes and is durable enough to withstand 100,000 hours of use.

Conclusion

In conclusion, this report presents a well-designed and efficient gearbox that is optimized for performance in two tests and has the ability to switch between maximizing operating torque and maximizing operating speed. The single stage shifting spur gear design with only an input and an output shaft is relatively simple, allowing for a reduction in material costs and the time required to 3D print. The assembly instructions for the gearbox are easy to follow and require only a screwdriver, making it easy to assemble and disassemble. Further work could involve testing the gearbox and making any necessary adjustments to optimize its performance. Overall, this gearbox design is a significant improvement over previous designs and has the potential to be used in a variety of applications.