Synopsis

The report outlines the design, technical specifications, and future work recommendations for a gearbox in continuation of Phase 1, Phase 2, and Phase 3 of the project. The objectives of the report are divided into three main sections, based on course lectures. Phase 1 concluded with gear ratios for speed and hill climb, and the pitch diameter of pinions and gears. 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. The report presents a well-designed and efficient gearbox optimized for performance in two tests, hill climb event and top speed event, and having the ability to switch between maximizing operating torque and maximizing operating speed. The design utilizes a single stage shifting spur gear with only an input and an output shaft, which is relatively simple and allows for a reduction in material costs and 3D printing time. The technical specifications section provides instructions for the gearbox assembly, including a complete parts list, and instructions for assembling the input and output shafts, the side walls, and the end walls. The assembly process is straightforward and the gearbox can be 3D-printed in approximately 5 hours and 45 minutes. The gearbox is durable enough to withstand 100,000 hours of use. Future work could involve testing the gearbox and making necessary adjustments to optimize its performance. Overall, the presented gearbox design is a significant improvement over previous designs and has the potential to be used in various applications.