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Manual gearbox design download
Recommended.Manual gearbox design download
Without appropriate motor-gearbox combos, your team will find that your robot does not function as quickly and effectively as intended, and may have a tendency to burn out motors. This tutorial will teach you the fundamentals of gearbox design and implementation. First, I will teach you about motor characteristics. Next, I will discuss how to choose a motor and gear ratio given application requirements. I will then provide information about choosing a gearbox, followed by an overview of the motors and gearboxes available in FRC.
Finally, I will demonstrate how to use what you learn in this tutorial in an example problem and point out extra tools and resources if you want to learn more. Prerequisites A basic understanding of physics — e. The equations for these curves are all derived from the four specifications discussed above using equations 1 through 4 of the previous few pages. Now that you have a motor and gear ratio chosen, you need to choose a gearbox. The first requirement for choosing a gearbox is that the chosen motor must fit on the gearbox.
Though most motors have unique bolt patterns, the BaneBots RS motor, Fisher Price motors, and AndyMark motor all belong to the RS series of motors and therefore have the same mounting pattern.
Next, the gearbox must have the gear ratio you have chosen. However, there is more leeway in this requirement. In addition, not all reduction needs to happen in the gearbox and can instead be achieved through power transmission systems such as sprockets and chain.
It is also possible that the exact gear reduction that you want is not available, in which case close enough is usually good enough. Finally, the gearbox must have an output shaft that you can use. Though various sizes of keyed shafts are most common, hexagonal shafts are becoming more and more popular in FRC.
There are also many different hubs to accommodate the various styles of output shafts. Ultimately, this is the least restrictive requirement when choosing a gearbox. Now I will work through an example problem to demonstrate how to go through the process of designing a gearbox. The drawing above shows a picture of a two stage elevator, an element of a manipulator commonly found in FRC. The challenge is to design a gearbox that is capable of driving the 3 inch diameter winch and lifting the elevator to its maximum height of 84 inches high in a time of 1.
Second, we will ignore acceleration and deceleration time, as these calculations are beyond the scope of this tutorial. First we will convert all units to metric because metric units are much easier to work with. Next we must turn our end goals into requirements that can be used to choose a motor and gear ratio. Calculating the required rotational velocity of the winch: Number of rotations to raise elevator: Calculating the load on the winch:. Now we must choose a motor and gear ratio.
In addition, it is commonly used in applications such as this, meaning that it is probably a good fit for the job in general.
To make estimations easier, I made a motor curve graph for the RS Looking at the graph, we can visually see that it takes a load of. Looking at the graph again, we see that this corresponds to a torque of. Now, we can calculate the reduction we would need to achieve the necessary torque of 3. Gear Reduction: We have now chosen a gear reduction of , which means we can calculate the exact load our elevator motor should encounter.
Next, we will determine the rotational velocity of the gearbox output shaft using equation 2. Motor Speed: Now we can check to see if our chosen gear ratio will allow us to achieve our desired output speed, rpm. Gearbox Speed: Finally, now that we have verified that our gear ratio satisfies our requirement, we can calculate how long it should take for the motor to raise the elevator.
Lift Time: We have now completely verified that our RS motor and gearbox will achieve or exceed our original goals. Doing so also ensures that our simplifications do not cause our system to perform much worse than expected. When you first go through this process, you may have to go through the calculations multiple times as you try different motors and gear ratios. As you gain experience, you will gain an intuition of which motors and ratios will work well for a job.
The final step in this process is to choose a gearbox. Not only is it compatible with our motor, but it also has the right gear reduction and a common.
Hopefully this example problem has helped you understand the process of choosing a motor and gearbox. In addition, I hope that it has shown you how to properly apply the theory you learned earlier in this tutorial. This section of the tutorial is meant to provide some additional resources for learning about motors and gearboxes, as well as some tools that can expedite the design process.
Instead, use them because you have verified them against your own calculations and because you understand how they work.
However, only use it once you understand the theory behind the calculations. I looked at its section on motor and gearbox theory to ensure that I had all of my information right for this tutorial. However, this tutorial goes into a bit more detail than its chapter on motors and gearboxes. Question 3 days ago on Step 1. Question 1 year ago. Question 1 year ago on Introduction. Your data graph for the motor to lift your elevator makes no sense.
The numbers quoted are too high: for example the stall current is 85A, but the stall current for a motor is 8A and would burn out very quickly at that. I'm baffled. Question 3 years ago. Answer 3 years ago. You cannot create horse power.. One horse power cannot make even another horse power because of gear friction you will only be able to get 0. The weight to be rotated is equal to kg. I am working on project of making small hydro generation unit. In which I have made hydro turbine of 'Pelton Wheel' type.
It rotates at rpm but as rated speed of synchronous generator which is to be connected is rpm, so to generate electricity I have to step up the speed from rpm to rpm. For that purpose is it feasible to use gear type arrangement??
Which type of gear to be used?? How will it work?? Explain me in detail Reply 6 years ago on Introduction. You can do 2x 2. What is the shaft size of your pelton wheel and what material is it? If it's metal or a shaped like a square or hexagon beam you can buy a spur gear or make one if your pelton wheel is large and as the main shaft spins you will spin your motor what sized shaft?
The size of the teeth. If you have a really tiny shaft you can't use a large pitch, for power transfer you want a large shaft and large teeth so your gears don't strip themselves. Gear material is also determined, wood has the potential to expand and contract, plastic probably won't hold up to how much stress you are putting on your wheel.
I would go with metal for you. The gears will be really expensive so honestly, I would go old school and use pressure treated wood to make huge gear teeth like an old fashion water wheel which is what I think you're using.
So all in all, you need a gear ratio of or close to it, will your wheel always be moving at rpm? If the motor can handle more, think about changing the ratio!
When I'm saying "huge gear" I'm imagining your wheel to be a foot or two or more diameter and you can cut the teeth using a pattern, then another gear. The reason larger is better is because there is less wear, but more importantly the larger the gear the less your human error impacts the gear.
No way you're going to machine a super tiny tooth gear! If you pelton wheel is rinky dinky and the shaft is only 1 inch diameter or so you can just buy a gear or two from servocity or another gear provider. Make sure the gear pitches match mod and pitch are the same thing so match 1 mod with 1 mod or 24dp with 24dp, etc.
Then make sure you can attach the pinion gear to your motor, press fit, glue, welding. Boat displacement is around lb. Hello, I'm having trouble viewing the images formulas when downloading this as a PDF. Is anyone else having trouble and if so, found a workaround?
This is good. Would love to see a follow-up about actually building geartrains - best practices for making a "breadboard" with parallel plates, sources for gears, axles, bearings, etc. Reply 8 years ago on Introduction. I posted an Instructable about how I made a gearbox here - it's kind of the same topic, but doesn't go into quite the detail it sounds like you want. It's definitely a good idea though - I'll put it on my list of ideas for future tutorials. Great tutorial!
Oh yes, I definitely would like to learn more about how to connect wheels to a motor and bearings as well :- Good luck with your study! What is the difference between torque and stall torque when dealing with an electric motor? As I recall, the highest torque rating of an electric motor is it's stall torque.
I thought separating them out was more a function of usable power in an IC engine rather than an electric motor. Or is that formula generic, it's been a dozen plus years since I've even had to look at that stuff. Also, are you going to get into the differences between DC and AC motors?
Manual gearbox design download.Understanding Motor and Gearbox Design
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