Table of Contents
Team Vision for Detailed Design PhasePlans during this phase:
- Get trained on CNC router and laser cutter
- Test different gear profiles
- Update BOM
- Contract construction of wheel faces to a local woodworker
- Determine acrylic mounting
- Finalize design
Accomplished during this phase:
- Trained on CNC router and laser cutter
- Tested five different gear profiles
- Updated BOM
- Contacted prospective woodworkers
- Updated design
Prototyping, Engineering Analysis, SimulationIterative activities to demonstrate feasibility, including assumptions you made in your analyses or simulations. Have you completed sufficient analysis to ensure that your design will satisfy requirements? Have you included all usage scenarios in your modeling?
We tested a selection of gear tooth profiles, Because the Trapezoidal Profile was most promising, we decided to test a couple of modifications to the profile.
The two modifications consisted of rounding the edges, and by increasing the steepness of the contact angle.
The rounded edges should decrease the irregularity of the gears, while the increased contact angle increases spacing in between teeth to help prevent binding.
After we were trained on the CNC router and Laser cutter, we cut out a set of 10 gears at half scale for testing. These gears were mounted to an axle to test meshing.
The laser cutter often did not fully penetrate the wood, even after multiple passes, later it was found out that the plywood was pressure treated. This releases toxic fumes when burned and prevented us from cutting out any more sets of gears for testing.
When the gears were added to the model, it was found that the pinions had very little spacing between each other, which may have resulted in interference. To remedy this, more teeth were added to the gear in order to decrease the total diameter and increase spacing.
Final selection consists of 24 and 48 trapezoidal tooth gears. Pitch diameters of 7 and 14 inches respectively. It is essential to leave some "play" in the meshing of the gears so that any expansion will not cause the gears to bind. Drawings documented here.
Drawings & SchematicsNote that drawings are subject to change during construction. To view finalized drawings see Customer Handoff & Final Project Documentation.
We were able to keep all holes away from the glue joints. It was later determined that this should not be an issue anyway, as glue is stronger than the wood if joined correctly.
Estimation of total weight 560 lb
Bill of Material (BOM)
The live document can be found here.
The live document can be found here
Plans for next phase
- Continue to update CAD model with any design/dimensional changes
- Assist in material transportation over the summer
- Get in contact with blacksmith (if we go that route)
- Create exploded views of assemblies to show assembly process
- Meet with Scott Peters of Truewood Products to discuss project
- Purchase wood
- Update BOM
- Perform Humidity Test on gear meshing
- Cut full sized gears
- Investigate material storage over summer
- Order material
- Get quotations from woodworkers
- Help with cutting gears