Close
0%
0%

3D printed GearBox

Made a Gearbox from scratch for an upcoming Kinetic Sculpture project

Similar projects worth following
Greetings, everyone!

I'm excited to introduce my newest creation—a 3D-printed gearbox!
In order to prepare for an upcoming kinetic sculpture project, the objective of this project was to construct a functioning gearbox with two output shafts that spin in opposing directions.

To generate spur gears, we installed an addon or extension in Fusion360 called GF GEAR GENERATOR. The gears are then organized so that they can output two shafts, each of which rotates in the opposite direction.

We have utilized 3D printing for the gearbox's body and even the gears themselves.
Originally, I intended to combine the gearbox and kinetic sculpture into a single part, but it would have been too lengthy, so I split the articles into two: one for the gearbox and one for the kinetic sculpture. The gearbox construction process is the primary subject of this article.

Design

Using the GF Gear Plugin, which will be explained in the Gear Setup Step, we first generate gears to begin designing the model.

Following the creation of gears, we constructed a three-layer enclosure around them. The top layer encloses all of the gears in place and has an opening that outputs the rotation produced by gear sets, while the middle layer is the layer onto which we fastened all of the gears using M6 bolts.

The small-gear DC motor, whose shaft is attached to gear A, is also located in the midlayer.

The bottom layer provides a stable foundation for the gearbox and holds the circuit.

We separated the three layers using specially made spacers, and we have fastened them all together with M6 bolts that are 75 mm long.

We used an Ender3 printer with a 0.5mm nozzle, 50% Gyroid Infill (for strength), orange PLA for the three layers, and black PLA for the gears and spacers. We exported all three layers, together with the gears and spacers, into a mesh file and 3D printed them.

Gear Setup

Two sets of gears are used in the model; one set rotates in a clockwise direction, while the second set rotates counterclockwise. Spur gears make up both sets, which were all produced using Fusion360's GF GEAR plugin.

Gear D from one set and Gear A from the other set are connected in the two sets; we modeled both sets so that Gear D can be placed on top of Gear A. Both gears revolve in the same direction because Gear A is attached to the motor.

GEAR SET 1-CLOCKWISE

Set 1 contains the Main Gear A, a 10-teeth spur gear with a 4 mm modulus. The modulus here is the size of the gear teeth.

In order to accommodate Gear D, we have modeled a holder that sits atop Gear A and functions similarly to a key socket.

Gear B, which is the same size as Gear A but is only modeled to transfer rotation from Main Gear A to Gear C, comes next in Set 1. This is the Idler gear, or gear B. The idler gear's main job is to transfer motion from gear A to gear C; it does not alter rotational speed or direction.

Gear C, a 15-teeth, 4mm modulus gear with a shaft in the center, is the rotation output gear. Out rotation will be transferred via this shaft.

Gears A, B, and C revolve in clockwise, counterclockwise, and clockwise directions, respectively.

This setup is useful for maintaining the same rotational direction between the input and output gears while transmitting motion over a distance. It is commonly used in various mechanical systems to manage space constraints and achieve desired mechanical advantages.

GEAR SET 2-ANTICLOCKWISE

In Gear Set 2, we have only two gears, Gear D and Gear E.

Here, Gear D serves as the input gear, receiving rotation from the lower Gear A that it is fitted onto. Gear D can be placed on top of Gear A to fit in position since it has a slot in the middle. The clockwise direction of rotation is the same for both Gear D and Gear A.

Gear D transfers rotation to gear E, which rotates in a counterclockwise direction.

Gear C from Set 1 and Gear E are positioned on top of each other and share the same rotational axis; Gear C rotates in a clockwise direction while Gear E rotates counterclockwise.

Circuit Construction

Regarding the circuit for this project, we created a custom board that uses a 3.7V 2000mAh Li-ion cell as the power source and an XIAO SAMD21 M0 microcontroller to drive a simple H bridge setup made with four N channel Mosfet AO4406. We utilize the IP5306 Power Management IC, which has low cut, high cut, and fuel indication functions, to properly charge and discharge the cell.

Additionally, we attached two indicator LEDs to the XIAO's GPIO D2 and D3. These LEDs will be used in code to inform the user of the motor's rotation; the first LED will illuminate if the gears are turning clockwise, and the second LED will illuminate if the gears are turning counterclockwise.

Let's have a closer look at the H bridge we have constructed.

Four A04406 N-channel Mosfet ICs, which...

Read more »

Gearbox for Kinetic Sclpture v13.step

step - 28.41 MB - 11/07/2024 at 13:47

Download

Gearbox for Kinetic Sclpture v13.f3d

fusion - 32.98 MB - 11/07/2024 at 13:47

Download

BACK PLATE.stl

Standard Tesselated Geometry - 114.44 kB - 11/07/2024 at 13:47

Download

GEAR5.stl

Standard Tesselated Geometry - 255.45 kB - 11/07/2024 at 13:47

Download

GEAR03.stl

Standard Tesselated Geometry - 174.20 kB - 11/07/2024 at 13:47

Download

View all 15 files

  • 1
    PCB Assembly Process
    • Using a solder paste dispensing needle, we apply solder paste to each SMD component pad to begin the PCB assembly process.
    • Next, we added all the SMD components in their place using a ESD Tweeser.
    • The circuit was then placed on the Reflow Hotplate, which heats the PCB from below to the solder paste melting temperature. All SMD components are connected to their pads as soon as the PCB reaches the solder paste melting temperature, which is typically 200° C.
    • Turning the Board over, we started the THT Components assembly by first placing the Lithium ion cell holder using a solder iron.
    • Next, we solder the pads to secure the other THT components, such as the switch, JST connection, and USB Type C port, in their proper locations.
  • 2
    Power Source

    We utilized a 3.7V 2000mAh Li-ion cell as the power supply, which was connected to the lithium cell holder in the proper polarity.

    After pressing the ON button and the device turns on, we measure the output voltage with a multimeter and observe that it is 5.1V, indicating that the circuit is working.

  • 3
    CODE and DRY RUN

    We attached an XIAO M0 microcontroller to the circuit and uploaded the code below to see if it worked or not.

    The JST wire connector for the motor is then inserted into the circuit JST connector.

    const int motorPin1 = 0; // Pin connected to H-bridge input 1
    const int motorPin2 = 1; // Pin connected to H-bridge input 2
    const int ledCW = 3; // Pin connected to LED for clockwise direction
    const int ledCCW = 4; // Pin connected to LED for counterclockwise direction
    void setup() {
    pinMode(motorPin1, OUTPUT);
    pinMode(motorPin2, OUTPUT);
    pinMode(ledCW, OUTPUT);
    pinMode(ledCCW, OUTPUT);
    }
    void loop() {
    // Turn motor ON in one direction (clockwise)
    digitalWrite(motorPin1, HIGH);
    digitalWrite(motorPin2, LOW);
    digitalWrite(ledCW, HIGH); // Turn on CW LED
    digitalWrite(ledCCW, LOW); // Turn off CCW LED
    delay(3000); // Wait for 3 seconds
    // Change direction (counterclockwise)
    digitalWrite(motorPin1, LOW);
    digitalWrite(motorPin2, HIGH);
    digitalWrite(ledCW, LOW); // Turn off CW LED
    digitalWrite(ledCCW, HIGH); // Turn on CCW LED
    delay(3000); // Wait for 3 seconds
    }

    This code controls an H-bridge motor driver to turn a motor in clockwise and counterclockwise directions for 3 seconds each. LEDs indicate the direction of the motor's rotation, with ledCW lighting up for clockwise and ledCCW lighting up for counterclockwise.

    The system is turned on and the motor begins to spin in a single direction after the power button is pressed. After three seconds, it reverses course for an additional three seconds, repeating the cycle.

    Now that the circuit is operational, we may proceed with the gearbox body assembly procedure.

View all 9 instructions

Enjoy this project?

Share

Discussions

Similar Projects

Does this project spark your interest?

Become a member to follow this project and never miss any updates