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...
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