The document outlines the design process for a gearbox. It discusses the design priorities of size, speed, and power. Preliminary calculations determined a coefficient of friction and required output force. Potential gear ratios were estimated. Design considerations included material strength, laser cutting effects, and limitations. Gear configurations, spacing, layout, and mounting methods were analyzed. An integrated mounting method was selected to reduce space and focus stress in the gearbox.

1. GearBox Group 4k
• Carlo Sinay
• Andrew Anthony
• David Jaffit
• Niq Nazrin

2. Design Time Line
Design
Priorities
Preliminary
Calculations
Gear
Configurations
Mounting
Methods
Analysis and
Selection
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3. Design Priorities
Performance Mark Equation: 𝑃 =
𝑚2 𝑔2ℎ2
𝑉𝐼𝑡2 𝐷3
Priority list:
1. Gearbox Dimension Size
2. Speed at which Gearbox pulls weight
3. Power used by gearbox
(Every controllable variable in equation was prioritised by their index)
GearBoxGroup4K

4. Calculated coefficient of static friction = ~0.3
Calculated projected required output force = ~92N
Estimated gear ratio (simple) based on motor specs and projected
required output torque = 1:34
Design Consideration – Friction and Torque
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5. Design Consideration - Limitations
- Acrylic strength
- Laser cutting effects on acrylic
- Limitations of laser cutting
GearBoxGroup4K

6. GearBoxGroup4K
Design Consideration - Limitations

7. Design – Gear Configurations
Friction elements
Volume of gearboxes
Spacing and layout of gears
Pulley Systems
GearBoxGroup4K

8. GearBoxGroup4K
Design – Gear Configurations

9. Design – Mounting Method
Gearbox
External
Mounting
Plate
Integrated
Mounting
Holes GearBoxGroup4K

10. Design – Mounting Method
External Plate Mounting:
- Extra space for gears
- Stress focused on plate
Integrated Mounting:
- Reduces wasted space in gearbox
- Stress is focused in gearbox
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11. Design – Conclusion
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12. References
http://www.globalspec.com/
http://forums.Autodesk.com/
User- Nathaniel.Parr
http://www.hercus.com.au/
GearBoxGroup4K