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Aaron Evans - UVic Mechanical Engineering Portfolio

QDD Gearbox Actuator

5:1 QDD planetary gearbox prototype. Rev 01 is assembled. Remaining work is running the motor and gearbox against the remaining requirements.

5:1Ratio
16 NmPeak target
Backlash
<$30Current spend
PendingEfficiency
FDMMfg
Current
Current Build
Rev 01 is assembled. The remaining work is the requirement tests.
Integrated motor housing assembled done
Dyno fixturing complete ready
Backdrivability torque is next next
Peak torque, efficiency, endurance, health remain pending
Hardware details
MotorD6374 150KV BLDC + ODrive v3.6
PrinterBambu P1S, PLA, 0.2 mm layers
Bearings6805 + 6710ZZ + 685ZZ ball bearings
CouplingV1 dyno coupling
Results
Measured Results
Backlash
5
Issues closed
5/5
Fits
T-012 backlash requirement passed pass
Bearing fits validated in Rev 00B done
Lid drag eliminated done
Rev 00A fit and mesh issues closed in Rev 00B done
Issue details
IssueRoot CauseFix
Gear mesh notchyHerringbone halves misaligned at FDM resolutionSwitched to spur gears
Lid dragTolerance stackup over-constrained assemblyFloating lid bearing
Carrier shoulderBearing shoulders printed as overhangCarrier wall redesign
Bolt torque bindingBolt preload deflected planets into ring gearRedesigned load path
Execution
Build Method
1
Skeleton
60-80
CATIA hrs
5/5
Fits validated
Target fit Finger-press transition for the printed bearing interfaces.
CAD and fit details
CATIASkeleton-driven assembly rebuilt from the first Onshape concept
ReferencesNo B-Rep references in the main assembly
CalibrationCoupon prints set the offsets before full parts were reprinted
InterfaceOffsetStatus
Main bearing bore+0.10Validated
Lid bearing bore+0.10Validated
Carrier bore+0.10Validated
Planet bore+0.15Validated
Ring-to-housing+0.30Validated
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