3D printed high torque servo/gearbox version 2

This servo/gearbox is the new and improved version of my original gearbox design (video:    • 3D-printed high torque servo/gear red...  ). I also made a shredder using this gearbox (video:    • 3D-printed shredder  ). The original one had a gear ratio of 30:1 and the speed of the output shaft was about 715 RPM which made it difficult to tune in the right PID parameters. This new version has a gear ratio of about 162:1 which lowers the speed and increases the torque.

I choose to go for double helical gears on this one because they produce a lot less noice than regular spur gears and the forces on the teeth are transferred more gradually. The gears rotate around a 6mm stainless steel shaft which is lubricated with bearing grease. Ideally all the gears should have some bearings, this is being considered for the next moment. Unlike my previous design I used 2 20mm bearings to support the output shaft.

The servo uses a 775 36V 9000rpm brushed DC-motor which is driven by my Universal Morion Controller (UMC)(video can be found here:    • Universal Motion Controller - UMC: Cr...  ). The stall torque theoretically is about 297kg*cm, I was able to test the servo to a torque of about 132kg*cm. During testing none of the gears broke, they were all printed in PLA. The weak link in this design however where the mounting tabs and the bevel gears used in the first stage on the motor shaft. These 2 gears tend to slip under high loads ,like when i tried to pull the car forwards with it's handbrake on, but this didn't occur when i performed the test where it pulled 132kg*cm of torque so it should be fine to at least this torque rating.

Timestamps:
00:00 Intro
00:11 Mechanical design
00:58 3D-printing
01:08 Assembly
03:40 First runs
04:55 Radio Controlled test
05:16 Torque tests
07:28 Outro

STL and Fusion 360 source files can be found here: https://bbprojects.technology/collect...

More info can be found here: https://bbprojects.technology/blogs/p...

My PayPal: https://paypal.me/BrockenBrian

Tools used for this project:
SMD rework station: https://www.banggood.com/YAOGONG-8878...

Infrared thermometer: https://www.banggood.com/AKKU-Infrare...

PLA filament: https://www.banggood.com/Creality-3D-...

Components used for this project:
1 × 775 brushed motor
link: https://www.banggood.com/775-Gear-Mot...

1 × M3 Bolt and nut 30mm
dimension: 30mm lenght, Used to secure the small possition feedback gear to the 20mm shaft

1 × Universal Motion Controller
Another project of mine used to control and drive the servo: https://hackaday.io/project/170604-um...

1 × heat shrinks
https://www.banggood.com/328pcs-Heat-...

2 × 6mm stainless steel shafts
link: https://www.banggood.com/681012mm-Dia...

7 × screws 30mm lenght
dimension: 4.5mm diameter, 30mm lenght, Used to mount the lid

2 × 20mm inner diameter 6004 bearings (20*42*12mm)
link: https://www.banggood.com/Deep-Groove-...

2 × Screws 15mm lenght
dimension: 4.5mm diameter, 15mm lenght, Used to mount the motor

1 × 10K potentiometer
link: https://www.banggood.com/5pcs-200V-0_...

2 × M5 bolt and nut 40mm
dimension: 40mm lenght, Used to secure the big gear and servo arm in place

Music credit:
Wild Flower by Joakim Karud   / joakimkarud  
Creative Commons — Attribution-ShareAlike 3.0 Unported— CC BY-SA 3.0
Free Download / Stream: http://bit.ly/_wild-flower
Music promoted by Audio Library    • Wild Flower – Joakim Karud (No Copyri...  

Music Credit: DJ Quads
Track Name: "Www Is A Thing"
Music by: Dj Quads @   / aka-dj-quads  
Official YouTube Channel HERE:    / Канал  
SoundCloud HERE:   / aka-dj-quads  
Twitter HERE:   / djquads  
Spotify HERE: https://open.spotify.com/artist/2VZrd...
Instagram HERE:   / djquads