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CHAPTER 9 Power Transmission
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Fig. 9-16.
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Split gears.
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forced in opposite directions. This way, the teeth are forced to mesh tightly with the connecting gear. Figure 9-16 illustrates this. As you can imagine, some trickery is needed to fasten a split gear to its shaft, and the amount of backlash protection is limited by the strength of the spring.
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MORE GEARS
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Try This: The gears we have studied so far have mostly been spur gears. Spur gears are designed to mesh edge to edge. In 8 we also saw a crown gear in the robot wrist machine. Crown gears are designed to mesh at a 908 angle to a spur gear, as shown in Fig. 9-17. Another gear designed to mesh at an angle is the bevel gear. Bevel gears mesh with other bevel gears. Though many bevel gears are designed to work at 908 angles to each other, as shown in Fig. 9-18, the bevel can be crafted to allow other angles. Bevel gears are more e cient than crown gears and can transmit more torque. The worm gear also runs at a 908 angle to a spur gear, but along a di erent axis. The worm gear is shaped more like a screw than a gear (Fig. 9-19). Worm gears can mesh with spur gears or gear racks. Worm gears provide a large reduction in speed and an equally large increase in torque. Worm gears also provide another useful property. They don t back-drive easily. Back-driving is when you can turn the output shaft of a gear system and the input shaft turns. Worm gears tend to lock instead of back-drive.
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CHAPTER 9 Power Transmission
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Fig. 9-17.
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Crown gear.
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Fig. 9-18.
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Bevel gear.
Fig. 9-19.
Worm gear.
CHAPTER 9 Power Transmission
Worm Gear Driven Arm
Try This: This project expands on the worm gear base from Fig. 9-19. First, build a simple arm with a locked gear at its base as shown in Fig. 9-20. Then you can build the worm gear base and attach the arm to it (Fig. 9-21). When you turn the long input shaft the arm raises and lowers. When you stop turning, the arm stops moving. Pushing or pulling on the arm demonstrates a little bit of backlash, but no back-driving. Having a joint that locks in place means that you don t have to use power to keep it there.
Fig. 9-20.
Worm gear arm part 1.
CHAPTER 9 Power Transmission
Fig. 9-21.
Worm gear arm part 2.
Even More Gears
We just touched the surface of gearing systems. There are many di erent ways to manage power transmission through gears, sprockets, and belts. For example, you can turn one of your gears inside out and call it a ring gear. Planetary gear systems use this inside-out gear to good e ect. Harmonic gears use a exible gear to create a novel and compact gear reduction. And gearing action can be done without gears using such things as cone drives.
CHAPTER 9 Power Transmission
Couplers
Most of what we have seen in these discussions on mechanics could be described as couplers, that is, devices that join two parts together. In power transmission a coupler s role is to connect the power source with the actuator while adjusting for misalignments and other impediments to motion. A coupler may be as simple as a tube with set-screws in it, used to fasten two shafts together. A step up in complexity and the tube has di erent-sized holes at each end to join shafts with mismatched diameters. Cut slots across the tube between the shafts and it can ex a little bit, adjusting for slight angle di erences. For lightweight connections, a short length of latex tubing can work. A spider coupler (Fig. 9-22) is like a universal joint and allows for larger di erences in angle. The central cross-shaped spider ts between the input and output ttings. There are many di erent types of coupler available to engineers today, for all di erent types of torque ratings and forms of misalignment. A di erent type of coupler disconnects the power from the load in the case of a jam or overload. Some attachments are naturally weak, such as a set-screw pressing on a round shaft. If the load becomes too great, the screw slips. Using a pin or metal key to hold the shaft to its load allows more torque to be transmitted than the set-screw. By carefully sizing the key, you can arrange for it to break before your gear-train does inconvenient, but better than ruining the whole system. The LEGO Mindstorms set comes with a clutch, the white gear in Fig. 9-23, which is a reusable torque-limiting coupler. A clutch has two sliding plates that normally stick together. When the torque reaches its built-in limit
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