How to Create a Custom 2 Speed Gearbox


Custom gearboxes can be designed based on your robotics goals, and in this article, we will learn how to create one. The materials you need to prepare to include aluminum plate, aluminum tube, aluminum hex bar, gears, bearings, motors, and bolts. The tools you need are CNC mill, lathe, band saw, 3D printer, socket wrench, hex wrench, and pliers. The first step is to design your spiral bevel gearbox, ensuring no clearance problems between its rotating parts with the use of a 2-speed gearbox sketch. It will help you define the exact shape you want for your gearbox.

With this 2 speed gearbox, you need to mill four parts using a CNC mill, requiring the building of G-code for controlling the tool. Take the 3D models and import into the CAM or Computer Aided Manufacturing program. You need to create several parts or the spacers separating the axles and gearbox wherein the gears are spinning on a lathe, then using the small bench in machining all these parts. With the use of a 3D printer, the final parts can be manufactured since these parts will not encounter high loads that are usually tricky using traditional ways. Next is assembling the motor by placing the plastic spacer on its shaft, inserting the key into the keyway of the motor. Slid on the 12 tooth pinion gear, following to press on the retainer ring with the use of 3/8″ socket wrench, and repeat this process for every CIM motors.

When it comes to the installation of motors onto the aluminum plate, you can insert the motors through the holes, lining up the screw holes, and tightening the self-locking screw (10-32x.5″) in each hole. You also need to press into place several bearings (3/8″). When assembling the output shaft and placing it in the gearbox, you need to install the e-clip ring on the shaft’s center. Press down the shaft and the ring against a hard surface, sliding the output shaft into the assembly’s plate lower bearing. The final step is assembling the rest of the 2-speed gearbox case by pressing the final 3/8″ bearing into the top hole’s enter and placing the aluminum spacers in the first plates’ holes, aligning the second plate with the spacers. Make sure you size the holes correctly for motor and bolts. For more information about the tutorial just presented, fell free to check our website for more photos.

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