3D-printable High torque servo/gear reduction

thingiverse

I've created a Universal Motion Controller to control the position of this servo. More information can be found here: https://www.thingiverse.com/thing:4245315. This servo/gear reduction uses mostly 3D-printed parts. The servo employs a 775 36V 9000rpm brushed DC-motor, which is driven by a BTS7960B motor driver that's controlled by an Arduino Mega 2560. The stall torque of the servo is about 55kg/cm, or roughly 5.39 Nm. The peak current is approximately 18 amps when using a 6s LIPO battery (about 22-24V). The reduction ratio is 1:30. I originally intended to use some 20mm ball bearings for the output shaft but they didn't arrive in time, so I ended up using two 20mm holes and a lot of lubrication. For the purpose of filming the internals of the servo for possible failures, I printed some colored gears and lasercut a 5 mm acrylic lid. Unfortunately, I didn't get to film any awesome footage of gears exploding because they were far too strong. Even at a peak torque of 54kg/cm, they showed no signs of flexing or cracking. The two middle gears (blue and red one) use a stainless steel shaft of 6mm diameter. The holes of the gears are designed at 6.2mm diameter so they would fit nicely around the 6mm shaft but some additional filing/sanding might be required. The same may have to be done for the 20mm shaft holes. I uploaded the dxf of the lid, allowing people with a laser cutter to cut the lid out of transparent acrylic. A video can be found here: https://www.youtube.com/watch?v=8sq4pHdSXYM. More information can also be found here: https://hackaday.io/project/162855-3d-printable-high-torque-servogear-reduction. Components used: 1 × 775 Motor DC 12V-36V 3500-9000RPM Motor Large Torque High Power Motor https://www.banggood.com/Creality-3D-Ender-3-Pro-V-slot-Prusa-I3-DIY-3D-Printer-Kit-p-1346320.html?p=E01411629100201406T1&custlinkid=677427 All my project files, instructions, schematics are provided for free so everyone around the world can enjoy them. Feel free to support me so I can create and share even more awesome projects. Feel free to take a look at my other designs: UMC - Universal motion controller: https://www.thingiverse.com/thing:4245315 3D-printable Davinci catapult gift card: https://www.thingiverse.com/thing:4067668 Arduino controlled photogrammetry 3D-scanner: https://www.thingiverse.com/thing:3958326 Fully 3D-printable turntable: https://www.thingiverse.com/thing:3723618 RC FPV tank rover: https://www.thingiverse.com/thing:3587738 Fully 3D-printable wind-up car gift card: https://www.thingiverse.com/thing:3308710 3D-printable High torque servo/gear reduction: https://www.thingiverse.com/thing:3292860 'BOOM box' high voltage capacitor bank case: https://www.thingiverse.com/thing:2980012 Subby the interactive youtube subscriber robot: https://www.thingiverse.com/thing:2928254 robot hand || bionic hand prosthesis prototype: https://www.thingiverse.com/thing:2838239 3D-printable linear actuator: https://www.thingiverse.com/thing:2783959 Mini 3D-printable crossbow: https://www.thingiverse.com/thing:2710472 8 legged spider robot: https://www.thingiverse.com/thing:2470882 best 3D-printable bearing: https://www.thingiverse.com/thing:2349065 Have a nice day!