Grundfos Challenge 2019

grabcad

Human: A straightforward three-gear design aimed at being practical, easy to access, and effortless to assemble. All assembly revolves around the Z axis. Specifications: - Gear material: Cast iron/brass/copper/steel - Gear ratio: - Gear 1 (10 teeth) to Gear 2 = 8:1 or, Gear 1 (12 teeth) to Gear 2 = 6.667:1 - Gear 2 big to small = 8:1 - Gear 2 (small) to Gear 3 = 8:1 Option 1: - Gear 1 (10 teeth) at approximately 619 rpm or 10.33 rev/second at the motor for 3 seconds for a half revolution at the output shaft. Option 2: - Gear 1 (12 teeth) at approximately 540 rpm or 9 rev/second at the motor for 3 seconds for a half revolution at the output shaft. Enclosure design considerations: 1. Injection molding 2. Machining - drilling/tapping 3. Gear 2 and Gear 3 held together using one aluminum plate, requiring stamping and bending. 4. Copper bushes pressed into the aluminum plate for smoother gear rotation. 5. A minor redesign at the valve's shaft area: - Added one bearing and one oil seal. 6. All gears are aligned at ±48 degrees. 7. The aluminum cover can be extended to the gear at the motor. B.O.M: 1) Gear 1: Dia 8.00mm x 6.5mm Thickness, 10 teeth - Minimum teeth and minimum diameter for small ratio and maintaining strength 2) Gear 1: Dia 10.00mm x 6.5mm Thickness, 12 teeth - Maximum teeth and minimum diameter for small ratio and maintaining strength 3) Gear 2: Dia 60.00mm x 33.0mm Thickness, 80 teeth/10 teeth - Maximum diameter and teeth without interfering with the 3rd gear's shaft. 4) Gear 3: Dia 60.00mm x 8.00mm Thickness, 80 teeth - Maximum size and teeth that can fit in the gray/black housing. 5) Copper Bush 6) Valve Shaft 7) Aluminum Cover 8) M3x10 screw 9) M4x12 screw Additional assembly file for 12 teeth and 10 teeth uploaded for reviewing and comments.