SUNY Canton Electric Baja Buggy Drivetrain s

CANTO
y

Ryan Burgos & Matthew Magaldi We would like to thank the

Woodside Scholar Foundation
Mr. Cullen Haskins, Dr. Lucas Craig, Mechanical Engineering Technology, Capstone for the support and funding

What is a Drivetrain? Drivetrain Decision Gearbox Iterations

A drivetrain transmits power from either a motor or engine to the wheels Weighted Objective Table evaluated different differential and gearbox options based on key
to provide the required rotational motion or movement. performance criteria and their relative importance. Each option was scored and weighted
according to how well it met critical needs such as cost, size, weight, and acceleration. The Version 1
CHAINDRIVE
NOFORCE
TRANSFERRCD
UNDER
COMPRESSION
!PUSHING! A chain drive is a
Audi Torsion Differential was selected due to its highest weighted score and lack of • Small design with few number of gears.
negative trade-offs. Similarly, the Spur Gearbox was chosen for its superior performance in
mechanical system that acceleration and cost—two of the most important criteria—resulting in the highest overall
• Some collision issues with the gears and
OUTPUT
IORIVEN
INPUT
!DRIVING)
transmits power from one score. These selections provide a strong foundation for an efficient and reliable drivetrain bearings.
I
place to another using a design.
FOil([TRAHSFERRE[)
UNDrnTENSION
chain and sprockets. Drive-train Desien Decision
IPULLINGI
Spur Gearbox Chain and Sproc~et Planetary Gearbox

Figure 1: Chain Drive Criteria Importance

Reach top speed of 40mph 4.16 0 0 0
Acceleration of at least 4m/s2 5.05 1 -11. 1
Maintain Center o,f gravity (Center
Figure 7: Version 1
and middle) 2.94 0 1 1

A planetary gearbox is a Minimize

Minimum
Cost
Frictio,n Loss
6.00
2.11
1
1
1
-11.
0
0
Version 2
compact gear system that Minimize Weight 1.77 -1 1 0 • More compacted design.
uses a central sun gear, Weighted Total: 11.39 3.55 7.99
• With this design we had an issue with the
Unweighted Total: 2 1 2
planet gears and ring gear Table 1 # o,f Positive scores 3 3 2
motor colliding with the differential.
which transmits power. # of negative scores 1 2 0

*All images are

Figure 2: Planetary Gearbox Differential Options ½ scale Figure 7: Version 2

A spur gearbox is a
mechanical system that Version 3
uses spur gears to transmit • Has idler gears which allow proper
,,
power and motion spacing in the gearbox.
between two parallel :;,::.}'::'
~-· '. • Biggest model we made with proper
,~ ... >,

shafts. '1, ' .........._ ............

Figure 4: Audi Diff Figure 5: Polaris Diff Figure 6: Chain Diff spacing and no collision of parts.
Figure 3: Spur Gear box
• All parts are available on selected
Engineering Specifications:
~h
34
Speed (ft/min)
29,92
3080
Wheel
591.5
Gear ratio
6.8
lio1rque from motor (N*mJ
248.1
241 ..0
Force IN) Acceleration
1012.7 -
(m/s"2)
4.05 websites.
35 608.9 6.6 983.7 3,93
36 31'68 626.3 6.4 234.3 956.4 3,83
Figure 7: Version 3 *All images
• Reach top speed of 40 mph are ½ scale
• Acceleration of at least 4 m/s2 38
39,
3344
3432
661.1
678.5
5.1
5.9
222 ..0
216.3
906.1
882.8
3.62
3,53
• Minimize Friction in the Gearbox 40 3520 695.9 5.8 210.9 860.8 3.44

• Design Components for 26 hp 41

42
3608
3696
713.3
730.7
5.7
5.5
205.7
200.8
839.8
819.8
3.36
3.28
Budget
• Minimize gear box weight 43 3784
3872
748.1 5.4 ]96.2
1.91..7
800.7 3.20
44 765.5 5.3 782.5 3.13 lte;mff Part ff ·Q:ty Nam,e Ma1t,e,rial Source $/Part Subtotal
• Minimize heat inside gearbox 45 3960 782.9 5.1 187.5 7'65.1 3.06
1 POOl 1 Audi Allroad Cerite r Difif St,e-el Ebay $259.9'9 $ :259'.9·91

• Effective torque output (h = 94%) Table 2 & 3 .2 P002 2: Metal Ge,arRound Bor,e12 Pitch, 48 lf,eeUn 102!0Carbon Steel McMa.ster-Cam $141.18 $ 282.:H:i
• Maintain Center of gravity (Center and middle) Length of Shaft Tangential Force Radial Force X - plane Y - plane Max Moment
3 P003 1 Metal Gear Round Bor,e10 Pitch, 15 lf,eetlTi 1117 Carbon Steel McMa:ster-Carr $ 63..23 $ 63.23
• Minimize size of gearbox and spacing Pinion 1
1 456 165.97 456 165.97 485.27 4 P004 1 Metal Ge,arRound Bor,e10 Pitch, 40 lf,eeUn 1117 Carbon Steel M cMa:ster -Cam $164.02 $ 164.02
Length of Shaft
Gear 1
Tangential Force Radial Force X - plane Y - plane Max Moment 5 P005 1 Metal Gear Round Bor,e12 Pitch, 24 lf,eetlli 102!0Carbon Steel McMa.ster-Cam $ 74.80 $ 74.80
456.000057 1713.420214
Capstone Objective: Pinion 2
3.7575
Length of Shaft
3.7575
Tangential Force
912.000114
165.97
Radial Force
331.94
X - plane
3426.840428
623.63
Y - plane
1247.27
1823.38
Max Moment
3646.77
i6
7
P006
PiQ07
1 Four Pi,eceClamping Collar 7/8 inch
.2 Four Pi,eceClamping Collar 1 ililch1
1045Steel
Carbon Steel
Ama2:on
Ama2:on
$ 11.99, $
$ '9 99
1 1
$
11.'99
19.9:8
1
1

• Make a working 3D printed gearbox

•

Length of Shaft Tangential Force Radial Force X - plane Y - plane Max Moment :9 PiQ09 ,5 Se,al,edBall Bearing ID: 1 in on:2 ilil St,eel McMa:ster-Carr $13.73 $ 82.38
Pinion 3
• Uses parts that can be bought online 3.7575 912.000114 331.94 3426.840428 1247.27 3646.77
10 POlO 1 Illirust Ball Bearing ID: .2.5in OD: 3.'969ilil St,e.el MSC $12!0.4'6 $ 12!0.46
Length of Shaft Tangential Force Radial Force X - plane Y - plane Max Moment
• Make a design report explaining what we have learned Gear 2
5 912.000114 331.94 4560.00057 1659.70 4852.65
SUNLU 3kg 3D Print,er Filament PLA.Plus

for future students 1. 75mm, 1.75mm Diameter, 3kg (i5.i5lbs)

Table 2 and 3 show us calculated data for theoretical max speed and gear 11 POll .2 Large Spool, Black PlA. Ama2:on $35.99• $ 71.9:8
ratio and the max forces on the gears. (All the data is at what the Total: $ !1.,151.!l.91
maximum capacity of the motor with a safety factor of 1.2) Table 4