Upright & Gearbox Design

Before the COVID-19 shutdown, our plan was to update the design and manufacture new drivetrain components with improved design for assembly, manufacturability, serviceability, and reduced weight to use with our previous motors. I started with an analysis of our previous system detailing what areas of the design needed improvement and coming up with proposed solutions. Along with another team member designing a 2-part planet carrier, I came up with several improvements to the front and rear upright and gearbox:

• Improved tool clearance for fasteners, more accessible to power tools and torque-measuring devices

• Fixed wheel rim clearance on upper/lower ball joint mounts over full suspension travel

• Motor housing bolt pattern and brake caliper mount adjusted to make bolt insertion easier and more room for 3-thread rule extending from locking nuts

• Made gearbox serviceable with 2-part carrier & clamped bearings instead of a permanent press-fit

• Changed to angular contact from deep groove ball bearings for increased axial load capacity with smaller diameter & thickness

• Changed bearing configuration from face-to-face to back-to-back improving moment load resistance allowing for smaller, lighter bearings

• Reduced ring gear and largest bearing diameter reducing weight and improving rim clearance