Grundfos challenge gearbox

grabcad

This is my take on the Grundfos challenge gearbox. Featuring 550x reduction, the output torque and speed should stay in spec when operating the motor at around 550 rpm (550 when assuming 97% gear efficiency, should be adjusted to reflect actual efficiency which will be derived by testing). Structural parts are mostly injection molded .The same material as for the box can be used to reduce costs associated with operating multiple production lines. The planetary gearboxes require metal construction to mate with the sun gear axles. Rotational constraint is mostly handled by oil embedded bronze bushings to eliminate the need for lubrication.The gears themselves can be made from either steel or phospor bronze (again to remove the need for lubrication). Shafts should be made from suitable tool steel. Some standard mounting harware is also used in the construction.Precision-requiring components are designed in such a way to be self-aligning. Plastic parts are optimised for injection molding with simple two piece molds (except for the original surfaces of the enclosure box, those were left unchanged)Unfortunately, my design does not entirely fit the specified design space envelope. I got so far into the design that miniaturisation would require substantial changes for which I did not have time.