Powertrain of 3D printed remote controlled 2-speed AWD car
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- čas přidán 9. 09. 2024
- This project is a DIY car including 2-speed gearbox, clutch, center differential with optional lock, parking brake, and Torsen differentials in the front and rear. The independent suspension of the wheels is supported by dual cardan joints and the rack-and-pinion steering approximates the Ackermann condition. Most of the mechanics are selfmade from 3D printed parts. The electronics and the remote control are custom-built based on ESP32 microntrollers.
The video displays the different components of the powertrain and shows how the actuators work. Gear shifter, clutch, and diff lock use brushed DC motors (N20). The brake uses a stepper motor (NEMA 14). The steering uses an RC servo motor (20 kg/cm).
You can find all details and files here: www.instructab...
All I can imagine is the time you put into designing this
What's really weird is I've owned a 2 speed AWD RC car and the drivetrain was nowhere near this complicated.
This is probably one of the most impressive 3D printing projects I’ve seen. Good job!
So much effort went into to this from so many different perspectives!
Really cool, and just as loud as I expected it to be! :)
Closing the bottom cover helps a little bit with reducing the noise 😄
coolest thing ive ever seen!
Gorgeous tight integration; a joy to marvel over. Thank you!
This is awsome, great stuff.
That's one complex car! Well done
This is so cooooooooool !
Absolutely amazing! I really really appreciate your use of a torsen differential!
"hold on something broke, see you next year".
It's not that bad - the drivetrain is modular, so I don't need to reprint and disassemble everything when something needs to be replaced 😂
Great project
I cannot imagine the effort that you put in to produce such an amazing thing. Great job
Super impressive!
Really nice, only thing missing are some nice CV shafts instead of the cardans.
Thank you! I opted for the Cardan joints on purpose because I really like this design. Also, since I'm using double Cardan joints for the drive shafts, the non-constant output velocity of a Cardan joint is compensated as long as the car goes straight. I can live with the remaining distortion on the front axle when turning :D
@@TRDB_ the problem with printed kardans that I have found, it that they brake easily due to the bending forces and self induced vibrations :D
I also expected them to be a weak point of the car, but so far, none of them shows any sign of wear.
VERY NICE I especially like the torsin differentials! Good work
Very interesting, thanks for sharing. Do you plan to show more details about the steering part? The method you use is different than the method usualy used on RC cars.
Thank you! Yes, I will share all details regarding this project, including the CAD files, in the upcoming instructable. The employed steering method is called rack-and-pinion steering. I just need some more time to finalize the instructable. It'll likely be online within the next four weeks :)
@@TRDB_ thank you for your quick answer! Can’t wait to see it more in detail. :-)
An incredible effort. Well done
Awesome job man! I also love 3D designing and I know how much tries it takes to make everything fit and work, soo cool design :)
Thank you! Yes, it took quite some time to finalize the design 😅
Impressive
Beautiful torsen 🤤
great work! and love the diffs
Nice
I wouldn't have thought that was normal, cool.
Awesome !!
great job, looks amazing
nice job
I am so envious of how the operation of your gears sound. Every time I try to make 3d printed gears they sound awful.
Thanks! Although I think the gears are quite noisy 😅
Incredible design! How much time in CAD did you spend? I can only imagine the project version number haha. Cheers
Almost 😄
Version 3 was my RC tank. I started working on the AWD car with V4, but V4 was a failure - thus, only two generations for this vehicle ;)
@@TRDB_ I can only imagine what the next version will be like! I'm looking forward to it😄
Amazing design and engineering skills and nice to see something different and innovative from the typical rc cars..would perhaps make a good rock crawler. There is a reason however that typical rc cars are not designed this way though, weight and friction losses, if you can achieve the same or better result with less then that is always the best design/engineering but as a technical piece of exploration this is nice to see.
Thanks! Yes, it doesn't make sense for an applied system to make it more complex than needed, which is why I never intended to compete in terms of performance or durability. It was about the engineering challenge :)
Super impressive, What program did you use to design?
Thank you! I use Fusion 360 for the mechanical parts.
@@TRDB_If you used fusion 360 to design the gears as well, I salute you. I've been trying to use it to design gears wver now and then, and I've NEVER had much success despite looking at a decent amount of resources to help.
@@tjpprojects7192 There's a great add-in for Fusion 360 called 'GF Gear Generator'. I use this tool to design the basic gears and then customize them as needed. This gear generator is really straightforward to use!
amazing
Cool project. Have you discovered brushless motors? Your Torsen differential should be limited slip, but it seems to behave like a normal, simpler diff. Torsen's should have cross gears, not worm gears...
Thank you! Yes, I'm aware of BLDCs and their advantage over brushed motors. However, they're more expensive and this project is not intended for maximum performance (if that would be the goal, all these powertrain parts would need to be removed...). That's why I considered the 775 brushed DC motor as sufficient for this project. The Torsen diff that I use is the type-A Torsen. Maybe you are referring to the type-B Torsen? The implemented design of the Torsen differential has a very weak torque bias ratio, so yes, it hardly acts as a limited slip differential because the friction is quite low. On the other hand, due to the poor tolerances of the printed parts, I was unable to increase the inner friction without resulting in noticeable high-friction and low-friction points at certain angles. I wanted the differential to operate smoothly, which is why all the gears are mounted on bearings so that the only friction-adding feature is the 45° helical gears between the output shafts and the planet gears.
Needs a dozen more gears
Wow
wow! This is art. This is a great stimulus to me as I work hard to automate my workshop. I'm subscribing. I look forward to more great works.
I'm curious to know what would be the weakest link, the first one to break/fail?
My guess would be the gear closest to the motor or a link close to the wheels. What do you think?
Since the torque increases with every gear reduction, the gears closest to the motor have to withstand the smallest torque. That's why the pinions at the front and rear diff are most prone to failure (particularly the rear one due to the asymmetric torque distribution). I updated its design already twice - I'm also curious if the latest update will last longer than a few hours!
Interestingly, the drive shafts don't show any signs of wear yet. But I had to create more sturdy rims because the spiders of the front wheels' rims had cracks after some test drive sessions.
@@TRDB_ Thank you for all your answers! I'm sure a lot of people will read them as well. We are very proud of yourself!
Do you have a rough idea how many hours you spend on this project? I know.. It's hard to tell, most of the time is thinking not making.
@@alexandrevaliquette3883 I never count the hours I spend on hobby projects (that could either be an impressive or depressing number, depending on who you ask 😂). I can tell that it took about one year from starting with the idea to finishing the Instructable. I did work on the project in my spare time on weekends and during vacation.
Will you put grease to make the gears last longer?
Do you plan to use it like a toy (long time) or it's more like a trophy for demo (no grease)?
There's grease on the gears and I've driven the car already for several hours :)
I design similar things so i can only imagine how much time you had to spend setting your inserts and screwing parts down. The rack and pinion steering was a nice touch, did you use nylon for the gears?
Thank you! All gears are made from PETG. Easy to print 👌
👍
What’s the torque value !
Does it run fast
It's not designed to go fast. The gear reduction in the slow gear is 39.1 and in the fast gear it is 21.7. Assuming that the motor delivers what its manufacturer promises (10k rpm), the resulting maximum speed is 6.5 km/h in the slow gear and 11.7 km/h in the fast gear. The torque is likely high enough to tear the powertrain apart (although I never tested that). I'm using an interpolation on the motor control to limit accelerations so that the wheels don't slip at full throttle, which also reduces the strain on the drivetrain.
been printing much...
This is so cool man! How reliable is it?
Thank you! It took some time, but after several design iterations, I'd call it quite reliable. The powertrain has been operated for several hours (actual driving, not with wheels freely spinning in the air), and what has been the weakest part is the pinion connecting the center differential with the rear differential. However, it didn't break since the last design update.
So many gears, so many power loss
Luckily, efficiency is not what this project is about 😄
Could of just gotten a summit and had lockers too
The project is now online as an Instructable: www.instructables.com/3D-Printed-Remote-Controlled-2-speed-AWD-Car/
How much mechanical loss
I don't know - but I guess a lot 😅
@@TRDB_ this is the dirtiest engineering porn ever!
Ähh........A 2 Gear Sprocked Is Available Since.......Decades
Yes, like a clutch, a differential, the Cardan joints, and so on: All the powertrain parts in this car are adapted from existing technology. That is the idea of this project 😅
Чем плоха серва?
If you refer to why I didn't use servo motors for the actuators of the powertrain, I can recommend that you have a look at the instructable of this project. There are explanations regarding my design choices. In brief, I did not like that cheap servos have backlash and poor accuracy, and in general, RC servos do not provide positional feedback. Therefore, it was easier to build a custom servo based on an N20 motor connected to a potentiometer instead of trying to fit a decent servo together with a position feedback circuit into the chassis.
Cool af, those mechanical torsen diffs are awesome, would love to see a detailed breakdown of the whole thing top to bottom
There's no full video of that, but you can find all details regarding the mechanics and electronics, including explanations for my design choices, in the Instructable for the car: www.instructables.com/3D-Printed-Remote-Controlled-2-speed-AWD-Car
You could have done it better with 50 times less parts!
I'm obviously kidding!
This is a masterpiece. Well, sure, as you obviously know, you can build a 4X4 RC with less parts and it will be lighter, more efficient and more durable. Just use one motor per wheel.
I design in Fusion 360, the level of complexity/details is very VERY impressive!
I hope you will make a lot of video about it. Explain the concept, how you overcome challenge, etc. Only if video is your thing, or maybe get someone interview yourself? This is too awesome to not share it with the world!
Fat thumbs up from Montréal!
Thank you - and you're right, this project is making an RC car unnecessarily complex. 😄
And that was the point: adding all these printed drivetrain parts and still having a somewhat robust, functional car.
I'm not adding more videos because the videos are only meant to support the Instructable of this project. If you're interested in more details, please check it: www.instructables.com/3D-Printed-Remote-Controlled-2-speed-AWD-Car/