Chronicle
Mechanical and Structural Design

Transmission and Motion

Wheels, gears, chains, belts, pulleys, mechanical advantage, efficiency calculations, and motion transmission systems

Transmission and Motion

Transmissions convert motor output into useful motion. Proper selection affects speed, torque, efficiency, and power consumption.

Wheels and Tires

Different types of robot wheels

Figure: Various wheel types for different robot applications

Wheel Types

Omni-Directional (Omni Wheel)

Structure:
    Main wheel

    ○───○  (small rollers around center)
   ○ ◯ ○   (blue = roller axis)
    ○───○

Motion:
├─ Forward: Main wheel pushes
├─ Side: Rollers allow sideways glide
├─ Rotate: In place rotation possible
└─ Diagonal: Any direction!

Advantages:
✓ Holonomic motion (any direction)
✓ No turning radius needed
✓ Perfect 90° turns

Disadvantages:
✗ Expensive ($30-60 each)
✗ Complex mechanically
✗ Less traction (roller slip)
✗ Requires 4 wheels minimum

Best for: Soccer robots, navigation in tight spaces

Mecanum Wheel

Structure:
  Angled rollers (45°)
     ↙ ↓ ↘
    □─◯─□  (rollers at 45°)
     ↙ ↓ ↘

Motion Pattern (4-wheel):
Forward:   All wheels rotate same direction
Strafe:    Left/right wheels opposite
Rotate:    Front/back opposite pairs
Diagonal:  Combinations of above

Result: Holonomic motion like omni wheels

Advantages:
✓ Holonomic capability
✓ Better traction than omni
✓ Simpler mechanism

Disadvantages:
✗ Expensive
✗ Requires precise alignment
✗ Complex control software

Standard Wheel (Most Common)

Simple cylinder (rubber or plastic)

  [O] = Wheel on axle

Motion:
├─ Forward/backward: Rotates
├─ Steering: Must pivot entire wheel
└─ Sideways: Zero slip (must turn)

Advantages:
✓ Very cheap ($5-15 each)
✓ Simple mechanics
✓ Reliable and robust
✓ Good traction

Disadvantages:
✗ Requires turning radius
✗ Three-point turns needed
✗ Differential steering complex

Best for: Most robots (wheeled platforms)

Tire Material

Rubber:

Advantages: Best grip, durable, all-weather
Disadvantages: Heavy, wear over time, affected by temperature
Best for: Outdoor robots, off-road, high traction required

Polyurethane:

Advantages: Good grip, durable, consistent
Disadvantages: More expensive, overkill for most robots
Best for: Commercial-grade robots

Hard Plastic:

Advantages: Cheap, light, never wears
Disadvantages: Poor grip, slips on smooth surfaces
Best for: Smooth floor line-followers, indoors only

Wheel Size Selection

Small wheels (2-3 inches):
├─ Pro: Faster acceleration, responsive
├─ Con: Slower max speed, bouncy
└─ Best for: Line-followers, tight spaces

Medium wheels (4-6 inches):
├─ Pro: Good balance, stable
├─ Con: Average performance
└─ Best for: General mobile robots

Large wheels (8+ inches):
├─ Pro: Highest speed, smooth over obstacles
├─ Con: Slow acceleration, heavy
└─ Best for: Racing, outdoor terrain

Gears

Gear Types

Spur Gear (Parallel Shafts)

Structure:
    Teeth

  ◯─●─◯  (flat teeth)
  ◯─●─◯
    ◯▼◯

Motion:
Input shaft ──→ [Teeth mesh] ──→ Output shaft
          90° rotation (shafts parallel)

Ratio calculation:
Output_speed = Input_speed × (Pinion_teeth / Gear_teeth)
Torque multiplies inversely

Example:
Input: 1000 RPM, 10 teeth
Output gear: 50 teeth
Output: 1000 × (10/50) = 200 RPM, 5× torque

Advantages:
✓ Simple, reliable
✓ Efficient (95%+)
✓ Compact
✓ Wide ratio range

Disadvantages:
✗ Noise at high speed
✗ Shaft misalignment causes wear
✗ Backlash (play) possible

Best for: Motors to wheels, gearbox stages

Bevel Gear (90° Shafts)

Structure:
    Shaft B

  ◣───┤───◢
  ◢───┤───◣  ← Angled teeth (cone shape)

    Shaft A

Motion: Right angle power transfer

Advantages:
✓ Compact 90° connection
✓ Good efficiency

Disadvantages:
✗ Expensive
✗ Complex to align
✗ Harder to replace
✗ Lower efficiency (80-90%)

Best for: Robot arms (elbow joints), differentials

Planetary Gear (Compact)

Structure (Epicyclic):
      Sun

   ◯ ◢◣ ◯  ← Planets revolve
   ◢ ◯ ◣
      Ring

Motion:
Input: Sun or Ring
Output: Carrier (planets)
High ratio possible in compact space

Ratios: 3:1 to 100:1 in same space as spur

Advantages:
✓ Extremely compact
✓ Very high ratios possible
✓ Smooth operation
✓ Good efficiency

Disadvantages:
✗ Very expensive
✗ Complex mechanics
✗ Difficult to repair
✗ Backlash harder to control

Best for: Compact robot joints, servo gearboxes

Worm Gear (90° + High Ratio)

Structure:
    Worm shaft
        ↓ (screw-like)
      ▔▔▔▔▔
    ◯ ████ ◯
    ◯ ████ ◯
      ▁▁▁▁▁

    Worm wheel

Motion:
Worm rotates 1 complete turn
Worm wheel rotates 1 tooth (high ratio!)

Ratio: 5:1 to 100:1 easily

Advantages:
✓ Extremely high ratio
✓ Compact
✓ Self-locking (no backdrive)
✓ Smooth quiet operation

Disadvantages:
✗ Very expensive
✗ Low efficiency (50-70%)
✗ Heat generation
✗ Limited to low-speed output

Best for: Robot arm joints, precision positioning

Gear Ratios

Formula:
Ratio = Pinion_teeth / Gear_teeth

Speed change:
Output_RPM = Input_RPM / Ratio

Torque change:
Output_torque = Input_torque × Ratio × Efficiency

Example Mobile Robot:
├─ Motor: 1000 RPM, 0.5 N⋅m
├─ Gearbox: 10:1 ratio, 95% efficiency
├─ Output: 100 RPM, 4.75 N⋅m
└─ Fast enough? Low torque? Adjust ratio!

Chains and Belts

Chain Drive

Structure:
    Sprocket  
    (tooth wheel)

    ◯───────◯  ← Chain links
    ◯───────◯

    Sprocket

Motion:
Input sprocket → Chain → Output sprocket
Mechanical connection (no slip!)

Advantages:
✓ No slip (positive drive)
✓ Efficient (95%+)
✓ Can span long distances
✓ Tolerates misalignment
✓ Easy ratio changes (swap sprockets)

Disadvantages:
✗ Requires lubrication
✗ Noisy
✗ Heavy
✗ Needs tension adjustment
✗ Wears over time

Best for: Robot wheels, conveyor systems, outdoor robots

Belt Drive

Structure:
    Pulley

    ┏━━━┓  ← Rubber belt
    ┗━━━┛

    Pulley

Motion:
Input pulley → Belt grip → Output pulley
Friction drive (slight slip possible)

Types:
├─ Flat belt (simple, weak)
├─ V-belt (wedge grip, powerful, still smooth)
└─ Timing belt (teeth, positive drive)

Advantages:
✓ Smooth quiet operation
✓ Isolates vibration
✓ No maintenance (no lubrication)
✓ Doesn't need precision alignment

Disadvantages:
✗ Slip possible (especially flat belts)
✗ Speed sensitive (changes with wear)
✗ Tension must be correct
✗ Heat generation possible

Best for: Smooth power transmission, conveyor, fans

Ratio Calculation

Chain/Belt ratio depends on sprocket/pulley size:

Ratio = Driven_size / Driver_size

Example:
Input pulley: 30mm diameter
Output pulley: 90mm diameter
Ratio = 90/30 = 3:1 (3x slower, 3x more torque)

For chains (teeth count):
Input sprocket: 20 teeth
Output sprocket: 60 teeth
Ratio = 60/20 = 3:1

Mechanical Advantage

Definition

Mechanical advantage (MA) = Output force / Input force

Simple machine examples:

Lever:
    ↓ Force in

────┼────────
    │        ↓ Load out
    
MA = Lever_arm_in / Lever_arm_out

Pulley:
    ☐ ← Fixed

    │ ── Rope

   Load

MA = Number_of_rope_segments

Incline:
   ╱╲
  ╱  ╲← Length
 ╱────╲
 Height

MA = Length / Height

Gearbox MA

Example 10:1 gearbox:

Input: 1 newton force (small gear)
Output: 10 newton force (large gear)
Mechanical Advantage = 10

Reality: Losses due to friction
├─ Efficient gearbox: 95% = 9.5× MA
├─ Chain drive: 95% = 9.5× MA
├─ Belt drive: 90-95% = 9-9.5× MA
└─ Worm gear: 60-70% = 6-7× MA

Compound Systems

Example: Gearbox (10:1) + Belt (3:1) + Chain (2:1)

Total ratio: 10 × 3 × 2 = 60:1

Efficiency:
├─ Gearbox: 95%
├─ Belt: 92%
├─ Chain: 95%
└─ Total: 0.95 × 0.92 × 0.95 = 83% efficiency

So: 60:1 mechanical advantage × 83% efficiency
     = 50× useful output

Motor Selection for Movement

Torque Calculation

Robot must overcome:

  1. Wheel friction
  2. Weight (on slopes)
  3. Acceleration resistance
Equation:
Torque_required = (Friction_coefficient × Weight × gravity × Radius)
                + (Weight × gravity × sin(angle) × Radius)
                + (Mass × Radius × Acceleration)

Example (flat ground):
├─ Weight: 10 kg
├─ Wheel radius: 0.05 m (5 cm)
├─ Friction coefficient: 0.1
├─ Torque = 0.1 × 10 × 9.81 × 0.05 = 0.49 N⋅m

Two motors (front wheel drive):
├─ Each motor needs: 0.49 N⋅m / 2 = 0.245 N⋅m
└─ Standard motor: 0.3 N⋅m works fine

Speed Calculation

Wheel speed = (Motor_RPM / Gear_ratio) × Wheel_circumference

Example:
├─ Motor: 300 RPM (after gearing)
├─ Wheel diameter: 0.1 m (10 cm)
├─ Circumference: π × 0.1 = 0.314 m
└─ Speed: 300 × 0.314 / 60 = 1.57 m/s = 5.7 km/h

Is this fast enough for competition? Depends on requirements!

Power Transmission Efficiency

Overall System Efficiency

Motor power → Losses → Final mechanical power

Typical breakdown (10W motor):
├─ Motor: 90% (inherent losses)
├─ Gearbox: 95% (friction in gears)
├─ Chain: 95% (friction, drive loss)
└─ Wheels: 97% (rolling resistance)

Total: 0.90 × 0.95 × 0.95 × 0.97 = 78% efficient

So: 10W motor × 78% = 7.8W useful mechanical power

Energy Loss Analysis

Where power goes (10W motor example):

Motor: 1W lost as heat
Gearbox: 0.5W lost (metal-to-metal friction)
Chain: 0.25W lost (link friction)
Wheels: 0.3W lost (rolling resistance)
Total losses: 2.05W
Useful: 7.95W

Solutions to improve:
├─ Better quality gears (reduce friction)
├─ Lubricate chain regularly
├─ Lower rolling resistance tires
├─ Reduce weight
└─ Use high-efficiency motor

Common Power Transmission Types

TypeRatio RangeEfficiencyNoiseMaintenanceCost
Spur Gear2:1 - 50:195%HighLowLow
Planetary3:1 - 100:192%Very LowVery LowHigh
Worm Gear5:1 - 100:160%Very LowLowHigh
Chain Drive2:1 - 30:195%HighMediumLow
Belt Drive2:1 - 30:192%Very LowLowMedium
Direct (no reduction)1:198%MediumNoneVery Low

Real-World Transmission Systems

Mobile Robot (Wheel Drive)

System:
Motor → Gearbox (10:1) → Wheel

Specs:
├─ Motor: 300 RPM, 0.5 N⋅m
├─ Gearbox: 10:1, 95% efficiency
├─ Output: 30 RPM, 4.75 N⋅m
├─ Wheel (5cm): Tangential force = Torque/Radius
│  = 4.75 N⋅m / 0.05 m = 95 N (enough to move!)
└─ Speed: 30 RPM × 2π × 0.05 / 60 = 0.157 m/s

For 1 m/s speed needed?
Required RPM: 1 m/s × 60 / (2π × 0.05) = 191 RPM
Gearbox ratio: 300 / 191 = 1.57:1 (lower reduction)

Robot Arm Joint

System:
Motor → Planetary gear (20:1) → Link arm

Specs:
├─ Motor: 200 RPM, 0.2 N⋅m
├─ Gearbox: 20:1, 92% efficiency
├─ Joint output: 10 RPM, 3.68 N⋅m
├─ Arm length: 0.3 m
├─ Load: Can hold 1.2 kg at end
│  (3.68 / 0.3 / 9.81 = 1.25 kg) ✓
└─ Speed: 10 RPM allows precise positioning

Tradeoff: Slow but strong (good for arms!)

High-Speed Conveyor

System:
Motor → Minimal reduction → Pulley

Specs:
├─ Motor: 1500 RPM, 0.1 N⋅m
├─ Reduction: 2:1 (just for extra torque)
├─ Output: 750 RPM, 0.19 N⋅m
├─ Pulley radius: 0.05 m
├─ Belt speed: 750 RPM × 2π × 0.05 / 60 = 3.93 m/s
├─ Carrying capacity: Good for light items
└─ Efficiency: 98% (direct drive, very efficient)

Tradeoff: Fast but weak (good for conveyor!)

Troubleshooting

Common Transmission Problems

Slipping belt/chain:

  • Cause: Insufficient tension, worn belt, misalignment
  • Solution: Tighten, replace, realign pulleys/sprockets

High noise/vibration:

  • Cause: Misalignment, damaged gear teeth, loose mountings
  • Solution: Check alignment, inspect for cracks, tighten fasteners

Excessive heat:

  • Cause: High friction, poor lubrication, overload
  • Solution: Use lubricant, reduce load, check efficiency

Motor stalls:

  • Cause: Insufficient torque, binding, overload
  • Solution: Reduce load, check for obstructions, increase gearing ratio

Loss of motion control:

  • Cause: Backlash (play) in drivetrain
  • Solution: Pre-tension system, use anti-backlash gears, adjust geometry

Design Checklist

Before selecting transmission:

  • What torque is required? (Calculate from load)
  • What speed is needed? (How fast must robot move?)
  • What's available space? (Compact or large?)
  • What's the budget? (Simple vs complex)
  • How much noise acceptable? (Quiet or OK?)
  • How often will maintenance occur? (Lubrication schedule?)
  • What's the duty cycle? (Continuous or intermittent?)
  • Must it be reversible? (Forwards and backwards?)

After selection:

  • Motor and gearbox match in torque/speed output
  • Driven components can handle calculated force
  • Alignment is within tolerances
  • Fasteners are properly secured
  • Lubrication is applied per manufacturer spec
  • System tested under full load
  • Emergency stop works if applicable

Summary

Wheels:

  • Standard wheels: simplest, most common
  • Omni/Mecanum: holonomic motion, expensive
  • Size and material affect grip and speed

Gears:

  • Spur: efficient, simple, noisy
  • Planetary: compact, high ratio
  • Worm: self-locking, but inefficient

Transmission types:

  • Direct drive: efficient, high speed, low torque
  • Gearbox: adjustable speed/torque ratio
  • Chain/belt: can span distances, smooth operation

Key calculations:

  • Torque required = Load considerations
  • Speed achievable = Motor RPM ÷ gear ratio
  • Efficiency = Product of all component efficiencies
  • Mechanical advantage = Force multiplication

How is this guide?