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
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 spacesMecanum 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 softwareStandard 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 requiredPolyurethane:
Advantages: Good grip, durable, consistent
Disadvantages: More expensive, overkill for most robots
Best for: Commercial-grade robotsHard Plastic:
Advantages: Cheap, light, never wears
Disadvantages: Poor grip, slips on smooth surfaces
Best for: Smooth floor line-followers, indoors onlyWheel 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 terrainGears
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 stagesBevel 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), differentialsPlanetary 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 gearboxesWorm 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 positioningGear 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 robotsBelt 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, fansRatio 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 = 3:1Mechanical 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 / HeightGearbox 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× MACompound 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 outputMotor Selection for Movement
Torque Calculation
Robot must overcome:
- Wheel friction
- Weight (on slopes)
- 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 fineSpeed 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 powerEnergy 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 motorCommon Power Transmission Types
| Type | Ratio Range | Efficiency | Noise | Maintenance | Cost |
|---|---|---|---|---|---|
| Spur Gear | 2:1 - 50:1 | 95% | High | Low | Low |
| Planetary | 3:1 - 100:1 | 92% | Very Low | Very Low | High |
| Worm Gear | 5:1 - 100:1 | 60% | Very Low | Low | High |
| Chain Drive | 2:1 - 30:1 | 95% | High | Medium | Low |
| Belt Drive | 2:1 - 30:1 | 92% | Very Low | Low | Medium |
| Direct (no reduction) | 1:1 | 98% | Medium | None | Very 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?