93% Efficient 10:1 Transmission

I was tasked with creating a 10:1 transmission optimized for both energy efficiency and mass efficiency. The transmission achieved a 93.8% energy efficiency, the best in the class. Our project presents a sophisticated rack and pinion transmission system featuring a PLA frame with M4 screw assembly, a two-stage transmission using five laser-cut 7075-T6 aluminum gears, and a rack with a linear rail and cart mechanism. The design prioritizes both efficiency and robustness, achieving a total gear ratio of 10.02 and supporting a minimum drop mass of 23.5 pounds to raise the 1kg (2.2lb) weight. The frame, constructed with a factor of safety of 1.9, ensures minimal displacement and friction. The transmission utilizes hardened steel D-shafts and flanged ball bearings for smooth operation, while the rack's optimized tooth pitch of 24 and strategic load placement prevent excessive moments. This system effectively balances material strength and performance, resulting in a highly reliable mechanical application.