Hopper Rotation Mechanism
Hopper Rotation Mechanism
Embedded Files
Mechanical Design | SolidWorks | Prototyping | Testing | Safety Analysis
Mechanical Design | SolidWorks | Prototyping | Testing | Safety Analysis
Challenge
Challenge
Our four-person team designed and fabricated a compact mechanism to rotate a cantilevered hopper through 360 degrees. The system needed controlled manual input, a target output speed of 3–4 rpm, self-locking behavior, and the ability to support increasing loads within an 18 × 18 × 12 in envelope.
Engineering Approach
Engineering Approach
We selected a worm-and-spur gear train to combine large speed reduction with self-locking behavior. I contributed to the mechanical layout, component analysis, CAD documentation, and evaluation of the prototype. The design used a 40:1 worm stage and a 2.6:1 spur stage to predict a 3.9 rpm output from a 60 rpm input.
• Checked spur gears using AGMA bending and contact-stress methods.
• Analyzed input, intermediate, and output shafts for bending strength.
• Evaluated keys, set screws, bushings, bolts, collars, and the 3D-printed input wheel.
• Produced the gearbox assembly, exploded assembly, housing, shaft, and miscellaneous-part drawings.
Results and Lessons
Results and Lessons
The physical prototype completed a full rotation with a 6 lb load and ultimately lifted 21 lb at a total cost of about $125. At higher loading, the spur gear slipped on its shaft because the set-screw connection could not transmit torque reliably. The test exposed a gap between the idealized connection analysis and the as-built hardware. A stronger revision would use keyed steel gears, accurately machined keyways, a stiffer metal housing, and wider gear faces.
Page updated
Google Sites
Report abuse