Robotics Project Brief
Project Title:
Helical Gear Spinner
Objective:
The primary objective of this project is to design, model, and fabricate a fully functional helical
gear spinner. This spinner will demonstrate smooth and continuous rotational motion by utilizing
interlocking helical gears. Through this project, students will deepen their understanding of
mechanical systems, gear dynamics, rotational motion, and enhance their 3D modeling and
printing skills. It will also encourage creativity and innovation in mechanical design, helping
learners visualize the real-world application of complex mechanical concepts.
Background and Relevance:
Helical gears are a vital part of modern engineering systems. Unlike spur gears, which have
straight teeth, helical gears are characterized by their angled teeth, forming a helix shape
around the gear body. This design allows for a smoother and quieter transfer of power and
motion between shafts, even under high load conditions. Helical gears are commonly used in
automotive transmissions, industrial machines, and power plants, making them an essential
topic of study for aspiring engineers and roboticists.
By engaging in the design and construction of a 3D-printed helical gear spinner, students gain
practical experience in understanding how helical gears reduce load vibrations, minimize noise,
and achieve smoother mechanical operation compared to traditional spur gears. Moreover,
hands-on experience with these systems provides insights into the physics principles governing
gear mechanisms, including force distribution, torque transfer, moment of inertia, and centrifugal
forces.
Additionally, working with 3D printing technologies helps to build proficiency in CAD
(Computer-Aided Design) modeling, slicing, material selection, and understanding tolerances in
additive manufacturing. The skills learned in this project are highly relevant to fields like
robotics, automotive engineering, aerospace, and industrial automation.
Helical gears, while offering many advantages such as durability, high efficiency, and
load-handling capacity, also come with some disadvantages like higher friction losses compared
to spur gears, greater manufacturing complexity, and slightly increased energy waste.
Understanding both the benefits and challenges of using helical gears will better prepare
students for practical mechanical design challenges.
Scope and Deliverables:
Research and Design:
The first stage involved extensive research into the fundamentals of helical gear design. We
explored the essential parameters, including gear ratios, helix angles, pressure angles, number
of teeth, and how these factors influence the operation of the gear spinner.
● Gear Ratios: Lower gear ratios were chosen to provide greater speed, as higher ratios
would result in increased torque but reduced rotational velocity.
● Helix Angle Considerations: A moderate helix angle was selected to balance
smoothness with ease of 3D printing, as very steep helix angles may cause printing
difficulties or structural weaknesses.
We studied various examples of helical gear-based spinners and chose a design that
maximized symmetry, ease of assembly, and smoothness of motion. Materials and tolerances
were also considered to ensure that the gears meshed correctly without excessive friction or
backlash.
Design Considerations:
While designing, several critical factors were prioritized:
● Tooth Profile: Special attention was given to designing a correct tooth profile to ensure
seamless meshing. Errors in tooth geometry could lead to jamming, high friction, or
uneven wear.
● Material Selection: PLA filament was selected for its ease of printing, environmental
friendliness, and sufficient mechanical strength for a light-load application like a spinner.
● Ease of Printing: Support structures, overhangs, and layer adhesion were considered in
the design phase to ensure successful 3D prints without excessive post-processing.
Balance and Symmetry:
For a spinner to rotate effectively and smoothly, it must be well-balanced. All gears were made
identical and symmetrically arranged around the central axis. The spinner was designed so that
when held from the center, the distribution of mass is even, minimizing vibrations and wobbling
during rotation.
Testing and Evaluation:
The gear spinner underwent multiple stages of testing:
● Friction and Smoothness: The friction between the gear teeth was minimized by
adjusting the clearances slightly during design. Despite helical gears inherently having
more sliding friction than spur gears, the smoother engagement helps reduce jerky
motions.
● Durability: The spinner was tested for continuous rotations to observe if any mechanical
failures occurred, such as tooth breakage or layer separation.
● Load Capacity: Although not designed to bear heavy loads, the spinner was subjected
to moderate axial loads to test how well the gears transmitted torque without slipping or
stalling.
● High-Speed Testing: Since spinners are generally spun at high speeds manually, we
observed how centrifugal forces acted on the gears. Ensuring that the layers were
bonded properly in 3D printing was key to surviving high-speed spinning without
delamination.
Physics Concepts Involved:
● Torque Transmission: Torque = Force × Radius. In the spinner, the torque generated
by the hand's motion is transferred smoothly between the gears.
● Centrifugal Force: At higher speeds, centrifugal forces act outwardly on the mass of the
gears. Proper design ensures that this does not deform or disassemble the spinner.
● Moment of Inertia: The spinner’s mass distribution affects how quickly it can accelerate
and decelerate. A well-balanced moment of inertia leads to longer, smoother spins.
● Energy Losses: Energy losses due to friction and air resistance were observed.
Reducing these helps achieve longer spin times, which is one of the project's
performance metrics.
Mathematical model:
Some of the mathematics behind the helical gear spinner are:
Angular position:
θ = θ₀ + ω₀t + (1/2)αt²
This gives us the track of how much the gear has rotated over time.
Angular velocity:
ω =Δθ / Δt
It tells us how fast the gear is revolving around at that moment.Also it is used to calculate torque
and power transmitted.
Gear ratio:
Gear Ratio = (Number of teeth on driven gear) / (Number of teeth on
driving gear)
It tells us how the speed is reduced.And used to compute the angular velocity and output
torque.
Kinetic energy:
KE = 1/2 * m * v²
It represents the energy stored in helical gear spinner and it is used to assess the work needed
to accelerate or decelerate the gear.
Applications:
The helical gear spinner is not just a toy but a powerful educational tool that demonstrates
real-world engineering principles.Like, understanding helical gears helps in learning how car
gearboxes function, enabling smooth acceleration and gear shifts. Helical gears are used in
mills, conveyors, and lifting machines where smooth, reliable power transmission is crucial.
Gears with minimal noise and high load capacity are critical in aircraft components. Wind
turbines and marine propulsion systems often utilize helical gears for their reliability under high
loads and challenging conditions.
Resources Required:
● 3D Printer (FDM printer capable of precise layer heights)
● PLA Filament (for durable and easy-to-print gears)
● Files and Sandpaper (for smoothing gear surfaces post-printing)
● Safety Glasses (for eye protection during filing and handling)
● Gloves (to avoid injury while handling tools and printed parts)
Timeline:
● 1st Week: Research into gear mechanics, helical gear properties, and 3D printing
techniques.
● 2nd Week: Finalizing project brief and initial sketches.
● 3rd–4th Week: Detailed 3D CAD designing, iterations for improvement.
● 5th–6th Week: Project design confirmation, preparing final files for printing.
● 6th–7th Week: 3D printing of components, post-processing, and initial assembly.
● 15th April: Final project confirmation, assembly, and testing phase.
Expected Outcomes:
By the end of the project, we expect to have a fully functioning helical gear spinner that rotates
smoothly, demonstrating the efficiency and advantages of helical gears. The spinner should
show prolonged spin times, minimal friction, and an aesthetically pleasing, balanced rotation.
Students will gain a strong foundation in gear physics, 3D printing techniques, and mechanical
design principles.
Safety Considerations:
● Protective Equipment: Gloves and safety glasses will be worn during filing and sanding
operations to protect hands and eyes.
● Tool Handling: Care will be taken while using sharp or rotating tools like drills to prevent
accidents.
● Material Handling: Printed parts will be handled carefully to avoid sharp edges or
splinters.
● Workshop Safety: Standard workshop safety protocols will be observed throughout the
project to ensure a safe learning environment.
