Technic Brick Power
How to use a Lego Technic differential for creating prime gear ratios for MOCs. Part 1
updated
Lego Technic Spirograph by TechnicBrickPower
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The gun can fire up to 5 meters and is very accurate at short distances. It has sight and is modelled after a machine gun.
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It is controlled via a Powered Up app program running on a tablet.
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The panel is driven either by hand using a crank or via a Powered Up motor. You can select which one to use via a manual switch.
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Find out the Lego Technic tops that rules supreme!
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The motors are disengaged from the main gearing output by moving the pivot to the center.
The high gearing ration is 4/9 and the low gearing is 4/27 (one third on the high gear).
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The gearbox uses the Lego Technic Powered Up functions to detect speed and deduce torque from that to make gear switching decisions. The gearbox switches between a high gear of 1 to 4, to a low gear of 1 to 12 (giving 3 times the torque at the output).
The gearbox is demonstrated using a proof of concept pushing vehicle to push two Lego Technic models across a table top. In the high gear the vehicle can only push one model, however when switching down a gear it can push both models.
The gearbox is so strong it can twist an axle more than three revolutions.
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Build Instructions:
rebrickable.com/mocs/MOC-114041/TechnicBrickPower/powerful-2-speed-automatic-gearbox-powered-up
In this follow up video I measure the high speed difference in friction between the new 12 and 20 tooth gears and the current bevel versions of these gears by running a high speed experiment with an up gearing of fifteen times.
In this experiment a symmetrical mirror image setup with two motors is used, where one motor drives a gear train using the bevel gears and the other motor drives an equivalent gear train using the new flat versions.
The speeds of the motors are compared using a differential and the relative torque loss calculated using the linear motor relationship between speed and torque.
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In this video I measure the difference in gearing efficiency between two gearboxes - one made from a stack of 3 of the original 12 and 20 tooth gears to create a 27 to 125 gearing ratio, and a similar version made from the new flat 12 and 20 tooth gears.
The gear box losses are measured using a powered up motor and a powered up App to determined the efficiency of each gear box by lifting different weights. The results are presented and compared for each gearbox.
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The correctness of the ratio is confirmed by matching it with output of a 2 differential gearing system that produces a ratio of 355/904 also approximating pi/8 to 7 significant figures.
Watch Pi Day 2020: youtu.be/fGg11gqZy8M
Watch Pi Day 2021: youtu.be/kcjW5oUxvdU
Watch Differentials Part 3: youtu.be/ORvnzx36j2g
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The gearbox is demonstrated by hand and by using a Lego Technic Large Power functions motor.
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Also shown is how to measure the motor speed using the Powered Up built in speed measurement widget. This speed display does not have clear unit values and I show a method for measuring the RPM (revolutions per minute) using an angular position sampling loop.
If you are new to Powered Up programming then watch my first tutorial for an introduction
TUTORIAL 1
youtu.be/0G6Qf5NHPWM
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The robot can produce topspin or backspin depending on the relative speed of the ball launch wheels. The robot is demonstrated on a table tennis table in backhand mode.
The lego technic table tennis robot is made of 1708 parts and measures 39.1cm x 27.2cm x 38.6cm and weight 1.593 kg.
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You can search for loops within different sized spaces and set the number of elbow pieces to be used. The programs supports both loops and dual axle mounted solutions.
A dynamic model is demonstrated using two elbow model solutions using about 80-85 elbow pieces each. The model is driven by a medium PF motor.
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Gearbox losses are due to friction within gears and axles rubbing on the liftarms. By measuring these losses gearbox designs can be improved.
Efficiency values are calculated and shown for several gearing combinations and for an automatic gearbox design.
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The Forklift is demonstrated in action picking up boxes and flipping Lego Technic cars.
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The tool has been updated to be able to analyze these lego technic gearing systems and show whether or not the gearing systems has underconstrained differentials and how many degrees of freedom they have. Additionally if multiple motors are connected such that there are no degrees of freedom then the speed of rotation of any driven component can be seen in terms of the weighted sum of the motor speeds.
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The car is put to the test by driving into barriers and up a ramp to see the automatic gear switching in action.
Check out my Gearing Ratio Calculator tool on technicbrickpower.com
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However as it turns out it is possible to simply use the main motor (Lego Techni powered up XL Motor) speed measurement to infer the torque on that motor simply through the inverse linear relationship between the motor speed and it's load or torque. This saves the entire torque measurement portion of the gearbox resulting in a more compact and robust design.
The Lego Powered Up app was used on an iphone to program the automatic gear switching points using a calculation based on an electric motor power curve and the gearing ratio between the current gear and the gear being switched down to.
The final lego technic 3 speed automatic gearbox using the Powered Up components is demonstrated at the end of the video.
The tool can be accessed from my new website at technicbrickpower.com
The tool only shows and supports Lego Technic parts related to gearing systems such as axles, gears, differentials, driving rings and worm gears etc. All other parts are now shown.
With this tool you can test and simulate your gearing creation before you go to the effort of building it and find out you have made a mistake!
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One motor is used to measure the torque at the output of the gearbox by detecting the rotation of an output differential; another motor is used to accurately set the position of an orange rotary catch controlling the switching between three forward gears, and finally one large powered up motor is used to drive the gearbox. The gearbox implements 3 forward speeds at gearing ratios of 1 to 1, 1 to 0.6 and 1 to 0.2 as well as one manual reverse gear.
The Lego Powered Up app has been used to program the gearbox controller on an iphone. Thanks to @racingbrick (racingbrick.com) for providing a great guide to all of the available programming blocks.
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Several improvements are made in this model mainly around the mode switching from driving forwards and backwards to rotating on the spot. In the previous model there was a lot of gear backlash causing one of the wheels to not fully rotate. This has been solved by reducing the number of gears to drive the wheel rotation and centralizing the motor driving axle.
Additionally the Lego Technic PF servo motor has been replaced by a lego technic medium motor with additional down gearing to create more torque on the wheel rotation mechanism.
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RELATED VIDEOS:
Lego Technic Omni Directional RC Vehicle v1.0
youtu.be/crj3kOiSmHg
Lego Technic Measuring Gear Backlash
youtu.be/RyvsA8jbtUs
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The lego technic mechanism opens and closes the Fantom Wallet uses a 4 state cycle based on an earlier design of a 4 state multi-function gearbox (youtu.be/AdWiViLtmdk) that switches between two outputs using the reverse directions of the motor for state changes. That gearbox drives one output at a time in either the forward or reverse direction which was exactly needed for the Fantom Wallet opener. One output drives the opening mechanism and the other output drives the closing mechanism.
In the lego technic Fantom Wallet opener the states are driven by the orange rotary catch component and changed by one length 2 liftarm driving another and using a 90 degree stepper.
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FANTOM WALLET: fantomwallet.com
RELATED VIDEOS:
Multifunction Gearbox: youtu.be/AdWiViLtmdk
The angle of lego technic gear backlash depends on the air gap and the number of teeth on the gear. It is measured for 16 tooth gears using a chain of thirty-one gears and measuring the cumulative angle and dividing by the number of gear meshes.
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The rotation mode is remotely activated by a lego technic power functions servo motor and it rotates each of the four wheels by 45 degrees to make a circular configuration. This allows the model to rotate on the spot in either a clockwise or anti-clockwise direction.
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The lego RC tank can be controlled remotely using a single remote channel and driven forwards, backwards, and steered left and right. These functions are implemented by exploiting the direction of rotation of the motor to either drive the tank or select one the four track functions.
This is done by a swinging liftarm with a gear that connects the motor output to one of two separate axles - one for driving the lego tank and one for selecting the track functions.
The track functions are built using 2 orange rotary catches to switch a lego gearbox design that allows both tracks to be selected to drive forwards or backwards or to drive in either of the two opposite directions for steering.
The track function selector uses a 90 degree stepper and a knobbed wheel to drive the rotary catches.
The lego technic tank has an indicator on top to show which function has been selected.
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RELATED VIDEOS:
Single Motor Tank: youtu.be/8rSQJKxv-e0
Lego Technic Multi Function Gearbox: youtu.be/AdWiViLtmdk
Lego Technic Dual Function Gearbox: youtu.be/U2ftXWO2yrE
Three lego gear meshing examples are working through - the first one being a straightforward rotation of the second gear in order to mesh with the first gear which is set to zero degrees.
In the second example the first gear as an arbitrary angle of rotation and the correct angle calculation of the second lego gear is demonstrated by using the angle combined with the gearing ratio between the two gears.
Each of the first two examples assumed the relative position of the second lego gear is at a multiple of 90 degrees. In the third example the position of the 2nd gear is at an angle relative to the first and again the correct meshing angle is calculated.
All of the examples are working through on the bricklink studio lego designer program. The examples are applicable to other programs such as lego's LDD design program.
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RELATED VIDEOS:
How to mesh any two Lego gears on a regular grid!
youtu.be/4gpTkVmYox4
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This is done by a swinging liftarm with a gear that connects the motor output to one of two separate axles - one for driving the lego tank and one for selecting the track functions.
The track functions are built using 2 orange rotary catches to switch a lego gearbox design that allows both tracks to be selected to drive forwards or backwards or to drive in either of the two opposite directions for steering.
The track function selector uses a 90 degree stepper and a knobbed wheel to drive the rotary catches.
The lego technic tank has an indicator on top to show which function has been selected.
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RELATED VIDEOS:
Lego Technic Multi Function Gearbox: youtu.be/AdWiViLtmdk
Lego Technic Dual Function Gearbox: youtu.be/U2ftXWO2yrE
This means you can build a lego technic remote controlled car or device that has two functions that can be remotely controlled with just 1 motor and just 1 channel of your remote transmitter and receiver combination.
BUILD INSTRUCTIONS: rebrickable.com/mocs/MOC-74906/TechnicBrickPower/multi-function-gearbox-single-motor
RELATED VIDEO: Dual function gearbox youtu.be/U2ftXWO2yrE
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This model has 23 binary digits and approximates Pi to 7 significant figures beating last year's model which approximated Pi to 6 significant figures using the continued fraction 355/113 and implemented using a differential pair. See the video youtu.be/fGg11gqZy8M.
This model has 202 gears and is almost 90cm long! The entire model is driven by a medium sized PF motor.
If you are interested in learning how to create a gearing ratio of N/P using differentials then check out this video youtu.be/ORvnzx36j2g
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This means you can build a lego technic remote controlled car that can drive, steer and change gears with just two motors, one remote receiver and one remote control unit.
This gearbox implements four gears - 3 forward and one reverse. The gearing ratios of the forward gears are 1:1, 3:5 and 1:3. The reverse gear is 9:25.
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BUILD INSTRUCTIONS: rebrickable.com/mocs/MOC-68850/TechnicBrickPower/dual-function-gearbox
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Alternative lower gearing ratios can be implemented in this lego technic 2 speed automatic gearbox by changing out the lower gearing path gears.
This 2 speed automatic gearbox operates in a bi-directional manner - meaning the input motor can rotate either way and the automatic gearbox still functions.
BUILD INSTRUCTIONS: rebrickable.com/mocs/MOC-70177/TechnicBrickPower/two-degrees-of-freedom-2-speed-automatic-gearbox
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RELATED VIDEOS:
"Lego Technic 3 Speed Automatic Gearbox"
youtu.be/TUCKzPP3HQY
"Lego Technic Two Degrees of Freedom Differential Analysis"
youtu.be/9Fyp2bzCfWk
The technic automatic gearbox will switch to a lower gears automatically as load is detected on the output of the gearbox allowing it to generate more torque to overcome the load.
The 3 speed automatic gearbox implements gearing ratios of 4 to 3, 3 to 4 and 1 to 2.
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The gearbox gearing ratios closely approximate the gearing ratios of the real Ferrari 488 GTE gearbox except that it implements a lego technic manual 8 speed gearbox instead of an automatic 8 speed gearbox.
This lego gearbox design implements the gearing ratios of 7 forward gears and one reverse gear matching the gearing ratios of the Ferrari 488 gearbox.
The design process to create the correct gearing ratio approximation is shown from paper design to actual implementation. The final model is demonstrated by driving an 8 cylinder lego technic engine using a large PF (Power Functions) motor and switching between all of the 8 possible gears.
This gearbox does not fit into the Lego Technic Ferrari 488 GTE model #42125.
BUILD INSTRUCTIONS:
rebrickable.com/mocs/MOC-79482/TechnicBrickPower/lego-ferrari-488-gte-manual-8-speed-gearbox
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The final gearbox is implemented into a lego technic 3 speed remote controlled car that can be driven backward and forwards and steered remotely, as well as remote gear changing between 3 different speeds.
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The gear shifting axle is controlled by a lever mechanism driven by the 4 state stepper from the lego technic bugatti chiron set. This mechanism in turn is driven by a medium power functions motor activated by the remote control.
The main driving axle is driven by a lego technic large PF motor.
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BUILD INSTRUCTIONS: rebrickable.com/mocs/MOC-63531/TechnicBrickPower/rc-three-speed-stepper-gearbox
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The second motor is turned on by a pole reversing switch component driven by the torque detector differential which simultaneously drives an orange rotary catch component. The rotary catch not only engages a secondary gearing path that reduces the overall gearing ratio but also engages the booster motor to provide more power at the output as required by the higher load conditions.
The gearbox is demonstrated in action by using a configurable loading mechanism that uses 10 lego clutch gears to provide ten levels of torque loading to simulate different loading situations.
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A simple derivation is presented of the physics involved in driving up a ramp in order to determine the amount of additional torque required at the motor output to be able to overcome the gravity and the corresponding potential energy.
The torque of the large lego power function motor is measured by measuring the output axle speed using a laser tachometer and relating that to the linear torque/speed relationship of the motor. These measurements are demonstrated for the car without any loading and with simple horizontal motion.
Finally the car is put to the test by attempting to drive up a 40 degree ramp.
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The worm gear switches gears by disengaging one path to the input differential, thereby reducing the overall gearing ratio. In this 2 speed gearbox design the output gearing ratio is halved when switching from gear 1 to gear 2.
By disengaging the 2nd path, the efficiency of the lower gear is improved due to the simplification of the gear train reducing the friction and power losses in that path.
The overall power of the Lego technic automatic gearbox is demonstrated by testing it against a ten level torque generation device, as well as using a rubber band pulling instrument to measure the output pulling force for both gears.
BUILD INSTRUCTIONS: rebrickable.com/mocs/MOC-67378/TechnicBrickPower/2-speed-automatic-gearbox
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The gear selector gear count has been reduced from 13 gears down to just 9 gears and a torque improvement of 40% is demonstrated via pulling on rubber bands and measuring the force using luggage scales.
The torque detector is analyzed mathematically and the equations determining it's gear ratio behaviour are presented.
Finally the overall improved Lego technic automatic gearbox is tested and demonstrated to have a powerful second gear.
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A technique for creating the 2nd gear is described by either adding to a differential by engaging a gear, or by subtracting by disengaging the gear. Issues around torque friction making it difficult to disengage a gear are mitigated by speeding up the gear switching axle to reduce torque.
A lego technic torque detection method is shown using a differential for torque detection and driving a rotary catch back to the gear selector to change gears. A strategy is shown to reduce the torque and power loss due to the lego torque detector by placing it on a secondary path from the main power path.
Finally an actual implementation of a lego technic 2 speed automatic gearbox is demonstrated and tested using a configurable torque generation mechanism using a series of clutch gears to create friction.
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Also a gear switching torque detector is fine tuned using the torque creation gadget by using two power transfer paths two transfer power from input to the output.
Finally the effect of torque on a rotary catch gear switching mechanism is demonstrated and shown that high speed and low torque is preferable to low speed and high torque for disengaging the gears.
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The peak power is calculated and a formula presented relating the power operating point as a percentage of peak power. From this an operational power range band is defined based on maintaining a power efficiency of at least E percent.
Based on this, optimal switching points relative to the motor torque are derived and the correct gear switching ratio determined. These are presented as formulas and graphs.
The peak torque and power points are shown for Lego technic PF medium motors, Lego Techinc PF Large Motors and Lego Technic PF XL Motors.
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A two path power transfer system using a differential is analysed and the power ratio between the paths is mathematically derived. This shows that the torque detector for a lego automatic gearbox can be placed on the path with the least power to reduce the overall system inefficiency.
Torque experiments show that the torque and power theory agrees in practice and will help to design a lego technic 2 speed automatic gearbox in the future.
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The gearing ratio of the 2nd gear of the 2 speed automatic gearbox can be set using a manual 4 speed gearbox to choose between gearing ratios relative to the first speed of 0.865, 0.775, 0.595 or 0.325.
The 2 speed automatic gearbox car is tested to see how well it drives up a steep hill, and is also compared to a lego manual gearbox version of the car to see the performance difference.
Finally the construction of the 2nd speed implementation using a differential is compared to a basic construction for the same gearing ratio by measuring their torque output by pulling a set of rubber bands and measuring the overall force generated.
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