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-<?xml version="1.0" encoding="UTF-8"?><rss xmlns:dc="http://purl.org/dc/elements/1.1/" xmlns:content="http://purl.org/rss/1.0/modules/content/" xmlns:atom="http://www.w3.org/2005/Atom" version="2.0" xmlns:media="http://search.yahoo.com/mrss/"><channel><title><![CDATA[Caden Kraft]]></title><description><![CDATA[Some of my Projects]]></description><link>https://cadenkraft.com/</link><image><url>https://cadenkraft.com/favicon.png</url><title>Caden Kraft</title><link>https://cadenkraft.com/</link></image><generator>Ghost 5.79</generator><lastBuildDate>Tue, 03 Sep 2024 19:37:30 GMT</lastBuildDate><atom:link href="https://cadenkraft.com/posts/rss/" rel="self" type="application/rss+xml"/><ttl>60</ttl><item><title><![CDATA[3D Printed Dual Cycloidal Actuator]]></title><description><![CDATA[This project builds on my previous axial flux motor. To improve the torque output of the motor I designed a cycloidal gearbox that integrates into the current motor design allowing for more torque.]]></description><link>https://cadenkraft.com/3d-printed-dual-cycloidal-actuator/</link><guid isPermaLink="false">65d922ddf6e4040001065708</guid><category><![CDATA[Motors]]></category><category><![CDATA[Build]]></category><dc:creator><![CDATA[Caden Kraft]]></dc:creator><pubDate>Fri, 23 Feb 2024 00:57:43 GMT</pubDate><media:content url="https://cadenkraft.com/content/images/2024/02/Title-Image.jpg" medium="image"/><content:encoded><![CDATA[<img src="https://cadenkraft.com/content/images/2024/02/Title-Image.jpg" alt="3D Printed Dual Cycloidal Actuator"><p>This project is a continuation of my previous axial flux motor project. If you&apos;ve not yet read that I would recommend doing so.</p><figure class="kg-card kg-bookmark-card"><a class="kg-bookmark-container" href="https://cadenkraft.com/designing-a-coreless-axial-flux-motor-part-1/?ref=10.0.0.222"><div class="kg-bookmark-content"><div class="kg-bookmark-title">Ironless Axial Flux Motor</div><div class="kg-bookmark-description">After my first custom brushless motor I felt confident enough with the basic theory of how they work to make a second design with significantly more thought and math defining the design. Creating a 3D Printed Brushless MotorWith my work in the Iowa State Solar Car club I have learned</div><div class="kg-bookmark-metadata"><img class="kg-bookmark-icon" src="https://cadenkraft.com/content/images/2022/11/favicon.ico" alt="3D Printed Dual Cycloidal Actuator"><span class="kg-bookmark-author">Caden Kraft</span><span class="kg-bookmark-publisher">Caden Kraft</span></div></div><div class="kg-bookmark-thumbnail"><img src="https://cadenkraft.com/content/images/2022/09/title-page-render-axial-flux-motor.16.jpg" alt="3D Printed Dual Cycloidal Actuator"></div></a></figure><p>After I was finished with making my last motor project I was quite proud of the results. However, while the motor could achieve extremely high RPM&apos;s, this came at the cost of torque.</p><p>Originally I thought about rewinding the stator and possible improvements via stronger magnets and/or Iron based 3D printer filament for the stator coils among other things. </p><h2 id="deciding-on-a-gearbox">Deciding on a Gearbox</h2><p></p><p>Wanting to work on something a little more different than pure motor design and not wanting to rewind any coils, I set my sights on developing a gearbox that could be integrated into my current stator design. There were 3 primary options that I was looking into when deciding what gearbox that I was going to make, Planetary, Cycloidal, and Harmonic.</p><figure class="kg-card kg-gallery-card kg-width-wide kg-card-hascaption"><div class="kg-gallery-container"><div class="kg-gallery-row"><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/cycloid1-1.gif" width="366" height="355" loading="lazy" alt="3D Printed Dual Cycloidal Actuator"></div><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/HarmonicDriveAni-1.gif" width="700" height="700" loading="lazy" alt="3D Printed Dual Cycloidal Actuator" srcset="https://cadenkraft.com/content/images/size/w600/2024/02/HarmonicDriveAni-1.gif 600w, https://cadenkraft.com/content/images/2024/02/HarmonicDriveAni-1.gif 700w"></div><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/planetary.gif" width="300" height="332" loading="lazy" alt="3D Printed Dual Cycloidal Actuator"></div></div></div><figcaption><p><span style="white-space: pre-wrap;">Cycloidal (left), Harmonic (center), Planetary (right)</span></p></figcaption></figure><p>All of these options definitely seem like good ideas but I had to narrow down which one I was going to choose.</p><p>Planetary would have been the easiest and probably would have performed the best but I cut it out because I didn&apos;t really find it interesting enough and wanted to learn more about the other gearboxes. </p><p>While I admire the simplicity of the harmonic drive I was wary of my ability to manufacture the flexible parts needed. I eventually chose the cycloidal drive because it seemed like the biggest technical challenge to design as well as the fact that it looks extremely cool. Cycloidal gearboxes also have nearly no backlash which definitely made it stand out against something like a planetary gearbox with the tolerances of 3D printed parts.</p><h2 id="defining-project-requirements">Defining Project Requirements</h2><p></p><p>Now that I knew what gearbox I wanted to make I started to define what I wanted the final design to look like.</p><ul><li>Dual cycloidal drive to reduce vibrations</li><li>Integration of motor and gearbox into one assembly</li><li>70mm Z height restriction to keep a low profile</li><li>10:1 reduction</li><li>Easy assembly/disassembly (no adhesives)</li><li>Use existing stator design from axial flux motor</li></ul><h2 id="actuator-design">Actuator Design</h2><p></p><p>With my requirements set, I moved on to designing the actuator. The base motor design is based on my last axial flux motor so I began modifying that in order for it to fit a gearbox. Next I had to start work on the design of the cycloidal gearbox system itself. This was quite challenging to figure out initially because the cycloid geometry is fully defined off of parametric equations.</p><p><a href="https://blogs.solidworks.com/teacher/wp-content/uploads/sites/3/Building-a-Cycloidal-Drive-with-SOLIDWORKS.pdf?ref=10.0.0.222">This guide</a> was immensely helpful in defining the geometry. After some time I had the parameters for my parametric equations ready to go based on the size and reduction that I wanted. </p><table>
+<?xml version="1.0" encoding="UTF-8"?><rss xmlns:dc="http://purl.org/dc/elements/1.1/" xmlns:content="http://purl.org/rss/1.0/modules/content/" xmlns:atom="http://www.w3.org/2005/Atom" version="2.0" xmlns:media="http://search.yahoo.com/mrss/"><channel><title><![CDATA[Caden Kraft]]></title><description><![CDATA[Some of my Projects]]></description><link>https://cadenkraft.com/</link><image><url>https://cadenkraft.com/favicon.png</url><title>Caden Kraft</title><link>https://cadenkraft.com/</link></image><generator>Ghost 5.79</generator><lastBuildDate>Tue, 03 Sep 2024 19:47:43 GMT</lastBuildDate><atom:link href="https://cadenkraft.com/posts/rss/" rel="self" type="application/rss+xml"/><ttl>60</ttl><item><title><![CDATA[3D Printed Dual Cycloidal Actuator]]></title><description><![CDATA[This project builds on my previous axial flux motor. To improve the torque output of the motor I designed a cycloidal gearbox that integrates into the current motor design allowing for more torque.]]></description><link>https://cadenkraft.com/3d-printed-dual-cycloidal-actuator/</link><guid isPermaLink="false">65d922ddf6e4040001065708</guid><category><![CDATA[Motors]]></category><category><![CDATA[Build]]></category><dc:creator><![CDATA[Caden Kraft]]></dc:creator><pubDate>Fri, 23 Feb 2024 00:57:43 GMT</pubDate><media:content url="https://cadenkraft.com/content/images/2024/02/Title-Image.jpg" medium="image"/><content:encoded><![CDATA[<img src="https://cadenkraft.com/content/images/2024/02/Title-Image.jpg" alt="3D Printed Dual Cycloidal Actuator"><p>This project is a continuation of my previous axial flux motor project. If you&apos;ve not yet read that I would recommend doing so.</p><figure class="kg-card kg-bookmark-card"><a class="kg-bookmark-container" href="https://cadenkraft.com/designing-a-coreless-axial-flux-motor-part-1/?ref=10.0.0.222"><div class="kg-bookmark-content"><div class="kg-bookmark-title">Ironless Axial Flux Motor</div><div class="kg-bookmark-description">After my first custom brushless motor I felt confident enough with the basic theory of how they work to make a second design with significantly more thought and math defining the design. Creating a 3D Printed Brushless MotorWith my work in the Iowa State Solar Car club I have learned</div><div class="kg-bookmark-metadata"><img class="kg-bookmark-icon" src="https://cadenkraft.com/content/images/2022/11/favicon.ico" alt="3D Printed Dual Cycloidal Actuator"><span class="kg-bookmark-author">Caden Kraft</span><span class="kg-bookmark-publisher">Caden Kraft</span></div></div><div class="kg-bookmark-thumbnail"><img src="https://cadenkraft.com/content/images/2022/09/title-page-render-axial-flux-motor.16.jpg" alt="3D Printed Dual Cycloidal Actuator"></div></a></figure><p>After I was finished with making my last motor project I was quite proud of the results. However, while the motor could achieve extremely high RPM&apos;s, this came at the cost of torque.</p><p>Originally I thought about rewinding the stator and possible improvements via stronger magnets and/or Iron based 3D printer filament for the stator coils among other things. </p><h2 id="deciding-on-a-gearbox">Deciding on a Gearbox</h2><p></p><p>Wanting to work on something a little more different than pure motor design and not wanting to rewind any coils, I set my sights on developing a gearbox that could be integrated into my current stator design. There were 3 primary options that I was looking into when deciding what gearbox that I was going to make, Planetary, Cycloidal, and Harmonic.</p><figure class="kg-card kg-gallery-card kg-width-wide kg-card-hascaption"><div class="kg-gallery-container"><div class="kg-gallery-row"><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/cycloid1-1.gif" width="366" height="355" loading="lazy" alt="3D Printed Dual Cycloidal Actuator"></div><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/HarmonicDriveAni-1.gif" width="700" height="700" loading="lazy" alt="3D Printed Dual Cycloidal Actuator" srcset="https://cadenkraft.com/content/images/size/w600/2024/02/HarmonicDriveAni-1.gif 600w, https://cadenkraft.com/content/images/2024/02/HarmonicDriveAni-1.gif 700w"></div><div class="kg-gallery-image"><img src="https://cadenkraft.com/content/images/2024/02/planetary.gif" width="300" height="332" loading="lazy" alt="3D Printed Dual Cycloidal Actuator"></div></div></div><figcaption><p><span style="white-space: pre-wrap;">Cycloidal (left), Harmonic (center), Planetary (right)</span></p></figcaption></figure><p>All of these options definitely seem like good ideas but I had to narrow down which one I was going to choose.</p><p>Planetary would have been the easiest and probably would have performed the best but I cut it out because I didn&apos;t really find it interesting enough and wanted to learn more about the other gearboxes. </p><p>While I admire the simplicity of the harmonic drive I was wary of my ability to manufacture the flexible parts needed. I eventually chose the cycloidal drive because it seemed like the biggest technical challenge to design as well as the fact that it looks extremely cool. Cycloidal gearboxes also have nearly no backlash which definitely made it stand out against something like a planetary gearbox with the tolerances of 3D printed parts.</p><h2 id="defining-project-requirements">Defining Project Requirements</h2><p></p><p>Now that I knew what gearbox I wanted to make I started to define what I wanted the final design to look like.</p><ul><li>Dual cycloidal drive to reduce vibrations</li><li>Integration of motor and gearbox into one assembly</li><li>70mm Z height restriction to keep a low profile</li><li>10:1 reduction</li><li>Easy assembly/disassembly (no adhesives)</li><li>Use existing stator design from axial flux motor</li></ul><h2 id="actuator-design">Actuator Design</h2><p></p><p>With my requirements set, I moved on to designing the actuator. The base motor design is based on my last axial flux motor so I began modifying that in order for it to fit a gearbox. Next I had to start work on the design of the cycloidal gearbox system itself. This was quite challenging to figure out initially because the cycloid geometry is fully defined off of parametric equations.</p><p><a href="https://blogs.solidworks.com/teacher/wp-content/uploads/sites/3/Building-a-Cycloidal-Drive-with-SOLIDWORKS.pdf?ref=10.0.0.222">This guide</a> was immensely helpful in defining the geometry. After some time I had the parameters for my parametric equations ready to go based on the size and reduction that I wanted. </p><table>
 <thead>
 <tr>
 <th>Parameter</th>