My team and I have run into a bit of an issue regarding the strength of plastic (or lack thereof). We have 2 high-torque motors driving an 84:12 gear ratio, so there are considerably large amounts of torque being exerted.
Small VEX shafts twisting and breaking have been a frequent problem for us in the past, but with this new setup, the high strength 84 tooth gear itself is breaking at its center (I guess it could be described as stripping, the center of the gear essentially becomes a circle and no longer spins along with the axle).
What are some workarounds you guys have for this? I’d love an all-metal 84 tooth gear, but sadly I don’t think those exist. Size is also a bit of a constraint, so just bolting 2 of them together is probably not optimal, although if it comes to that, I suppose I’ll have to find a way.
Would using the high-strength thick shafts instead of a small shaft with inserts make a difference in the wear of the gear center? I’m assuming that once this problem is fixed, a new one to arise will simply be the axle twisting.
Any and all feedback is appreciated, I’m sure this isn’t the first time someone has wanted to make the “High Strength” parts even stronger.
Thank you all for your time,