3D printable high torque servo/gearbox version 2

<b>Video can be found here:</b> https://youtu.be/d8us3OWgS1A

<b>STL and Editable Fusion 360 source files can be found here: </b>https://bbprojects.technology/collections/stl-fusion-360-source-files/products/3d-printable-high-torque-servo-gearbox-version-2-files

This servo/gearbox is the new and improved version of my original gearbox design (https://www.thingiverse.com/thing:3292860). The original one had a gear ratio of 30:1 and the speed of the output shaft was about 715 RPM which made it difficult to tune in the right PID parameters. This new version has a gear ratio of about 162:1 which lowers the speed and increases the torque of the output shaft.

I choose to go for double helical gears on this one because they produce a lot less noice than regular spur gears and the forces on the teeth are transferred more gradually. The gears rotate around a 6mm stainless steel shaft which is lubricated with bearing grease. Ideally all the gears should have some bearings, this is being considered for the next moment. Unlike my previous design I used 2 20mm bearings to support the output shaft.

The servo uses a 775 36V 9000rpm brushed DC-motor which is driven by my Universal Morion Controller (UMC)(https://www.thingiverse.com/thing:4245315). The stall torque theoretically is about 297kg/cm, I was able to test the servo to a torque of about 132kg/cm. During testing none of the gears broke, they were all printed in PLA. The weak link in this design however where the mounting…