After brainstorming with Prof. Marshall and Zack for a while, we developed a strategy for salvaging as many components of the drive system as possible to keep water-jetting time for recuts at a minimum. Examining the all the dimensions and looking over the aluminum frame led us to believe that an error was not made in the dimensions of the components, but the frame and piano hinges were the source of our gear meshing issues.
The Group members that fabricated the frame are in no way to be blamed. They did the best that they could with the tools that they had access too. Unfortunately, the method of construction led to irregularities, albeit small, that compounded to make the alignment of CNC gears impossible.
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A New Plan
The alignment of the axle and small gears within the frame is accurate as far as I can tell, so we're re-cutting the large gears, and customizing (grinding) each one to be placed in the center of rotation. It's excrutiatingly slow, but it will will be the best way to verify that the gears are meshing correctly-
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Pieces of the Old Plan
Aluminum Rod For Motor Coupling
Final coupling after lathe work and tapping for set-screws
Assembled Motor Mounts (CNC'ed Delrin, Aluminum Motor Coupling)
with the filed and cleaned gears and support plates
A single complete Drive Unit
Installed Drive Units
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