Transfer Case (In Progress)

The transfer case for the 2024-25 car, the only one our team has made thus far, was very overdesigned. With this design, one of my main goals was to reduce the weight and size of the gearbox to only what is necessary. 

Since our team doesn’t have the ability to custom-manufacture gears, I chose two commercially-available spiral bevel gears with a calculated factor of safety of 1.20. This maintains a good margin of safety while not forcing us to use larger, heavier gears. 

So far, I have created a draft design of the shaft assemblies for both the input and output shafts. With this draft, I created a spreadsheet to automatically calculate factors of safety for the shafts and bearings as parameters like shaft material, components, and distances change in further design iterations.