Manual Transmission Demonstration model

This is a working manual gearbox that has 4 forward gears and one reverse gear.  It uses 3D printed components and store-bought ones. 

To complete the model, the following off-the-shelf parts are needed:

• 1* microcontroller that can control a servo motor (this design uses an ESP32)

• 1* medium-sized continous servo motor (this design uses an MG996r)

• 1* power supply (this design uses a 3 * AA battery case bought from the BambuLab website)

• Wiring needed to connect the electrical components

• 59* M3 Heat-set inserts (this design uses the ones available on the BambuLab website)

• 27* 15mm long M3 Fasteners

• 30* 8mm long M3 Fasteners

• 2* 20mm long M3 Fasteners

 The gear shifting mechanism uses an H pattern, with the gears written onto the H plate. 

The gear ratios are the following:

• 1st gear: 3:1

• 2nd gear: 2:1

• 3rd gear: 1,4:1

• 4th gear: 1:1

• Reverse gear: 1:1

The following parts should pe printed multiple times:

• Output Spinner - 2*

• Box Connector - 2*

• Shift Connector 2 - 2*

• Shift Connector 1 - 3*

The project requires assembly, so here is the assembly guide

Insert all the heat-set inserts into their places.

Assemble the shaft. The parts should be in ascending order, from left to right (Shaft1 on the left end, then Shaft 2 and so on)

Assemble the Gear Forks for Revers and 1-2 Gears. (the assemblies look similar)

Assemble the Reverse Gear Selector Mechanism (Shift Connector+Reverse Gear Fork+Reverse Gear Selector Part)

Assemble the 3-4 Gear Selector Mechanism(Shift Connector 2+3-4 Gear Fork+Shift Connector 1)

Assemble the 1-2 Gear Selector Mechanism(Shift Connector 2+1-2 Gear Fork+Shift Connector 1)

Put the Shaft into its place on the Box.

Assemble Box Part 2. (Box Part 2+Electronics Holder)

Put the Reverser Gear and its holder into their places on the Box.

Put the Servo and Motor Connector in place.

Assemble the lower part of the Box.

Assemble the Gears as shown on the pictures. (some parts are removed from the images for better visibility)

The parts that go onto the Rod are in the following order:

1. Reverse Gear

2. Reverse Gear Selector Mechanism

3. Gear 4

4. 3-4 Gear Selector Mechanism

5. Gear 3

6. Gear 2

7. 1-2 Gear Selector Mechanism

8. Gear 1

Assemble the Shifter and its Holder as shown on the images.

Parts added in order:

1. Shifer Holder Box Part

2. Shifter Holder Lower

3. Shifter

4. Shifter Holder Upper

Assemble The upper part of the Box as shown on the images.

Part added in order

1. Assembly from the previous step

2. Box Part 3

3. Box Part 4

4. H Plate

5. Shift Knob

Put the Box Connectors onto the lower part of the Box.

Lock the Gear Forks in place with the Gear Fork Holder Rod.

Assemble the Box.

Put the rest of the electrical components in place.

Put the Output Spinners in place.

The project is now fully assembled and ready for use.