Figure 1. Bogie Structure
From the picture, it can be seen that the largest change so far is that there will be three wheel instead of two wheels at the bottom of each bogie. This is in order to keep the bogie perpendicular to the track at all time, independent of one another.
Figure 2. Cross Section of members with thread inserts
Figure 2 shows the new design for mounting the support wheels on the bogie structure. Last year they used a threaded rod that went through the length of the member, this year we will mill threaded inserts that will be welded into place and the wheels will be on should bolts that will have some kind of bushing to allow for free spinning.
Figure 3. Initial Joint design for Bogie Connection
Figure 3 is the initial design that has been done for the joint between the bogie uprights. It uses should bolts, brackets, a center shaft insert, and middle x joint to allow for 2 DOF for traveling up and around bends.
Figure 4. Off the Sheld Bearing Unit
Figure 5. Start of Custom Bearing Unit for Main wheel
Figure 4 and 5, are an example of issues with off the shelve purchase parts I am currently having. I would like to be able to buy a full bearing unit for the main wheel, however, The ones available are too wide, and won't allow for the wheels to be aligned with the current track config. This means I need to design a custom one that will need to be machined. Not shown in figure 5, is addition bearing retaining plate that will also act to position the wheel in the correct location. The bearing is required because Propulsion is planning on integrating the drivetrain onto the main wheels. This is going to make fitting everything difficult, so this is currently one of the top issues in my mind.
Lots more work needs to be done.
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