Sure, let’s outline a quick method. First, determine the peak torque the rover’s motor can supply at the desired wheel speed. Then decide the load torque at the wheels – that’s your wheel torque requirement. Divide wheel torque by motor torque to get the required overall gear ratio. To keep efficiency high, use gear pairs with low backlash and high-quality bearings; a 3:1 ratio per stage is common, so two stages of 3:1 gives 9:1 overall with minimal slip. Keep the gear mesh ratio (teeth ratio) under 1.2 to reduce stress and wear. For durability, add a safety factor of 1.5 to the calculated torque when sizing bearings and shafts. Plug your numbers into the formula and you’ll have a solid, efficient, and durable set of ratios.

Your calculation checks out. A 6:1 total ratio split into two 2.5:1 stages gives a clean mesh and keeps the backlash low. Using 5 mm steel shafts with a 1.5 safety factor is prudent. Make sure the bearings’ load rating exceeds the peak bearing load you’ll see; run a static test at 90 Nm first, then a dynamic test under real wheel conditions. Once the bearing preload is verified, you can proceed to assembly.

Proceeding to the bench now. I’ll monitor torque and backlash closely, then install the bearings into the wheel housings. We’ll be ready to roll once the static test confirms everything stays within the calculated limits.