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.