Allison 1000 transmission by marcinszydlowski

Last crawled date: 4 years, 3 months ago

Hello everyone,
model presented here is a variation of Allison 1000 transmission derived from InterlinkKnight's 6 Speed Allison Automatic Transmission
It's operated manually by pushing/pulling breakes and shifting clutches. Model was designed for be assembled with bearings, Seeger rings, rods, shims and forming screws.
Gears and other parts have been prepared in Fusion 360 using paid add-in for generating planetary sets (available for Win and Mac).
In addition to the STL models there are also following documents:
assembly guide,
template for drilling holes in the support board (must be printed in 1:1 scale or scaled for the same factor as models if you'll do),
power flow, kinematic models and calculations of ratios,
sheet for calculating ratios for single stages.
Full video which shows it in action is on YouTube:
Main requirements
Type
Time/cost/dimensions
Notes
Printing time
77h
Assuming continuous operation (no breaks between parts) by one printer; in practice 1 week
Postprocessing time
4h
Removing supports, deburring, grinding
Cost of filament
$20
1 spool of 850g refill Fiberlogy Easy PLA if no other color used and success at first time
Cost of metal parts
$20
Cheapest parts found on the market
Assembling time
6h
Drilling holes in support plate, cutting grooves for Seeger rings on 8mm rod, cutting 8mm and 3mm rod
Dimensions (WxLxH)
28x44x16 cm
Printed parts
Name
Qty
01_Crank_placeholder.stl
1
02_Handle.stl
1
03_Knob.stl
1
04_Pointer.stl
1
05_C1_text.stl
1
06_C2_text.stl
1
07_C3_text.stl
1
08_C4_text.stl
1
09_C5_text.stl
1
10_P_text.stl
1
11_Input_shaft.stl
1
12_Bearing_support.stl
2
13_Clutch_rail_start_guide.stl
2
14_Clutch_rail_middle_guide.stl
1
15_P_support_back_bearing_lid.stl
4
16_P_support_front_bearing_lid.stl
4
17_Clutch_guide_front_bearing_lid.stl
2
18_Clutch_guide_back_bearing_lid.stl
2
19_P_support.stl
4
20_Clutch_support.stl
2
21_Break_teeth.stl
4
22_Break_support.stl
4
23_Break_handle_left_side.stl
4
23_Break_handle_right_side.stl
4
24_P5_planet.stl
4
25_P4_planet.stl
4
26_P3_planet.stl
4
27_P5_Synchronizer.stl
1
28_P4-P5_Synchronizer.stl
1
29_Clutch_1.stl
1
30_Clutch_2.stl
1
31_P3_sun.stl
1
32_P3_ring.stl
1
33_P4_ring.stl
1
34_P5_ring.stl
1
35_P4_P5_sun.stl
1
36_Output_carrier.stl
1
Metal parts
Name
Qty
Rod 8/297mm
1
Rod 8/95mm
2
Rod 3/20mm
4
Rod 3/14mm
4
Rod 3/41mm
12
Set screw 6/6mm
1
Set screw 8/8mm
1
Forming screw 3/12mm
40
Forming screw 4/20mm
4
Seeger external ring 8mm
4
Seeger external ring 20mm
4
Seeger internal ring 15mm
2
Seeger internal ring 48mm
2
Ball bearing 8x22x7mm
14
Ball bearing 20x47x14mm
2
Needle bearing 8x12x12mm
3
Needle bearing 20x26x20mm
1
Shim 3mm
24
Others
Name
Qty
Board or plate for support no smaller than 44x28x1cm
1
Tools
Name
Used for
Upholstery knife
removing supports, finishing surfaces
Pliers
removing supports
File
finishing surfaces
Drill (for steel) 8mm
deburring 8mm holes
Drill (for steel or wood) 2mm
drilling holes for forming screws in support board
Allen screwdriver 3mm
set screw in synchronizer C1
Allen screwdriver 4mm
set screw in sun P4-P5
Phillips screwdriver 3mm
forming screws 3x12mm
Phillips screwdriver 4mm
forming screws 4x20mm
External and internal Seeger calipers
mounting Seeger rings
Silicon or machine oil
lubricating parts
Grease
lubricating internal shaft's bearings
Tweezers
easier putting shims on planets' shafts
Recommendations
3D-printing settings
All models available here are oriented in a way which guarantee quite good quality in FDM technology. However, it's not enought to be sure that parts will be matched together when slicer use automatic settings. I strongly suggest to use advanced slicers like Cura, Prusa Slicer or any other which lets you to set:
elephant foot compensation (in Prusa Slicer)
Linear Advance (for my case K=0.04 or K=40 was ok),
horizontal expansion (hole, initial layer, general - in Cura),
support types and orientation
Metal parts
Bearings, screws, shims and Seeger rings can be cheapest but in case of rods you need to be sure that theirs diameters are exact. In other case, you can waste a few hours for grinding 8mm rod for be able to put 8mm needle and ball bearings on them or making 3mm holes in plastic parts slightly bigger.
Known problems
Assembly
breaks aren't designed well for beeing both assembled or disassembled - try to follow the assembly guide for putting these parts together,
mounting planets into carriers - unfortunately it's the worst thing here (I realized too late) and it's a one-way operation; it cannot be reversed and for removing shaft, carrier needs to be damaged; you need a thin tweezers, knife, screwdriver or similar kind of tool and be very patient for putting shaft throught the carrier, shim, planet and the last shim
mounting bearings is (and generally, should be) tight but try to pushing them rather than hitting by hammer; you need to be careful for not breaking parts,
internal Seeger rings (15 and 48mm) requires strong calipers - cheapest sets of calipers may be unable and dangerous to bend rings of those sizes (wear safety gogles for mounting snap rings)
Operating
shifting clutches may be difficult especially for overdrives or for some othe configuration of switches. If so, try to do this by pushing clutches instead of C1/C2 shifts;
4th and 5th gear (overdrives) requires more forces and for synchronizers designed for this model' design it tends to shifting clutch C2 back - it need to be hold during spinning the input shaft.