Dual Plunger Gear & PCB Upgrade
Budget: $50 – $0 USD
My prototype runs on two independent 360-degree servos that each turn a separate gear train to drive plungers. A 1.68" display and a small vibration motor round out the user interface. Functionally it works, but the mechanics feel rudimentary and the control electronics are still at a breadboard stage.
Mechanical scope
• Keep the existing architecture but focus on Optimization of current gear system – smoother meshing, tighter tolerances and balanced loads so each plunger actuates cleanly without stalling or backlash.
• Verify torque requirements against the present servos; if calculations show a shortfall we can discuss alternate motors, yet the preference is to retain the dual-servo approach.
Electrical scope
• Redesign the control PCB with Increased durability and reliability in mind: solid power rails, proper decoupling, heat-spreading, and protected motor drivers.
• Accommodate the 1.68" screen, vibration motor, two servos and basic I/O while fitting within the current physical envelope.
Key deliverables
- Updated mechanical CAD (STEP + source files) showing the refined gear system and plunger carriage.
- Manufacturing drawings and BOM for gears, shafts, bushings and any custom housings.
- Complete PCB package: schematic, board layout (KiCad/Altium), fabrication Gerbers, pick-and-place, and annotated BOM.
- Firmware or example code that exercises both plungers, the display and vibration motor.
- A working prototype or documented assembly pack ready to send to my fabricator.
Timeline
I need the design files and a tested, functioning build no later than 10 July. I realise that is aggressive, so propose intermediary milestones to keep us both on track; I will be available daily for quick design decisions, component sourcing and rapid feedback.
Mechanical scope
• Keep the existing architecture but focus on Optimization of current gear system – smoother meshing, tighter tolerances and balanced loads so each plunger actuates cleanly without stalling or backlash.
• Verify torque requirements against the present servos; if calculations show a shortfall we can discuss alternate motors, yet the preference is to retain the dual-servo approach.
Electrical scope
• Redesign the control PCB with Increased durability and reliability in mind: solid power rails, proper decoupling, heat-spreading, and protected motor drivers.
• Accommodate the 1.68" screen, vibration motor, two servos and basic I/O while fitting within the current physical envelope.
Key deliverables
- Updated mechanical CAD (STEP + source files) showing the refined gear system and plunger carriage.
- Manufacturing drawings and BOM for gears, shafts, bushings and any custom housings.
- Complete PCB package: schematic, board layout (KiCad/Altium), fabrication Gerbers, pick-and-place, and annotated BOM.
- Firmware or example code that exercises both plungers, the display and vibration motor.
- A working prototype or documented assembly pack ready to send to my fabricator.
Timeline
I need the design files and a tested, functioning build no later than 10 July. I realise that is aggressive, so propose intermediary milestones to keep us both on track; I will be available daily for quick design decisions, component sourcing and rapid feedback.