[DampRobot]

We are using two belts, one on either side of the ball. The lower of the two rollers has a pitch diameter of 3.14in, the upper, around 1.69. As for the measured current, that was told to me by the programmers (I really just do mechanical stuff), I suspect off the dashboard. The motors are run by Jaguars with CANBus, and were run a 100% to get that speed and current.

Your suggestion about removing the second stage is interesting. If I was unclear before, we are getting that ratio with sprockets, so a 1:1 set up would be very possible. You are essentially saying that our motors are having trouble because they have too much load? It seems like that would improve overheating, although at the cost of range.