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Originally Posted by IKE
As an LRI, I came across several teams that were getting hot motors and/or voltage drop outs. A common issue I saw was:
Kit bot modified to 6" wheels with no other mods. The effective free speed for this arrangement is quite high (something on the order of 20 FPS). This lead to a lot of hot motors.
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We did the 6" wheel mod to our kit chassis, and we also changed the gears (we used some gears from older AM transmissions). It worked great! we had some 6" white wheels left over from something else, and we notched the ends of the chassis so they'd fit.
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I also helped a few teams that had placed a gear backwards in the gearboxes. There is a small offset that helps keep the gears from dragging on the housing. this drag resulted in hot motors as well. It might be good to add a current check on blocks for a chassis to see if you have un-necessary drag. this can be done with the PDP board and your laptop. Might be good to add a diagnostic tool.
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The instructions sort of show the offset on the gears, but don't explain it nearly well enough for most students to notice.