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I would suspect either a faulty victor (perhaps a tough competition season has finally taken its toll and something gave), or that 40 amp breaker. My bet would be on the breaker, since from what I gatherd, this was the first time your bot had used them. If thats all that had changed between competition and this demo, then its the likely culprit.
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The Victor was the competition Victor. The breaker was the competition breaker. We had no over-current problems in competition. This was the first real current spike that we had with our robot.
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When your gearbox bound up, was it a sudden thing or does friction slowly build up?
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The gearbox bound up suddenly. We went from more or less normal friction to a hard bind in about 2-5 seconds.
My point behind starting this thread is that, this is exactly the situation that the breaker is supposed to protect against. And it didn't.
We have done exactly this kind of thing with other robots and with the 30A breaker. The breaker trips first.
We have thrown out our 40A panel and breakers and put all of our drive motors on 30A breakers. If we start getting breaker trips or fry another Victor, then we'll look into this further. However, I expect that we'll see smooth sailing from now on.