[dtengineering]

Nice design... but watch your assumptions on the FP/Banebots combo. I get the sense (now I'm the one making assumptions) that you are using the peak torque figure for the FP when calculating your output. FP's don't last long at peak torque. Since this motor will be in intermittent operation and you have calculated a factor of four over your peak design load, you will probably be okay, but I normally calculate FP torque based on a 10 amp load... and even then plan to provide cooling for continuous operation.

Secondly the little BB 256:1 gearboxes have the ability to pull themselves apart when driven to the peak torque of an FP. I highly doubt that 10 ftlbs would be a problem, but 40 is starting to get up there.

So assuming your load calculations are correct, your design should still work, but I don't think you have nearly as much "extra" torque to work with as you have calculated.

Here's a suggestion that came to mind the first time I saw this design... why not also pivot the tread modules about one of the rollers. That way you could also lift the robot up onto "tiptoe" when more ground clearance is needed. No reason it couldn't be done with pneumatics if you didn't want to slip another motor down there.

Jason