We used set screws to mount a pulley to the falcon 500 shaft but with time it came loose. Is there a better way to mount a pulley without a splined hole ?
Please send pictures, this helps a ton, as I am not quite sure how it was mounted based on your question. By setscrew do you mean you had a thru-hole bore on the pulley you were using and the setscrew was in the pulley hub? If so that is not… ideal.
Once we know a few more details about the set-up, we as a community can help better.
Using a set screw on a splined shaft is most definitely a bad idea. Assuming you can mount to a “standard” 8mm output shaft, I would use something like this
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It is unavailable to us because we are a team from turkey and hava a competition this monday.
Hmm… do you have access to a 3D printer fine enough to print the spline?
If you have a 3D printer but it’s not that precise, you could try printing a cylinder with an ID approx. equal to the ID of the spline and pressing that on, then using the set screw in that.
About what rpm and load is the motor experiencing? High rpm low load, low rpm high load, something else?
High rpm low load as a part of the shooter mechanism
If you have access to a 3d printer, I would try some different prints and see what works. Try printing the spline itself, printing a small hole and press fitting, etc.
I would also recommend the trick of using a pinion if those are available to go between the pulley and the shaft. The gear profile is easier to reproduce with a printer than the spline.
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I don’t know that a casually 3D printed part would be able to handle the shock loads as balls passed through.
If you have a manual or CnC mill and lathe, you could make an 8mm keyed output shaft pretty trivially.
An easier, faster, and potentially riskier solution is to replace the set screw with a roll pin (aka a spring pin). It’s potentially riskier because you need to drill through at least part of the shaft, which weakens it.
I hate to even suggest this - but if you wax the spline shaft thoroughly, you could use a 2 part system like JB Weld. The wax will allow you remove the pulley later with a gear puller.
I guess it depends how desperate you are.
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Do you have any other motors available? Such as a CIM or Neo? If so, then you could use a keyed hub with a setscrew and it would work fine.
The Falcon 500 is a great motor…but you need to have access to the necessary parts to make it work, unfortunately.
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This solution depends on your machining abilities, but we milled one of the Falcon spline gears to a 1/2” hex and glued that into a standard hex pulley (didn’t have the right falcon spline pulley size)
I hear rumors that the Falcon Slim attaches to the robot via adhesive. The only glue you’ll ever need!
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I almost suggested putting the shaft and a nylon hub drilled a little small in a lathe (or other centering device), hitting the shaft with a blowtorch, and smooshing them together while keeping them centered.
That’s a desperate ploy, but I’d trust it more than JB Weld.
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