New falcon issue?

[Juniormunk]

New video by Cameron Coesens

This is an odd one. This shaft came out of our wcs swerve drive module.

[cad321]

Looks similar to the failure reported here earlier today:

Falcon 500 Output Shaft Failure

While our team has shared many of the same Falcon 500 failures as others (Vex has been great at resolving and sending us replacement units/parts) I have not seen any posts related to this specific failure. [ezgif-3-9bf21b0a9f] As you can see in the gif the shaft is free spinning from the mounting flange. The laser weld on the bottom securing these 2 seperate pieces together has sheared in half and while the shaft remains retained in the flange it does not spin with it. We have had this failur…

[troy_dietz]

here it goes again…

[billbo911]

Sounds like the laser weld is not quite what it should be.

[cody29158]

This happened to the Falcon on our intake this past weekend… The Falcons have been unharmed in all these but I’m really starting to question the claims of not needing to support the end of your falcon shaft with a bearing.

[sanddrag]

This is reminiscent of the KOP BaneBots planetary output plate failures of 2007. Here’s your fix https://www.thethriftybot.com/bearings/8mm-Keyed-Motor-Output-Shaft-p157387731

[cody29158]

Can you confirm these shafts are a single piece of machined steel? If so we’ll definitely be making the switch

[cad321]

Almost certain they are, but @Ryan_Dognaux should be able to confirm whether or not fairly easily.

[Sam_Dare]

They are indeed. Disclosure: I work with Thrifty.

[Ryan_Dognaux]

Yep, they’re solid stainless steel.

We’ve also recently updated them to include a 10-32 hole at the end of the shaft. Just need to update the product listing here with new pictures and an updated CAD model.

[Andrew_L]

@asid61 wake up babe, new falcon failure just dropped.

[nuclearnerd]

@Ryan_Dognaux

We’ve also recently updated them to include a 10-32 hole at the end of the shaft.

I hope future versions of NEO motors incorporate this feature too.

[troy_dietz]

What, you don’t like installing and removing whatever these satan spawn are?

[Ryan_Dognaux]

Pretty sure there’s some universal robot law that says there’s a 50/50 chance of a retainer clip springing off into the universe never to be found again.

[Emerson1706]

I think it might actually be closer to 75/25 chance.

[FrankJ]

Actually a 80/60 chance.

[cody29158]

If I were to say run these on my Falcons on a MK4i Module would the press fit NEO pinion for steering be the same press fit onto a Falcon with one of these installed as it would be a NEO shaft or would it be more comparable to a CIM where they’re known to be slightly looser.

15 Tooth 32 DP 8 mm Round Bore Steel Pinion Gear for EVO

[jtrv]

For better or for worse, this looks like it has happened before, back in 2021 to 1684:

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[cody29158]

Unfortunately that means the V1 shafts are also not safe from this failure. I’ll be keeping my eyes peeled for V3 shafts to see if they fix this apparently old but seemingly uncommon issue.

[Ryan_Dognaux]

Honestly that’s a great question, I haven’t tried pressing one of these on. I’ll purchase one and see how it fits and get back to you.

Edit - I do think you’d need to press this on while it’s on the Falcon motor and I’m not sure how dangerous that is to the motor. I have a Falcon and can try it out though, may need some support method so you don’t ruin anything else on the motor.