Movable-shaft design for adjustable gear teeth engagement

[Flying Whale]

I have a geared motor bolted onto a moving plate supported by rollers standing on a fixed base. The same fixed base has a rack on the bottom. There are 4 rollers, 2 on each side of the fixed base, and they're on separate shafts (there's material between the two sides, and it cannot have holes). The moving plate assembly can get up to a mass of 1,000 kg.

Sizes and materials here are quite large (plate is 600mm wide, made of 12mm laser-cut steel, and the fixed base is a standard beam profile) so no tolerances can be reliably specified to get the correct mesh engagement. This has been built and tested, it failed because the gear teeth didn't fully engage, then solved with a not-so-repeatable nor time-efficient method for a long-term product line. (Having to shim the rack to push it into the pinion is not a solution, at least for our requirements)

I've tried to find some existing designs where gears are designed with adjustable centers, but my research has led me nowhere. One idea I've had is to mount the rollers on shafts with offset centers (one of which is threaded and tightened to the plate by a nut), but that adds complexity to the assembly pretty quickly, since the four rollers have to be adjusted independently.

Any help is appreciated, thanks.

 

[mfgenggear]

OP
I hope you have taken my comments constructive.
You are stuck . So lt limits corrective action.

The correct mounting of racks

Correct mounting of racks is very important, not only for the accuracy of the entire installation but also for wear.

www.apexdyna.nl

 

[mfgenggear]

Adjusting the pinion

Rack and pinion Rack and pinion - Apex Dynamics

www.apexdyna.nl

PS : this obviously this is over design for what it requires. Use geesman advice using a similar concept. Make subplate, with slotted holes
Adjust the back lash a the worst and best backlash, take the average. Lock it down
With socket head bolts. Drill and tap holes
as necessary.
Use a magnetic drill press
Then drill and ream holes , position to suit
As to have correct edge distance.
Assemble precision dowel pins. Done.
This as good it is gone to be with current build.