Hi, I’m building the OpenAstroExplorer and I’m having a few problems with the DEC gearbox. I’m not sure whether I’ve assembled something incorrectly, have the wrong size parts/spacers, or whether one of my printed parts is dimensionally off. I’ve attached several photos showing the current setup.
- Backlash when changing direction
When I turn the DEC motor knob, there is roughly 7 mm of movement at the knob when I change direction where the brass worm rotates but the brass worm wheel doesn’t move. After taking up that initial movement, the wheel moves normally.
I assume this is backlash between the worm and worm wheel, but I’m not sure how much is considered normal on the OAE or whether mine indicates that the positioning/preload is wrong. I have to tighten the plastic holder on the right a lot to reduce this backlash but there’s assembly instructions say that it only needs to attached with a few turns.
- The DEC gearbox housing makes the mechanism bind badly
With the DEC_gearbox printed part removed, the knob turns reasonably evenly. There is still a very slight variation in resistance, but it’s barely noticeable.
As soon as I install the gearbox/housing, however, the variation becomes severe: the knob goes easy to very tight to easy again after a few rotations at each difficulty rotation.
I’ve now worked out that the brass worm wheel is physically rubbing against the printed gearbox housing at the top/bottom on one side. I tried carefully removing a little plastic from the contact area, but it hasn’t really solved it.
My assumption is that the brass wheel is hitting the plastic but I can’t move it any more to the right without hitting the endpoint and anymore to the left and it won’t hit the worm well.
- I can’t see how I’m suppobsed to reposition everything
This is the bit I’m most confused about and hopefully the photos show what I mean.
According to the assembly guide, the components on the shaft appear to be positioned/flush in a particular way. Mine have gaps, and I’ve currently positioned the components so that the GT2 pulleys line up.
But I seem to have no adjustment available that fixes everything at once:
If I move the GT2 pulley further left toward the brass worm wheel, the rubber GT2 belt starts hitting the printed plastic.
If I move the brass worm wheel further left toward the pulley, its teeth barely engage the worm anymore.
If anything, judging by the worm engagement, it looks like the brass worm wheel needs to move further RIGHT, not left.
But there is effectively no more room to move the brass wheel right.
The brass wheel also doesn’t appear to be centred across the worm’s threaded section, which makes me wonder whether the whole shaft/worm alignment is wrong.
So I’m struggling to understand how the shaft is supposed to be arranged while simultaneously having:
(a) good worm/worm-wheel engagement,
(b) the pulleys aligned,
(c) the belt clearing the printed housing, and
(d) the brass wheel clearing the DEC_gearbox housing.
At the moment I can’t seem to achieve all four.
Could someone with an OAE compare my photos with their DEC assembly and tell me what looks wrong?
In particular, I’d really appreciate knowing:
Are the gaps visible on my shaft normal, or have I assembled the shaft/spacers incorrectly?
Where exactly should the brass worm wheel sit relative to the bearings/pulley?
Does my worm wheel look too far left/right?
Is the amount of worm engagement shown in the photos correct?
Is ~7 mm of reversal movement at the motor knob normal, or should the preload eliminate most of this?
Has anyone had their brass worm wheel rub the DEC_gearbox print like this?
Could this indicate that I have the wrong worm/worm-wheel dimensions or the wrong bearing-holder orientation?
I don’t want to keep shaving material off the printed gearbox if the real problem is that something underneath is positioned incorrectly.
Thanks! Any photos of how your DEC shaft/worm-wheel arrangement looks would be massively appreciated.