Product Overview:
This is AndyMark's premier shifting two-speed transmission.

The Super Shifter includes hardware for both pneumatic shifting and servo shifting (the pneumatic cylinder is not included). Pneumatic shifting hardware is installed as standard, while servo shifting hardware is packed in a hardware baggie. This shift-on-the-fly gearbox, uses a dog gear shifting method. Motor input includes two CIM motors, or two AM Planetary Gearboxes or a combination of either (not included). The output shaft is a 1/2" 4140 steel shaft with a 1/8" keyway. Two sets of reduction gears are available, while the ratio between high and low gear is 2.56:1.

Three differences compared to the AM Shifter design:

• An extra reduction stage has been added. Two gear sets are available to be used on this stage. A 2.25:1 reduction set (45 and 20 tooth gears) is standard, while an optional 2.82:1 ratio, using (48 and 17 tooth gears) are available for purchase. This added stage allows for direct drive applications of 6" and 8" wheels.
• The output shaft is extended from the side of the gearbox, as opposed to being captured within the side plates as on the AM Shifter transmissions.
• A 2" long extruded aluminum box tube is used as a protective spacer, enclosing the gearbox. This is a safety improvement over the AM Shifter gearboxes.

Shift Style:
Two shifting methods are available for the Super Shifter. The pneumatic method is much stronger and faster than the servo method.

• Pneumatic:
• A pneumatic cylinder, Bimba model 04-0.5-DP, 3/4" bore x 1/2" stroke, (not included) shifts between high and low gear. This cylinder mounts with a 5/8-18 nut (not included). This is a strong, fast method of shifting, lasting under 0.5 seconds and pushing with 26 pounds of force (if using 60 psi). This pneumatic shift can be done while a robot is accelerating.

• Servo:
• A Hi-Tech Servo, model HS-322HD is included, using an actuation fork to shift between the 2 gear settings. This is a slow, weaker method of shifting (compared to pneumatic), taking 1.5-2 seconds and pushing with up to 8 pounds of force. A robot driver may need to back off of the throttle to let a servo shift gears while moving.

Weight: 4.0 lbs., without motors or pneumatic cylinder installed

Included Hardware:
Attached Hardware:

• Shielded, flanged ball bearings
• 4140 steel 20 dp gears, w/ 14.5 degree pressure angle
• 1/4" thick aluminum side plates
• encoder, cable and servo included

Loose Hardware:

• Two - CIM gears (12 tooth)
• Two - 5/16" retaining clips
• Two - 2mm x 2mm machine keys
• Four - #10-32 screws, for motor mounting
• One - servo w/ aluminum servo arm
• One - 1/4-28 screw for servo actuation
• One - 1/4-28 nut
• Six - 5/16" id washer to space out CIM gear (3 for each motor)
• One - US Digital CA-3285-1FT encoder cable

Motor Input:

• Designed for 2 (or 1) motor inputs
• Use CIM motors or AM Planetary Gearboxes or a combination of both

Gearing:
Standard Gearing Information:

• Ratio between High and Low gears: 2.56:1
• FINAL STAGE, w/45:20 gear set
• Low Gear: 24.0:1
• High Gear: 9.4:1

Optional "Final Stage" Gearing:
(available as optional parts)

• FINAL STAGE w/ 48:17 gear set
• Low Gear: 30.1:1
• High Gear: 11.8:1

Optional "Output" Gearing:
(available as optional parts)

• Ratio between High and Low gears: 4:1
• Replace the standard 35 Tooth Small Output Gear (am-0023) and the standard 28 tooth Medium Cluster Gear (am-0025) with the 28 Tooth Small Output Gear and the 35 Tooth Medium Cluster Gear, to get these new output ratios below
• FINAL STAGE, w/ 45:20 gear set
• Low Gear: 24.0:1
• High Gear: 6.0:1
• FINAL STAGE w/ 48:17 gear set
• Low Gear: 30.1:1
• High Gear: 7.5:1

Optional Super Shifter Output Shafts:

• Long SS Wheel Shaft (output shaft, sticking out 3.94")
• Long SS Hex Shaft: this is an extended intermediate shaft, used if the final stage is not needed
• Hex SS Wheel Shaft provides a hex output shaft, if a FR8ZZ-Hex bearing is used.
• Hex SS Long Wheel Shaft provides a longer hex output shaft, if a FR8ZZ-Hex bearing is used.

Weight Reduction:

• An aluminum Hex SS Wheel Shaft can replace the standard steel Wheel Shaft
• Four 2" long spacers can replace the black box extrusion, but this exposes interior gearing.

Common Parts:
The Super Shifter uses many of the same fabricated parts as the AM Shifters (am-0001 or am-0957) transmissions: CIM gears (12 tooth), Large Cluster Gear, Medium Cluster Gear, Small Output Gear, Large Output Gear, Dog Gear, Cylinder plate, Shifter Shaft, and Shift Block

• Super Shifter Assembly Instructions (.pdf)
• Super Shifter Motor Mounting Instructions (.pdf)
• Super Shifter Servo Shifter Installation (.pdf)
• Super Shifter Pneumatic Cylinder Installation (.pdf)
• Super Shifter Layout File (.pdf)
• Pneumatic Super Shifter /w motors and air cylinder CAD file (.stp) (right click, save as)
• Super Shifter /w Servo CAD file (.stp) (right click, save as)
• Pneumatic Super Shifter with long 500 Key shaft CAD file (.stp) (right click, save as)
• Pneumatic Super Shifter with hex output shaft CAD file (.stp) (right click, save as)
• Pneumatic Super Shifter with long hex output shaft CAD file (.stp) (right click, save as)

Encoder Alignment:

The encoder wheel fits on the back end of the Wheel Shaft so that the outer face of the encoder wheel is aligned at the same level as the tips of the encoder clip posts, as shown in this picture:



Mounting the Servo Shifting Hardware: