After having produced the first functional demonstration of the moteus servo mk2, my next step was to decrease the weight.  While I was at it, I made two other changes:

• Axial connections: I switched to a design with entirely axial connectors, which removes the need for 4th axis machining when producing the parts.
• Planet Input Bearing: I switched the planet input bearing to be inserted from the rotor side.  This way, the bearing is captured between the planet input and the rotor, rather than between the planet input and the gears.  That also improves the ability to assemble and disassemble the unit.

Another step in my plan for the next revision of the moteus servo mk2, is an updated controller board.  As mentioned in my roadmap, I wanted to revise this board to make improvements in a number of domains:

• Communications: Now instead of RS485, the primary communications interface is FD-CAN.  This supports data rates of up to 8 Mbit and packet lengths up to 64 bytes.  The header is nominally at the original CAN bit rate, but I have no need to be standards compliant and am running very short busses so I may run everything at the higher rate.
• Connectors: Now there exist power connectors, in the form of XT30 right angle connectors and they are also daisy chainable like the data connectors.  Additionally, all the connectors exit from the bottom of the board to make routing easier in configurations like the full rotation leg.
• Controller: This uses the relatively new STM32G4 controller series.  It is lower power than the STM32F4, supports FD-CAN, and also supports closely coupled memory, which may allow me to improve the speed of the primary control loop execution by 3 times.
• Voltage range: This board now has 40V main FETS, with all other components at 50V rating or higher.  Thus it should be safe with inputs up to 8S (34V or so).

Now that I have at least one functioning version of each of the pieces made for the moteus servo mk2 (planet input, outer housing, front housing, and back housing), I integrated all of them together into a functional prototype.

The back housing is the final piece of the moteus mk2 servo that I wanted to prototype.  (The planet output is identical to the mk1, so I could use extra stock I had of it for the prototypes).  It is large, and only mates directly to 4 other things, which makes it a little less complex than the front housing.

Design

I had initially designed the back housing to mate to the as-yet-unannounced new version of the moteus controller, the r4.x series.  Unfortunately, I don’t have any of those working yet, so I tweaked the design to temporarily fit a r3.1 controller, which looks like this:

The front housing is the most complex machined piece in the moteus servo mk2, as it was in the mk1.  It is relatively large and mates with many other components with the associated tight tolerance surfaces.  For mk2, the front housing is even larger in diameter, but otherwise has the same basic features.

Manufacturing

Building a prototype of this was a real challenge given the tools I have available to me now.  For mk1, I didn’t even try and just had Xometry build my prototypes, and was lucky enough that the first ones worked.  My only CNC currently is the Pocket NC v2-50, which is just barely big enough to deal with this part, and has no convenient workholding that can be used for the stock.  Also, it has a low material removal rate, such that starting from stock here would be prohibitively time consuming.

The outer housing for the moteus servo mk2 is just a precision round tube with some mounting holes drilled peripherally.  Still, manufacturing it was slightly annoying, mostly because of my available machining resources.

Manufacturing

I started off with round tube stock with some extra margin on the inside and outside:

Then I went and used the manual lathe at Artisan’s Asylum to get the correct ID, OD and length:

As the first part of the new moteus servo mk2, and continuing in my series of learning about CNC by building parts for the quadruped, next up I machined the input to the planet gears on my Pocket NC V2-50.  This was a part, that for my quad A0 build, I used a 3d printed part in PETG as it is probably the least stringent part in the gearbox in terms of tolerances and load, although I still expect the plastic ones will likely wear and fail after some time with heavy use.

As described in my roadmap, making a new revision of the moteus servo is up there on my list of things to do.  The initial servos were a work of art, yes, but also pretty fragile, very labor intensive, and still not all that robust.  My goals this time around are:

• Manufacturability: The servo mk1 took about 2 or 3 man-days of manufacturing time per servo once all the steps were factored in.  I’d like to get that down to an hour or two at most per servo.
• Robustness: The planet input, outer housing, back housing, and controller cover of the mk1 servo were 3d printed, mostly to save cost and time.  This necessitated adding reinforcing rings on the outer housing, as it is nearly impossible to 3d print something with the required material properties in a single print.  At this point, all of these components should just be made of aluminum like the others.
• Repairability: Once the mk1 was assembled, there was no way to disassemble it, as installing the stator interfered with the ability to remove the outer housing, and the outer housing in place interfered with the ability to remove the stator.
• Convenience: The mk1 servo used the r3.1 moteus controller, which had RS485 connectors sticking straight out the back, and bare power wires coming out the back.  That orientation for connecting things was not terribly convenient in the full rotation leg design, and required making extension cables.  The newer moteus controller has the connectors sticking out the bottom, so the servo needs to accommodate that.

CAD explosion

Some time ago I put in orders for all the long lead time items on a second version of the moteus servo.  This is primarily aimed at improving the manufacturability and reliability, along with some minor performance improvements.  I’ve now got at least samples of all the long lead time parts in house!

When I was trying my first pronking, I kept having over-voltage issues when the servos were trying to dump power back onto the DC bus, no matter how high I set the voltage limit.  During that test, I was running with a nearly full battery, so my working theory is that the battery protection circuit was disconnecting the battery either because of too high a charging current, or too high a system voltage.  When the battery was disconnected, and the servos were still putting power onto the bus, that resulted in the voltage spiking arbitrarily high, followed by a total loss of power when they all faulted and then nothing was powering the bus at all.