Quote: "There is a problem with keying the axles on the steam engines, with more than one axle powered:
If the customer takes it apart. If the worm gets a tooth off from the worm gear, depending on whether odd or even teeth, and/or the connection between gearboxes gets moved…lining the drivers back up can be a time consuming effort.
You’d have to put all the gearboxes together, connect them to each other, fit drivers, and see if they line up…then take it all apart and futz with it until you get it right."
Dave,
when simple assembly techniques cannot be taught successfully on a production line, could you imagine any manufacturer taking on a task such as all powered keyed driving wheels on a steam outline locomotive. The variations in assembly are mind boggling. Think how many poorly performing (if at all) locomotives would leave the assembly area for perhaps packaging (most likely) or returning for reassembly/repair (hardly likely).
Edit: the only method I could think of was individual assembly of each gearbox complete with both wheels fitted prior production line assembly. This would involve a separate assembly line just for the prime mover drives and fitment of wheels. Each drive would need to be assembled on a jig to ensure the end result was the same for all drives (wheel quartering correct for the alignment of the input drive).
Then a new connecting shaft would be needed between each drive such that the drives could only be connected in one plane only (no variation allowable between gearboxes when connecting so that wheels do not rotate independently). I do not know the prime mover input drive design but it possibly may involve modifying the design of the connecting shaft between each gearbox input (if there is one).
Then the complete drive assembly would be straight forward, ensuring all wheels were correctly positioned (quartered) on the final drive assembly line. All this would require some precision and skill and reliable assembly could not be 100% guaranteed across the whole batch production run.