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Spur-gear axial offset: measure finite face overlap beyond the 2D layout

Published: October 9, 2026 by Physical AI Lab

An unchanged authored nominal in-plane layout does not establish finite axial overlap. Measure both face intervals before choosing spacers, shoulders or retention positions.

Categories World Models and Simulation

Wedge lift geometry: verify rise and full shoe support together

Published: October 9, 2026 by Physical AI Lab

With the same 30 mm horizontal input, the 10° ramp raised the shoe 5.29 mm and left 0.23 mm at the limiting edge; the 25° ramp raised it 13.99 mm and left 1.55 mm.

Categories World Models and Simulation

Bell-crank endpoint travel: a longer arm also increases lateral drift

Published: October 9, 2026 by Physical AI Lab

At ±20°, the 80 mm arm produced about 27.36 mm of tangent travel and 4.82 mm of radial drift, while the 50 mm arm produced 17.10 mm and 3.02 mm.

Categories World Models and Simulation

Hex-head wrench entry: across-flats clearance depends on clocking

Published: October 9, 2026 by Physical AI Lab

The same 10 mm across-flats head cleared a 10.2 mm rigid mouth when aligned, intersected both jaws at 30°, and regained about 0.13 mm clearance in an 11.8 mm mouth.

Categories World Models and Simulation

A fixed spherical center does not certify stud-neck clearance at the socket rim

Published: October 9, 2026 by Physical AI Lab

The center stayed fixed, but neck-rim separation fell from about 6.97 mm to 2.28 mm before the finite solids intersected at 35 degrees.

Categories World Models and Simulation

Linear-guide travel limits: check the whole carriage against the finite rail

Published: October 9, 2026 by Physical AI Lab

At a 50 mm center position, the carriage center remained inside the rail while the body overhung its end by 10 mm and retained 30 mm of overlap.

Categories World Models and Simulation

Four-bar coupler midpoint: check the departure from a straight reference

Published: October 9, 2026 by Physical AI Lab

Three valid static closures put the same coupler midpoint near the reference at 90 degrees but on opposite sides at 60 and 120 degrees.

Categories World Models and Simulation

Flat-faced cam followers: keep the support on the finite face

Published: October 9, 2026 by Physical AI Lab

At the same 45-degree cam pose and follower height, a 20 mm face missed the support edge while a 40 mm face contained it with positive margin.

Categories World Models and Simulation

Universal-joint fork clearance: check more than the shaft bend angle

Published: October 9, 2026 by Physical AI Lab

At one 35-degree bend, three compatible static phases changed the controlling fork pair and produced bounded clearances from about 2.54 to 2.88 mm.

Categories World Models and Simulation

Sheave fleet angle: check cable thickness as well as the centerline

Published: October 9, 2026 by Physical AI Lab

At 6 degrees, the cable centerline remained about 1.68 mm clear while the full 6 mm cable envelope had a certified interior intersection with the flange.

Categories World Models and Simulation
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