GEARSUITE

GEARSUITE — Cycloidal

An eccentric wobbles a lobed disc inside a ring of teeth. One lobe fewer than there are teeth, so one input turn walks the disc back exactly one lobe.

The teeth are cut straight into the ring: one part, nothing to source, no teeth to index wrong. The disc profile is the same either way, because a tooth is the metal a pin was standing in. Between the teeth the valley is one arc tangent to both, so the whole bore is arcs meeting tangentially and a cutter can follow it in one pass.

There was a second ring here, with loose rollers dropped into half-round grooves, the way a bought reducer does it. It bought rolling contact instead of sliding and cost a ring of ground dowels, a groove each, and a housing that has to retain them - and on a printed drive the rollers were the part least likely to be to size. Gone, along with everything that had to ask which of two machines this was.

Ring and pins

21 teeth of ⌀7.0 on a ⌀100.0 circle, giving 20 lobes and 20:1.

The reduction is exactly the lobe count, Np − 1, so it can only be a whole number — there is no such thing as a 20.5:1 cycloidal.

Disc

Eccentricity 1.4 mm, disc 8.0 mm thick, bored ⌀12.0 with 39.1 mm of rim under the lobes.

Curtate ratio E·Np/R = 0.588. Keep it between 0.4 and 0.8: the lobes cusp as it nears 1 and vanish as it nears 0.

Three diameters, one inside the next. Name a cam and a bearing of that bore is fitted, and the disc's centre bore becomes that bearing's outside - so with a cam named it is the bore that follows, not the other way round. Name a shaft and the journal bearings take that bore instead of the largest one that happens to clear the cam, which is what they do on automatic and what used to make the two look welded together. The shaft has to stay under the cam: the cam's bearing is pressed on and has to slide over the journal to reach it. The motor shaft is the hole up the middle, bounded by the shaft rather than by the cam, since that is the part being drilled.Stock bores are 3, 4, 5, 6, 8, 10, 12, 15, 17, 20, 25 and 30, and asking for anything else is answered rather than rounded. 0 hands a field back to the drive, which is also how to undo a size you have outgrown - none of these has a minimum, so a number that will not work is refused in words instead of being made untypeable.
Balance

2 discs on the eccentric, 0% of one disc left unbalanced.

Residual orbiting unbalance 0% of one disc. The discs are forced 9.00° apart — half a lobe pitch for a 180° pair. That is not a choice: α = −Nl·ψ ties each disc's rotation to its own eccentric.

Each disc carries a group of counterbored marks in the web between its bore and its output holes: one dot on the first, two on the second, and so on. Count them to tell the discs apart, and put the counterbored face up — they are handed parts and the dots are the only thing that says which is which by eye. Assembled, the groups sit exactly 180° apart, and they stay that far apart wherever the input is parked — so if they are not evenly spaced, a disc is on the wrong cam or turned over.

Output
They run the whole length: through the collar over the output bearing, the wall, the seat at the motor end and the cap. ⌀5.4 clearance on a ⌀107.6 circle, which is mid-wall. 0 lets the count pick itself from the size of the drive.

Holes are ⌀15.00 mm for ⌀7.20 mm pins — oversized by exactly the orbit diameter 2E, so a fixed pin never binds.

Preview

Input turning at 120 rpm, assembled.

The parts come apart in the order they go together, from the motor end up: cap, base flange, eccentric, discs, housing wall, output flange, collar. Bearings and pins travel with the part that holds them, which is what says where they belong.

Parts, as exported

One chip per file. Dashed ones are drawn and never written: ring pins and bearings are bought, and a printed one of either is how you get a drive that binds. Each part is a single closed solid, sections and all - the housing is its wall and the collar bored into it, the output flange is its plate, its boss and the pins pressed through it. The switches below still apply on top of this.

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20 lobes / 21 teeth 20:1 reversed output 6.00 rpm disc ⌀95.80 mm
Geometry20 lobes
Lobes20
Reduction20:1 reversed
Curtate ratio0.5880 good
Disc outside ⌀95.800 mm
Disc root ⌀90.200 mm
Lobe depth2.800 mm
Pin-to-pin gap7.90 mm
Output hole ⌀15.00 mm
Residual unbalance0% balanced
Stack height16.00 mm
Cut in the solid the contact slides rather than rolls, because a tooth cannot turn the way a loose roller does. Friction and wear both go up, and the ring wants a harder surface than the disc. In return it is one part instead of 22, the teeth cannot fall out or index wrong, and there is nothing to source.
The discs are handed parts, not duplicates. Each one's output holes must be drilled 9.000° round from the previous disc's, which is 4.01 mm at the hole circle - far more than the 2.80 mm of clearance, so identical discs would simply not go together. An output pin count of 40 would absorb the rotation and let one part serve for all.
Housing & output
Disc orbital envelope98.60 mm
Housing bore99.02 mm
Housing outside ⌀115.05 mm
Housing length49.24 mm
Wall outside the ring7.40 mm
Mounting6 × M5 on ⌀107.6 mm
Flange outside ⌀86.40 mm
Output pin length18.00 mm
Crossed roller rings are thin and are usually clamped between flanges rather than pressed. Follow the manufacturer mounting drawing: bolt pattern, seat flatness and clamping torque matter more than the diametral fit here.
Bearings

Eccentric 128, pins 6700, input 683, output RA8008.

Find by ratio

Find tooth counts for a ratio

The reduction is the lobe count, so it can only ever be a whole number — 47.5:1 means choosing between 47 and 48. Useful from about 8:1 to 120:1.

Export

Export

Nominal geometry, for machining or resin. Every surface moves in by this much, so teeth get thinner and bores get wider from the one number. It applies to STL only; STEP keeps the nominal geometry, because a CAD file that carries one printer's shrinkage is wrong everywhere else.

PartSTLSTEPDisc 1 of 2Disc 2 of 2Housing wall (lobed)Output collarMotor end capOutput flangeBase flangeEccentric shaftWhole set
8 parts, every one a single watertight solid at the sizes the seats were worked out to. The disc carries its centre bore and all 6 output holes at ⌀15.00 mm, oversized by the orbit diameter 2E = 2.80 mm so an output pin turning with the flange never binds as the disc swings around it.
Bearings and ring pins are not here and will not be: a bearing is a designation and a fit, a pin is ground dowel stock, and a printed one of either is how you get a drive that binds. What the parts carry is the seat for them. Everything else is one file per lump of metal, which is not the same as one file per shape: the housing wall and the collar bored into its top are one part, and so are the flange plate, its boss and the pins through it.