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The gear ratio for the system is 4:1 which results in large gears. The ratio for gears is determined by the relative diameters or tooth counts such that the following equation is satisfied

D1/TC1 = D2/TC2

Where D = Diameter and TC = Tooth Count
The diameters we are referring to here are the diameters to the center of the peg circle on each gear as shown in the pictures.

The tooth count determines the spacing between the pegs – aka the pitch of the gear. This is limited by the diameter of the pegs and the amount of backlash between gears that you can tolerate. I decided on a final tooth count of 48 for the large gear and 12 for the small gear. The minimum spacing between teeth determines the tooth limit.

Minimum spacing = 2* peg diameter. This is the chord length. Practically you need to allow for more than this because you only want the driving peg to be in contact with one receiving peg. The driving peg needs to be free to slide down between pegs.

Arc Length Spacing = ( PI * Gear Circle Diameter / TC ) > 2* Peg Diameter
Spacing = ” 2*Peg Diameter = ”

NOTE: For this circle I am making the approximation that the Arc Length ~ Chord Length

The peg circle diameter of the small gear is ” and the peg circle diameter of the large one is ”. The pegs are ” hardwood dowel pins ” long. You can find the pegs at Lowes or Home Depot. You can make the gears using a jig-saw/scroll saw/router and a drill but I chose to use CNC. It’s a lot quicker and makes the gears very accurately. The gears where modeled using Solidworks, then drawings were created and exported as DXF. The DXF file was imported into CamBam which generated the g-code. I have described this overall process in this instructable https:///id/Tetris-Puzzle/step3/Data-manipulation/ so won’t repeat it here. The Solidworks files are attached to this step. The CamBam files are attached as well - remove the .pdf from the filename - these are not PDF files but a work around for the INstructables importer :-)

The gears are the most complicated part of the build and need to be reasonably precise to have consistent tooth engagement. A total of 4 gears – two of each type – are needed. The larger gear has two different hub sizes. One is ” and the other is ”
I adjusted the CNC program in Cam Bam to cut each type to the correct overall size.

Here's a video of the larger gear being cut on the CNC.

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