User Manual - Gearify Software
Contents
1. 1 2 Activat ing on machines with an Internet connection 1 3 Installing Gearify on Machines without an Internet connection 1 4 Activat ing Gearify on machines without an Internet connection 2 Quick Start Guide 2 1 Creating gears using Free Draw 2 a 2 2 Create a gear using an Image 20 2 0 000002 2 eee 2 3 Create a gear using DXF 1 1 ee 2 4 Pan Zoomi Controls 24 3 4 tes ce os a ae ae es ey ee es a ig a ee ae 3 The Basics 3 1 The Bas sGutve fa T rd krosa ada e kOe oe ok EE E e ese 32 Tooth Outlines 2 ins aa OR OR ee ee ae ee dh A DE tea ad 33 gt ROtatlon Ratio a 2845 winds GS eee Ge Oe Echt ad a de Agee A Atte SA 3 4 Internal Indicator mia e A ee EEA DAD cone a 4 Base Curve Design Modes 41 F t Polar Functions o 4 ted th ee AR LAS GOSS Soa E 4 2 Draw Free hand drawing cido paar As 4 3 Param Parametric Functions e e 4 4 Implic Implicit functions Math savvy users only ooo 45 Ime Image Upload i iarsi e AA ee ee A ee ed 4 6 svei sVi Upload mc a e ar hee Rois e aaa ALA DR EAA LO DAF Upload DXF eai dade 4 4 Ooch AAA A a a 5 Tooth outline Design Suh Options 4 4 fa 2 hee Pee A a a Gh PAE A Sete 5 2 Caleulate Teeth 842 aap leh A a ee ee eh ab pew u Dds Tooth Design 24 8 mani Yh SR WARE OA ae Re E EA RRE 4 5 3 1 STD Standard Tooth Design o e 5 3 2 F t2. Gearify User Guide Version 1 0 1 postmaster gearifysoftware com WARNING The purpose of this software hereafter referred to as Gearify is to hypothesize the shapes of interlocking gear mechanisms While most reasonable designs will produce gears that will interlock smoothly the mechanisms designed and calculated via Gearify are not guaranteed to be reliable or safe Gearify can occasionally produce designs that will be depicted as smoothly interlocking mechanisms but will slip apart or grind to a halt when made into physical models While parameters can be adjusted to produce highly accurate designs Gearify is not explicitly designed for industrial grade mechanisms The creation of gears for industrial applications is a highly developed engineering science Gearify is only partially based on this science and instead relies on an original approach using Differential Equations Numerical Methods and Computational Geometry in order to allow more freedom of design In any situation building and operating machines is potentially dangerous Gears have the capacity to generate massive amounts of torque which can pinch and crush It is entirely up to you the end user to verify the suitability reliability and safety of any design explicitly or implicitly suggested by Gearify for any application The developer s of Gearify are in no way responsible for any injuries or accidents involving any machine which contains designs produced by Gear
3. Parametric tooth design Math savvy users only 5 3 3 Draw Freedraw tooth design o o e 5 3 4 img Image tooth design o o e e 5 3 5 dxf DXF tooth upload e 5 3 6 txt csv CSV tooth upload o o o 12 12 13 13 14 15 15 17 18 19 20 21 21 5 3 7 export Exporting tooth designs 5 4 Import full tooth outline 2 2 2 ee ee 6 Gear Calculation 6 1 Calculation Parameters 2 2 ee ee 6 2 G ar SyMMetry A g OK a len Se a a a added oa 7 Viewing Saving and Exporting PL Viewing Gears a Gs aes a Sa oe Ta EES ea tiny ae Oe a Gud DAVE EXPO 8 2k Gow Take ae of oa ty Renae wee ee eS ees Se SS 7 3 Re opening Gearify files o a AD Chaining Gears sath E A od AEE a A eS 8 Astronomer 8 1 Quick Start Guide ce Le of a pe Ai enone BO GR ee lee SS 8 2 Basic Astronomer Non Math Users 2 00 0 eee ee 8 3 Number of planet gears and Rotation Ratio ranges 8 4 Accurate Gear Calculation 0 0 0 000000 00 ee ee 8 5 y General iTiDS a A Eee ee ee ee Se he a a S 8 6 Advanced Astronomer Math savvy users only 9 Troubleshooting 10 Expression Parser 11 Credits Chapter 1 Installation and Activation Gearify is very easy and fast to install and activate but step by step instructions are provided for extra clarity and convenience 1 1 Installing on machines
4. have make and model download the appropriate driver installer from the makers website and install it on your target machine If you are still having errors restart your computer and attempt to run Gearify once more If all else fails email a clear description of your problem and any error messages you are receiving to postmaster gearifysoftware com Step 5 Once you are sure that Gearify works on your target machine you are satisfied with the software product and you wish to activate the full version go to www gearifysoftware com and purchase a product key The payments page will carry out the transaction using Paypal and it will walk you through the payment process It will conclude by emailing you a product key To activate follow the activation instructions in the next section 1 4 Activating Gearify on machines without an Internet connection Step 1 e After you have purchased a product key Be sure you evaluate and test the software before doing so Copy your product key from the email that was sent to you and paste it into a simple text editor such as notepad Save the file call it gearify product key txt to a flash drive or external device e Open Gearify on the machine you wish to activate it on Hereafter referred to as the target machine e Click on the Activate tab at the top of Gearify e Click the Activate button e You will see a new window appear with a list of options Click on Other Options e On
5. or press cent to make it the center of the image the default If Gearify does not correctly detect your background color right click the background on the image to read the color The color of the crosshairs should match the background This is a place where you will definitely want to experiment with the sample points slider control at the top of the design tab Reading an image at 360 radial divisions can produce sloppy results especially if the image is low resolution For this consider lowering the number of sample points to 180 90 or even 45 Lastly you must adjust the tolerance which is a value between 0 and 1 Use a high image tolerance 0 5 or higher when there is stark contrast between the content of the image and the background like a black image with a white background Use a low tolerance when there is only a slight difference between the content of the image and the background like a light gray image with a white background Experimenting with image tolerance will be key to reading the shape as you desire it A technical description of the tolerance is that it is the maximum Cartesian distance within the color cube that a pixel can deviate before it is recognized as a non background pixel The background color is defined as the color of the upper left most pixel in the imported image Once you have selected the gear center point adjusted the number of sample points and the tolerance click the Read Image button and the gea
6. symmetry value of your know gear This is explained further in the next section Gear Symmetry Once you have set your rotation ratio you may check the Internal option to indicate that you want the known gear to roll along the inside of the conjugate gear If you choose this option your rotation ratio must have a larger top number than bottom number this ensures that the conjugate gear is larger and therefore the known gear is capable of fitting inside it If your top number is smaller than the bottom number Gearify will automatically make it 1 larger than the bottom number when you check Internal There is also the trim speed slider control This determines the speed of the calculation High trim speed uses fewer iterations to calculate the shape of the conjugate gear low trim speed uses more iterations A high trim speed will work faster but produces less accurate results A low trim speed will take longer to complete but be much more accurate You may adjust the trim speed while the calculation is in progress but this is not recommended if you are using the calculation to build a physical model A technical description of the trim speed is that it is the angle delta used to rotate the known gear for each iteration of the vertex trimming process which is the animation displayed after you click Calculate Gear 29 There is also the Extra High Accuracy check box For some designs especially those that feature teeth with sharp edges you ma
7. tooth design Here you can quickly draw tooth designs using a few simple clicks In the left hand side of the display you create the Left Tooth The left tooth should be pointing upward but arching downward like this M In the right hand side of the display you create the Right tooth The right tooth should be pointing downward but arching upward like this U You may begin by clicking anywhere on the screen Left click to add a horizontal segment Right click to remove the highlighted horizontal segment The highlighted horizontal segment is the one nearest the mouse If you are clicking on the left half of the screen you will modify the left tooth If you click on the right half you will modify the right tooth By default left horiz symmetry is checked This means if you click near the red vertical line the center of the left tooth an identical vertex will be placed at the same location on the opposite side of the red vertical line Similarly by default right horiz symmetry is checked This means if you click near the green vertical line the center of the right tooth an identical vertex will be placed at the same location on the opposite side of the green vertical line If you uncheck either left horiz symmetry or right horiz symmetry then you will have to make two clicks to add a horizontal segment If you don t like where you placed a vertex on the first click then right click to terminate the segment You will also notice that
8. with an Internet connection Step 1 Go to www gearifysoftware com and download the free evaluation version Right click the downloaded zip folder Gearify zip and click Extract or Extract all to unzip it this may vary depending on what compression software you have installed on your machine Step 2 To install Gearify you must first uninstall any previous version of Gearify that is installed on your machine If you have a previous version installed go to the Add Remove Programs section of Windows often found inside control panel Search for Gearify and click uninstall Follow the instructions to complete the uninstallation Now open the Gearify folder you un zipped in step 1 and double click the setup file to begin installation Follow the instructions to complete the installation You must agree to the terms of the license agreement Once the installer completes you should see a Gearify icon on your desktop and in your start menu Double click on either to open the software Evaluate it thoroughly on your machine to make sure it functions properly I recommend following the Users Guide from start to finish with the exception of the exporting sections which require activation before purchasing a product key Step 3 If you have errors otherwise proceed to Step 4 When you start Gearify you may get an error message that says something along the lines of To run this application you must first install one of the following versions of th
9. activation response file to complete the activation For a detailed walk through see the steps below Step 1 e Ona machine with an Internet connection go to www gearifysoftware com and download the evaluation version e Save the downloaded file Gearify zip to a flash drive or external device e Disconnect your flash drive or external device Step 2 e Connect your flash drive or external device to the machine you wish to install it on the one without an internet connection We ll refer to this as the target machine from here on e Copy the file Gearify zip to your machine to My Documents for example Right click the zipped folder and click Extract or Extract all to unzip it the unzipping process may vary depending on what compression software you have installed on your machine Step 3 e Uninstall any previous version of Gearify that is installed on your machine If you have a previous version installed go to the Add Remove programs section of Windows often found inside control panel Search for Gearify and click uninstall Follow the instructions to complete the uninstallation e Open the Gearify folder you unzipped in Step 2 and double click the setup file to begin installation Follow the instructions to complete the installation You must agree to the terms of the license agreement e One the installer completes you should see a Gearify icon on your desktop and in your start menu Double click on either to ope
10. ad a file of comma separated x y coordinates with one vertex per line For example suppose square csv contains the following text 1 1 1 1 1 1 1 1 This will produce a square shaped base curve This is very useful if you want to use the result of a previous gear calculation as input for a new calculation See Chaining Gears Notes on symmetry Symmetry auto detect is enabled You can enter it manually if the auto detect fails but carefully consider if the auto symmetry was correct See Gear Symmetry for more details 4 7 DXF Upload DXF This design mode lets you upload DXF files so you are free to design gear shapes using your favorite CAD software Click the Design tab then click the dxf tab to enter this design mode Adjust the sample points slider at the top as desired though the default value 360 should be suitable Click the DXF button and browse to a DXF file Open your file and your base curve will appear in the display Should you choose to adjust the number of sample points you will have to re upload the DXF file 21 This design mode is very useful if you want to use the result of a previous gear calculation as input for a new calculation See Chaining Gears Notes on symmetry Symmetry auto detect is enabled You can enter it manually if the auto detect fails but carefully consider if the auto symmetry was correct See Gear Symmetry for more details 22 Chapter 5 Tooth outline Design At the bottom of the Des
11. age as shown Lastly you may adjust the tolerance which is a value between 0 and 1 Use a high image tolerance 0 5 or higher when there is stark contrast between the content of the image and the background like a black image with a white background Use a low tolerance when there is only a slight difference between the content of the image and the background like a light gray image with a white background Experimenting with image tolerance will be key to reading the shape as you desire it A technical description of the tolerance is that it is the maximum Cartesian distance within the color cube that a pixel can deviate before it is recognized as a non background pixel Once you are ready click Read Image and you will see line segments generated following the tooth shape depicted Adjust the number of Vertices as desired and then click Read Image again until the outline is read as you desire Click Pan Zoom to re enable the standard view controls 26 5 3 5 dxf DXF tooth upload Use the two Browse buttons to upload individual tooth designs for the left and right teeth The left tooth should be an open curve pointing upward and arching downward Like this N The right tooth should be an open curve pointing downward and arching upward Like this U The Vertices attribute will determine how many points are used to decompose the DXF files for each tooth 5 3 6 txt csv CSV tooth upload Use the two browse buttons to upload individ
12. alculated in attempt to optimize them based on their current location In some cases you may not want this As an alternative you can upload a full tooth outline as a file This full tooth outline will be used regardless of the value of v You do not need to manually create a full tooth outline you can Export your known gear tooth outline as a DXF of CSV after creating your initial design Then in the Design tab click the Import Full Tooth Outline tab and upload your tooth outline 8 6 Advanced Astronomer Math savvy users only All of the principles of Basic Astronomer apply here with one exception Instead of the v parameter corresponding to a location on the curve the v parameter can be inserted directly into your equations in the polar and parametric gear design modes Under the Design tab under f t and param respectively Simply insert v into your functions and click graph A value of v 0 5 will be used in the initial preview but clicking on the Astronomer tab you can drag the Preview V slider and see the gear deform The value of v will still range between 0 and 1 It has been proven that the amount of variability in graphs generated by astronomer is bounded in a particular sense by the maximum and minimum radius of the gear design Try to offer significant difference between the maximum and minimum radius in your design for a better shot at finding intersections Using the math design mode is the ONLY instance where you may want to t
13. all the functions available see the expression parser info Instructions for Non Math Savvy Users Fear not This requires no voodoo calculations or solving for x Have you ever played with a graphing calculator This is exactly the same Click on the textbox beside r t and type a single number 12 is a good number We l call this the leading constant Now what we l do is add wave forms to that Waveforms look like the following e 2cos 3t e 6sin 7t e cos 4t 13sin 2t The number in front of cos or sin is called the amplitude The number next to the t is called the frequency So the waveform 2cos 3t has an amplitude of 2 and a frequency of 3 Let add two waveforms 2cos 3t and 3sin 6t to our expression r t 12 2cos 3t 3sin 6t And that all you have to do Experiment with different waveforms for more interesting results If you get a message that says Warning Negative radius increase the leading constant 12 value to something larger or shrink your amplitude values then click Graph curve again You can also add exponents to your waveforms using the symbol For example you might try r t 12 2cos 3t 3 3sin 6t 2 I would keep your frequencies relatively small less than 13 and your exponents small as well Your leading constant should probably be larger than the sum of the amplitudes In the above expression the leading constant is 12 and the sum of the amplitudes is 2 3 5 You can also multiply wavefor
14. an cotangent acotan arc cotangent sqrt square root fpart fraction part fpart 3 71 0 71 ceil round up to nearest integer 41 e floor round down to nearest integer round round to nearest integer e fac factorial e sfac semi factorial sfac 6 6 4 2 e abs absolute value Comparison Operators All logical expressions evaluate to either 0 or 1 e lt less than e lt less than or equal to e gt greater than e gt greater than or equal to e equal to e not equal to Logical Operators e amp amp and e or e not Constants e euler 2 71828 pi 3 14592 e nan not a number infinity infinity gt t 1 for all t true 1 false 0 42 Chapter 11 Credits Gearify uses unmodified versions of the following LGPL libraries e Expression Parser Author Patrik Lundin www lundin info mathparser e netDXF Author Daniel Carvajal https netdxf codeplex com e Clipper Author Angus Johnson ww angusj com delphi clipper php Special Thanks to all the users of the early version of Gearify known asGear Creator for their enthusiastic emails and compliments that motivated me to finish this software 43
15. an therefore be used to compute an internal and external gear mechanism with the same center to center distance and therefore create a planetary gear mechanism You may adjust the number of sample points using the slider just to the left of the V Samples label The default is 32 You may reduce the number of sample points of faster calculations but this will produce a rough and imprecise graph 8 3 Number of planet gears and Rotation Ratio ranges Recall that you specify a range of rotation ratio values when searching for planetary gears When you select an intersection say between a graph of rotation ratio 3 1 and a graph of rotation ratio 6 1 the maximum number of planet gears you can place inside the resulting mechanism will be the Greatest Common Divisor of the rotation ratio Numerator The greatest common divisor just means the highest number that divides both So in this case the greatest common divisor of 3 and 6 is 3 If you found an intersection between a graph with rotation ratio 10 3 and 15 3 the number of planet gears would be the greatest common divisor of 15 and 10 which is 5 For this reason when specifying rotation ratio ranges you can specify 36 Multiples of a particular value in the numerator If you specify multiples of 3 for example and provide a range of 3 to 9 it will search the rotation ratios 3 6 and 9 This allows you to find only intersections where the Greatest Common Divisor will be 3 or more so that y
16. ars Suppose you want to generate a chain of gears Gear A connects to B Gear B connects to C C connects to D and so on Gearify does not explicitly support this design type though options to automate this may be available in a later revision but it is still possible to achieve this Simply begin with a gear design Set your rotation ratio and then calculate your gear When you are finished export your conjugate gear base curve and your conjugate gear tooth outline in separate files CSV or DXF Then re upload the conjugate gear base curve and full tooth outline as your known gear and repeat the process Also note if you simply desire a chain of 3 gears A connects to B connects to C then use B as your know gear and use different rotation ratios to generate A and C 34 Chapter 8 Astronomer In addition to this tutorial detailed video tutorials are available on Gearify s YouTube Channel 8 1 Quick Start Guide Click the Design tab and design a gear shape of your choosing using any of the available methods such as draw or img for example When you are finished click the Astronomer tab In the Variable Known Gear window left click 4 points inside the gear design to draw a curve Right click to erase the curve and start over Try to draw a curve that spans the overall length of the gear Click the Search button and you will see a red and yellow graph generated in the main display area If the graphs intersect you will
17. at itself every 360 n degrees For example if the symmetry value is 4 then the same pattern must repeat itself every 360 4 90 degrees This information is highly important for two reasons 1 It tells the automatic tooth calculations that the teeth MUST possess the same symmetry The tooth patterns must be repeated EXACTLY every 360 n degrees 2 It determines what sensible rotation ratio you can use For example suppose you design a base curve using the f t design mode with r t 3 sin 3t This will produce a symmetry value of 3 The gear has 3 repeating patterns As a result the smallest rotation ratio you should use is 1 3 That is 1 full revolution of the known gear 3 revolutions of the conjugate gear to mesh with the 3 repeating patterns on the known gear You are able to increase the top number to allow more revolutions of the conjugate gear but the minimum value is 1 3 For this reason Gearify automatically sets the bottom number of the rotation ratio to be the known gear s symmetry value See the Gear Calculation section for more info on the rotation ratio Each base curve design mode has its own way of determining the gear symmetry see their individual descriptions for more info Most modes have an auto detect as well as a manual option to set the gear symmetry value In case the auto detect fails 30 If you choose to upload a full tooth outline using DXF or CSV be absolutely sure that the symmetry of your to
18. ave uploaded the ActivationRequest xml file or pasted its contents into the textbox click Activate If all went well you should see a screen that says Activated Successfully If you do not see this return to Step 1 and make sure you entered the correct product key and that your product key is valid Remember you may have up to 2 activations per license e Gearify software has now confirmed your activation is valid but you have a little more to do Click Download the ActivationReponse XML file Save the downloaded file ActivationResponse xml to your flash drive or external device e Disconnect your device and return to your target machine Step 3 e Connect your flash drive or external device containing your ActivationResponse xml file to your target machine e Open Gearify and click the Activate tab e Click the Activate button e Click Other options on the Activation window that appears e Click Manually activate Gearify offline e Click Open the Activation Response file e Browse to the file ActivationResponse xml saved on your flash drive or external device then click Okay e You should see a confirmation screen saying Activation was successful If so congratula tions you have successfully installed and activated the full version of Gearify Chapter 2 Quick Start Guide Feeling impatient This Quick Start guide shows you how to use a few of the most common and user friendly design options and will have you making gears
19. d e txt csv CSV tooth upload e export Exporting of tooth designs to CSV DXF Let s look at each tooth design mode individually 5 3 1 STD Standard Tooth Design This simply provides some commonly desired tooth designs Adjust the Vertices value if desired higher vertices mean slower calculations but yield smoother designs and then switch to whichever design you want round square or triangle If you change the Vertices you will need to change to a different tooth design and back so that the tooth design is re calculated with the new number of vertices W hen you have finished making your selection click add teeth and return to your active base curve design tab 24 5 3 2 F t Parametric tooth design Math savvy users only You are able to supply two sets of parametric functions to design each tooth Your left tooth should be facing up and arching downward and your right tooth should be facing down and arching upward Example functions are provided You are able to set the range values of t for each set of functions The Vertices number above will determine how many points the functions are evaluated at but this won t take effect until you use set left and set right to graph the curves You may enter values such as Pi Euler or any expression recognized by the Expression Parser Once you are satisfied with your design click add teeth and return to your active base curve design tab 5 3 3 Draw Freedraw
20. e NET framework v4 0 This means you do not have the NET 4 0 framework installed on your machine which is required to run this software If this occurs you will need to go to http www microsoft com en us download details aspx id 17851 Or if that link fails Google NET 4 0 web installer Follow the installation instructions and when you are done re attempt to open Gearify It should open without trouble at this point You may experience slowness or freezing of the software when images or textures are being displayed on screen You may also experience blank images This likely means your display drivers need updating The steps for updating your display drivers will vary per machine so you will need to research this topic online Generally you need to determine what graphics hardware you have make and model download the appropriate driver installer from the maker s website and install it on your target machine If you are still having errors restart your computer and attempt to run Gearify once more If all else fails email a clear description of your problem and any error messages you are receiving to postmasterQ gearifysoftware com Step 4 Once you are sure that Gearify works on your target machine you are satisfied with the software product and you wish to activate the full version go to www gearifysoftware com and purchase a product key The payments page will carry out the transaction using Paypal and it will walk you thr
21. e Draw e param Parametric Functions e implic Implicit Functions Math savvy users only e img Image Upload e csv CSV Upload e dxf DXF Upload Gearify is designed to let you simultaneously experiment with the various design modes Whichever of the above tabs is currently selected is considered the urrent base curve and is the curve that will be employed when you click the Create Gear button The Rotation Ratio in the Calculate Gear tab will also remember which rotation ratio you used for each design mode as you switch between tabs The Base Curve design section features a sample points slider control and a Color box Most design methods make use of the sample points value when computing curve shapes in various methods See each individual design mode s description to learn if and how the sample points value is used The Color determines what color the base curve is drawn with inside the display area 4 1 F t Polar Functions This is a mathematical means of describing gear shapes but don t worry if you are not a mathematician or engineer Easy instructions are provided for non math savvy users To enter 15 this mode click the Design tab then click the f t tab Instructions for Math Savvy Users Enter a function of t into the r t text box and click graph curve The function will be evaluated from t 0 to 27 I recommend expressions involving sines and cosines such as r t 7 sin 3t 2cos 2t For a list of
22. e much slower but will be brutally accurate Lastly after selecting an intersection after using the Search button you must Refine your intersection calculation This will more accurately compute the location of the intersection so that the internal and external gear calculated will have a center to center distance that agrees more closely After you click Refine you will see the two computed distances shown beside the External Distance and Internal Distance labels If they do not match accurately enough you may repeatedly click Refine to find distances that agree more closely it should easily be able to exceed the accuracy that is provided by your CNC machine or 3D printer 8 5 General Tips The rotation ratios that are easiest to find planetary gears for are 3 to 3 external and 6 to 6 internal Slightly more difficult but fairly easy still is 4 to 4 external and 8 to 8 internal Another useful tip is that if you can find an intersectio between two rotation ratios you can increase both rotation ratios by the same ammount and you will typically find an intersection as well For example if you find an intersection between 3 and 6 you will likely find intersections between 4 and 7 5 and 8 6 and 9 etc Likewise if you find an intersection betweeen 4 and 8 you will likely find them between 5 and 9 6 and 10 7 and 11 8 and 12 37 It is worth mentioning that whenever you test a different value of v the teeth of the planet gear are re c
23. e sort of artistic display which features smooth irregular shapes rolling together Perhaps they would be connected to toothed versions of themselves which are concealed from view For completeness this option is available 3 3 Rotation Ratio The rotation ratio is a fraction which gives the number of rotations of the known gear per rotations of the conjugate gear For example If the rotation ratio is 2 5 then your known gear will complete 2 full rotations for every 5 rotations of the conjugate gear By design you only get to specify the numerator Top number 2 in the above ratio The denominator Bottom number 5 is determined by the symmetry of your gear The denominator is intimately related to symmetry so see the Gear Symmetry section for more info on that 13 3 4 Internal Indicator To indicate that you want your known gear to roll along the inside of the conjugate gear you can check the Internal checkbox in the Calculate Gear tab Currently only the known gear can be on the inside The option of having the conjugate gear on the inside may be featured in a later revision 14 Chapter 4 Base Curve Design Modes The Base Curve design section is the primary means of designing your gear shapes In this chapter we will explore the various design modes available When you open Gearify on the Design tab in the Base Curve section you will see 7 tabs each with unique design modes They are e f t Polar functions e draw Fre
24. e using the output files to build a physical model it is strongly recommended that you shrink the tooth outlines ever so slightly to allow for a small margin of error Some experimentation may be needed to determine an appropriate offset amount Enter an offset Delta percentage and click the Offset button The percentage is relative to the overall size of the gears This is determined by the maximum distance from the center of either gear to its respective edge 33 Lastly you may Save your gearify file This is used only to save the result of a calculation not to save your entire design environment this may be featured in a later revision Click the Save File button and browse to a file Gearify will create a folder with all the necessary info inside it If you check the Copy Textures option any custom textures that you added will be copied into your saved folder otherwise they will reference the textures at their original locations Check this option if you want to share your design with another Gearify user 7 3 Re opening Gearify files To enter this view click the Re open tab T ore open a gearify file simply click the browse button and browse to a save file you created previously There will be a folder with the name you used to save the file and inside it will be a file called gear gearify Select and open this file From here you should be able to view and re export the file as if you had just created it 7 4 Chaining Ge
25. e which features you want to export Check or uncheck them to see the effect In short what you see is what will be exported Sometimes the number of vertices of the tooth outlines can be so high that some users ex perience slowness or freezing when trying to open the files in CAD CAM software To address this there is a Reduce Vertices section This features slider controls which reduce the number of vertices in the tooth outlines Gearify will attempt to distort the design as little as possible while reducing the number of vertices but this will inevitably distort the design the more points you eliminate So use this option sparingly if at all If you want to export a design to a CSV file click the Export to CSV button browse to where you want to save your file Gearify will split the various items you have checked into separate CSV files and add suffixes to the file names for you to distinguish them For example if you export your known gear base curve and your known gear tooth outline to a file called myFile it will export to 2 files that look something like myFile_known_base_curve csuv and myFile_known_teeth csv To Export to DXF click Export to DXF and browse to where you want to save your file DXF export unlike CSV will export all the selected items to the same file An important option on this page is the Offset button Gearify is capable of producing quite accurate calculations assuming you use the right parameters but if you ar
26. ect the resulting gear mechanism carefully and when you are satisfied save or export your results You must provide 4 things 1 A Base Curve A smooth curve representing the overall shape of your gear Or what your gear would look like ithout teeth 2 A Tooth Outline A full outline of the shape of your gear teeth and all By default this is automatically generated from your Base Curve 3 A Rotation Ratio This is the ratio of the number of rotations of the Known Gear per rotations of the Conjugate Gear 4 An Internal indicator A simple check box to indicate if you want the Known Gear to roll along the interior of the Conjugate Gear Let have a more detailed look at each of these 3 1 The Base Curve The base curve is necessary for certain calculations that Gearify performs The base curve must be relatively smooth and should follow along roughly the midpoint of the tooth outline The base curve MUST have its center of rotation at the origin 0 0 It is permissible to have sharp corners and discontinuities in your base curve but these sometimes lead to less satisfactory results Gearify offers 7 ways to design base curves to offer maximum design flexibility They are e Polar functions e Free Draw 12 Parametric Functions Implicit Functions Math savvy users only Image Upload CSV Upload DXF Upload I encourage users to explore all available design options Except maybe for Implicit Functions because each m
27. elliptical Be careful about adding lone constants in your expression For example if you use x t 5cos 3t 7 The 7 will shift the graph 7 units to the right this can be a problem since your base curve needs to contain the origin You probably want to avoid having constants like these in your expressions unless you want a slight shift So in short if you add constants make them relatively small Third and finally you cannot use the requency rule discussed in the olar functions section to get a desired symmetry value as explained below Notes on Symmetry With parametric functions there is no easy way to generate curves with any particular symmetry value unlike polar functions The auto symmetry will attempt to detect symmetries Once again you can enter it manually if the auto detect fails but carefully consider if the auto symmetry was correct See Gear Symmetry for more info 4 4 Implic Implicit functions Math savvy users only This somewhat crude design mode is offered for completeness To enter this design mode click the Design tab and then click implic The equation is given in terms of x and y and is in the form f x y 0 If you have a two sided implicit equation such as g x y h x y then let f x y g x y h x y and enter this A useful method is to start with f x y x 2 y 2 10 and then add small perturbations to the equation to morph the shape The evaluation radius gives the range of values cen
28. ethod provides new and interesting designs that may not have occurred to you using another design method You do not need to be a math genius to use the Polar or Parametric design options Instructions are provided for the non math savvy user You can find more information about each of these design modes in the Base Curve Design Modes Chapter 3 2 Tooth Outline The tooth outline is quite plainly the shape of your gear The tooth outline as its name would suggest typically features teeth but this is not technically necessary It must be at the same location and size as the base curve The center of rotation must be at the origin Generally speaking there are 3 ways to provide the tooth outline 1 Calculate from base curve The default behavior for creating your tooth outline is that it is automatically calculated from your base curve This is provided to allow quick and easy design but you may have to adjust the parameters to obtain aesthetically pleasing results There are many options to design the shape of the teeth which are used to produce the tooth outline so see the Tooth Design section on that 2 Manually upload tooth outline If you want to take full design control over your tooth outline you may upload it as either a DXF or CSV file You may use any of the base curve design options in combination with your manually uploaded tooth outline 3 Use the base curve as the full outline In some instances the user may want to create som
29. fic point on the curve you drew that is suitable for planetary gear creation Next you must provide a range of rotation ratios in the Rotation Ratios box The reason and purpose of this will be explained shortly You must provide a range for both internal and external gear calculations You only specify the range of the numerator The denominator of the rotation ratio will be fixed and almost always be 1 except in the advanced mode explained in a later section Now that you have drawn your center of rotation curve and specified your rotation ratio range values you must click Search What happens is Astronomer will graph a curve for each rotation ratio you specified in the Rotation Ratios range The horizontal axis is the value of v that is a specific point on the center of rotation curve The vertical axis is the spacing or center to center distance between the known gear and the gear calculated using the given rotation ratio Red curves on the graph correspond to external gears yellow curves correspond to internal gears When graphing a curve it chooses a value of v a point on the center of rotation curve and calculates the resulting gear spacing using the given rotation ratio Areas where the red and yellow graphs intersect represent specific values of v specific points on the curve such that an internal and and external gear mechanism have the same center to center distance This value of v point on the center of rotation curve c
30. ify whether those designs are explicit or implicit In short building any design suggested by this software is completely at your own risk Before you purchase Gearify is provided as an evaluation version which contains all the features of the full version except that it adds a slight visual distortion or wobble to the display of calculated designs and disables the ability to save and export designs to DXF CSV and gearify files Purchasing a product key from www gearifysoftware com removes these limitations If you are interested in purchasing the full version be absolutely sure you install and test the evaluation version extensively BEFORE making your purchase You ARE NOT entitled to a lifetime of service by purchasing a license and you MAY NOT re distribute or sell the design files or derived design files exported from Gearify You are however permitted to re distribute or sell physical parts models and mechanisms created using Gearify s exported design files Future versions of Gearify may utilize a different sales model and Gearify may but is not obligated to provide licensed users with free access to these future versions Instead Gearify will endeavor to provide a minimum of 1 year of functional and supported software but only as time allows and not by obligation The software is provided as is without warranty Contents 1 Installation and Activation 1 1 Installing on machines with an Internet connection
31. ign tab is the Tooth Outline section There are three tabs e Options e Calculate Teeth e Import Full Outline Let s have a brief look at each 5 1 Options In the options tab you can select your mode for how to supply your tooth outline The first default option is auto calculate teeth This means the tooth outline will automatically be deduced from your base curve using the design settings in the Calculate Teeth tab The second option same as base curve means your tooth outline will essentially contain no teeth and will match the base curve This is probably not of much use to most users but is provided for completeness The third and final option is uploaded outline This will be grayed out initially and automatically activated if you upload a full tooth outline 5 2 Calculate Teeth The Calculate Teeth tab offers a wide variety of options for tooth design For starters there is the Teeth number which by default is set to 32 This is the approximate number of teeth that will be generated along your base curve the exact number may vary based on symmetry value and other settings There is also the Vertices number which is the number of vertices per tooth See each tooth design mode description to learn if and how this value is used By default this is set to 16 which is a bit low for use in physical designs but good for experimenting with calculations quickly Therefore Approximate Total vertices Number of Teeth Vertices per
32. in seconds 2 1 Creating gears using Free Draw e Click the Design tab if not already open e Click the Draw tab in the Base Curve section e Click the black display area in several places to add spokes to generate a curve Right click to remove a highlighted spoke You need at least 3 spokes before a gear shape will appear e Click the Calculate Gear tab at the top e Click Create Gear 2 2 Create a gear using an Image Click the Design tab if not already open e Click the img tab in the Base Curve section e Upload an image of your choosing The image must have a solid colored background that is distinctly different from the contents e Click Read Image and wait for a gear shape to appear Enter a small offset value 1 or 2 and click Offset Click on the Calculate Gear tab at the top e Click Create Gear 10 2 3 Create a gear using DXF e Click Design tab if not already open Click the dxf tab in the Base Curve section Click the DXF button and browse to a file containing a smooth curve with no teeth The file must contain only a single closed curve which contains the origin 0 0 Option 1 If you want to use the auto calculated teeth click the Calculate Gear tab and click Create Gear Skip the remaining steps e Option 2 If you want to upload your own full tooth outline click on the Import Full Outline tab in the Teeth Outline section at the bottom Click Browse and select a file The file should contai
33. mmetry option and click Add Teeth under the Calculate Teeth tab at the bottom before moving to the Calculate Gear tab 4 3 Param Parametric Functions Similar to Polar Functions this is a mathematical design mode but you do not need to be a mathematician or engineer to use it Instructions are provided for the non math savvy user To enter this design mode click the design tab and then click param Insructions for Math savvy users Enter two parametric functions for x t and y t then click graph The function is evalu ated from t 0 to 27 The number of sample points to generate the curve is determined by the sample points slider control Intermediate values are interpolated Instructions for Non Math savvy users First read the instructions for the base curve design mode F t Polar functions This graphing method is mostly the same You enter your expressions and then click graph But this design mode is different from polar functions in three ways First you have two expressions to enter One for z t and one for y t For example x t 12cos t sin 3t cos 2t y t 12sin t cos 2t 0 5sin t 18 Second the leading contant described in the design mode F t Polar functions must have a cos t in front for the z t expression and a sin t in front for the y t expression notice the 12 in both the above expressions You can even make the leading constant different for x t and y t which will make the shapes more
34. ms together by wrapping them in parenthesis and added a between them for even more interesting results such as the following r t 12 0 5 cos 3t 2 3 cos 2t sin t The sky is the limit really 16 Notes on Symmetry If you want your gear shape to possess a particular symmetry value you can achieve this by using wave forms where all frequencies are divisible by the symmetry value Don bother to understand why If you are not math savvy just take it as a fact For example in the following equation r t 3 sin 3t cos 6t All frequencies 3 and 6 are divisible by at most 3 so this shape will produce 3 repeating patterns yielding a symmetry value of 3 On the other hand the equation r t 4 cos 5t sin 2t has a symmetry value of only 1 because there is nothing higher than 1 that evenly divides both 5 and 2 If the auto symmetry box does not correctly compute the symmetry you can uncheck auto and enter the symmetry value manually before clicking graph curve again However take a moment to consider carefully if the auto symmetry detection was actually incorrect Some designs such as ellipses have an apparent symmetry of 4 but in terms of radial symmetry it actually 2 4 2 Draw Free hand drawing This is an easy design option that lets you design gears with just a few clicks in a matter of seconds To enter this mode click the Design tab then click the draw tab Instructions Move the mouse over
35. n the entire gear shape with teeth It must be the same size and location as the base curve The base curve should fall roughly inside the midpoint of the teeth Click on the dxf tab in the Base Curve section once again even if already open to see the base curve and tooth outline together and make sure they line up Click on the Calculate Gear tab and click Create Gear 2 4 Pan Zoom Controls Almost all of the visual feedback provided in Gearify is shown in the large black display area to the right of all the interface controls Usually when something is shown here you can use the Standard View Controls They are e Double click on the display area to zoom in e Right click on the display area to zoom out e Drag on the display area to pan e Click once on the display area and press to zoom all This should reset your view so that all the interesting content is visible and easy to see There are a few design modes where the standard view controls are disabled but all of these modes feature a Pan Zoom check box which allows you to re activate the standard view con trols 11 Chapter 3 The Basics This chapter explains the basic structure of Gearify and should greatly demystify all the available options Gearify works as follows You design a Known Gear and set a few simple parameters Then you click a button that says Create Gear Gearify then calculates a Conjugate Gear to mesh together with your Known Gear You then insp
36. n the software Evaluate it thoroughly on your machine to make sure it functions properly I recommend following the Users Guide from start to finish with the exception of the exporting sections which require activation before purchasing a product key Step 4 If you have errors otherwise skip to Step 5 e When you start Gearify you may get an error message that says something along the lines of To run this application you must first install one of the following versions of the NET framework v4 0 This means you do not have the NET 4 0 framework installed on your machine which is required to run this software If this occurs you will need to go to http www microsoft com en us download details aspx id 17718 Or if that link fails Google NET 4 0 Standalone installer you cannot use the web installer since your target machine does not have an internet connection You will have to download and save the NET 4 0 installer to a flash drive transfer it to your target machine open it and run the installer Once it is complete Gearify should open without trouble e You may experience slowness or freezing of the software especially when images or textures are being displayed on screen You may also see blank images This likely means your display drivers need updating The steps for updating your display drivers will vary per machine so you will need to research this topic online Generally you need to determine which graphics hardware you
37. oth outline matches the symmetry of your base curve Unpredictable results may follow otherwise One final note Circles have a radial symmetry value of infinity This being the case the auto symmetry detect reads a value of just 1 You can manually set the symmetry when using a circle to make sure the tooth calculations and rotation ratio respond accordingly For example if you want to create a pair of circular gears with rotation ratio of 1 4 you can use the f t base curve design mode uncheck the auto symmetry box set the symmetry value to be 4 then enter a radius such as r t 1 then click graph curve You will now have a tooth pattern that exactly repeats every 360 4 90 degrees and the rotation ratio will be automatically updated to 1 4 You could then change the rotation ratio to 2 4 3 4 4 4 and so on as desired 31 Chapter 7 Viewing Saving and Exporting It is important to view and inspect your gears before exporting You can also save a gear design and re open it to view it again This chapter will discuss these topics 7 1 Viewing Gears Click the View tab at any time to enter this view The purpose of this view is to review the results of gear calculations and see them in motion You are automatically brought to this view after gear calculation completes You may enter it at any time to review a previous calculation You may adjust the rotation speed option to increase the speed of mo
38. ou can fit 3 planet gears in your mechanism If you want 4 planet gears search using multiples of 4 If you want 5 use multiples of 5 etc IMPORTANT NOTE The denominator or symmetry value of the rotation ratio should be left at 1 except for the advanced astronomer mode for math users The meaning of symmetry is more delicate since the center of rotation is not going to be at the center of symmetry Do not touch the denominator of the rotation ratio unless you are using the math mode and fully understand what you are doing See the Advanced Astronomer section for more details on this 8 4 Accurate Gear Calculation By default the accuracy of calculations when using Astronomer are low This will provide fast searching but the results may not be suitable for building a physical model You may observe this when viewing a planetary gear mechanism and zooming into the teeth and notice that they do not quite mesh accurately This is not a bug simply the result of low accuracy settings Fortunately the accurate calculations behave similar to the low accurate calculations Once you know what type of design you want go to the Calculate Gear tab and in the Integration Accuracy box check High As with the rest of Gearify you may also want to check the Extra High Accuracy box and drag the Trim Speed down to 1 0 5 or 0 25 for best results Once you are done you must return to the Astronomer tab Search for your planetary gear The calculation will b
39. ouch the rotation ratio denominator In this case you will need to make sure that the symmetry about the center of rotation will hold For all values of v For example the formula r t 1 01 v sin 3t will have radial symmetry of 3 for all values of v In this case you would want a rotation ratio denominator of 3 Note you need not enclose v in parenthesis as shown above It is virtually impossible to achieve radial symmetry using Basic Astronomer It is possible to achieve symmetry with parametric graphs but more difficult So usually polar graphing will be the only instance where you ll use a denominator other than 1 38 Chapter 9 Troubleshooting Issue Gearify is running very slow whenever there are any textures or images on screen Solution This likely means your display drivers need updating The steps for updating your display drivers will vary per machine so you will need to research this topic online Generally you need to determine which graphics hardware you have make and model download the appropriate driver installer from the makers website and install it on your target machine If the problem persists after updating your display drivers it could be that your graphics card is too old outdated or simply not powerful enough and may need to be upgraded Issue Gearify calculations are too slow Solution Your calculation parameters may be too intense for your machine Try increasing the trim speed in the Calcula
40. ough the payment process It will conclude by emailing you a product key To activate follow the activation instructions in the next section 1 2 Activating on machines with an Internet connection e Open Gearify e Click the Activate tab at the top e Click the Activate button e In the activation window that appears click Activate Gearify Online Now e On the next screen you will be prompted for a product key Paste your product key the one that was emailed to you when you made your purchase into the textbox and click Next e Follow the instructions and you should soon see an Activation Successful screen If so congratulations you have successfully installed and activated the full version of Gearify 1 3 Installing Gearify on Machines without an Internet connection It is possible to install and activate Gearify on a machine without an internet connection The process is still simple but requires more steps as well as a flash drive or other external device The short story is that you will have to save the evaluation version to a flash drive or external device copy it to the machine without an internet connection and run the installer To active you must enter your product key in Gearify and save an activation request file to your flash drive or external device You will upload this activation request file to www gearifysoftware com and it will give you an activation response file You then re open Gearify and submit your
41. r shape will be determined from the image Moreover the same image will be used as a texture in the View mode after your conjugate gear is calculated Keep in mind whenever you change any of the parameters such as the number of sample points the tolerance or the image center you will need to click Read Image once again to re generate the curve It is worth mentioning that sometimes the color of the base curve or the tooth outline can match the image and it is helpful to change the color to make them more visible 20 Once the image read is complete enter a small offset percentage beside the Offset button try 1 or 2 and then click the button This percentage is relative to the overall size of the gear which is determined by the maximum distance from the center of the gear to its edge The reason for this feature is that the tooth outline tends to extend beyond the base curve and so to keep the teeth fully contained within the image you offset the base curve slightly Notes on symmetry Symmetry is a rare occurrence with images but auto detect is still featured for this Once again you can enter it manually if the auto detect fails but carefully consider if the auto symmetry was correct See Gear Symmetry for more information 4 6 Csv CSV Upload This mode lets you create gears using files containing comma separated values CSV Click the Design tab then click the csv tab to enter this mode Simply click the CSV button to uplo
42. s useful when you are basing your design from an image but the image does 17 not possess the desired features to be calculated in the Image Upload design mode To add a stencil click the img button inside the Stencil box and navigate to an image file Most standard image file types are supported After you e selected an image you can enter the pixel coordinates of where you want the center of the gear to be in the X and Y textboxes Or you can click cent to make the center of the gear at the center of the image Default A s when using Image Upload you can enter an offset amount Enter a small percentage like 1 or 2 and click the offset button This percentage is relative to the overall size of the gear which is determined by the maximum distance from the center of the gear to its edge The reason for this feature is that the tooth outline tends to extend beyond the base curve and so to keep the teeth fully contained within the image you may offset the base curve slightly The stencil if one exists will be used as a texture for the known gear after the conjugate gear is generated Notes on Symmetry This mode does not contain an auto symmetry calculation because it is extremely rare that the user would produce a radially symmetric design unless using the radial symmetry option For this reason symmetry is determined explicitly by the divisions parameter If you do not want this symmetry detection to occur simply uncheck the radial sy
43. see small square markers over the intersections If this is the case click on an intersection and you will see a purple circle hovering over the intersection Then click Calculate Planetary Gears Your gear will be calculated and displayed within a few moments If you do not find any intersections right click on the Variable Known Gear window to erase the curve and re draw your curve 4 clicks make sure it spans the full length of the gear The default settings will generate a planetary gear with 3 planets If you would like a planetary gear with 4 planets go to the Rotation Ratios box and from Numerator Multiples of 4 from 4 to 4 External and 8 to 8 Internal Then click Search again Select your intersection and click Calculate Planetary Gears as before For more options see the subsequent more detailed sections 35 8 2 Basic Astronomer Non Math Users T he core concept of astronomer is the following You draw a curve on your current known gear design displayed in the Variable Known Gear window This tells Astronomer that it may place the center of rotation of the gear anywhere along that curve Once you have placed the curve drag the slider control inside the Preview V box This shows the numerical relationship between a variable called v and the points on the curve In short one end of the curve corresponds to when v 0 and the other corresponds to when v 1 Astronomer s job is to find a specific value of v that is a speci
44. te Gear tab or using fewer teeth and fewer vertices Uncheck the extra high accuracy box if you can afford to You may need to upgrade the amount of RAM on your machine especially if it is fairly old Issue After successfully installing Gearify I get an error message when trying to run that says something like To run this application you must first install one of the following versions of the NET framework v4 0 Solution You will need to install the NET 4 0 framework on your machine See the instal lation instructions in Chapter 1 for information on this Issue The software crashed produced an error dialog I found a bug or otherwise Gearify did not behave as expected 39 Solution The first thing you should do is to close and re open Gearify and re attempt whatever you were doing If the problem still persists restart your computer and see if the problem occurs again If it does send an email to postmaster gearifysoftware com and provide a clear description of what you were doing that produced the error If you have any specific files that were involved in producing the error attach those files in the email 40 Chapter 10 Expression Parser Operators Add Subtract Multiply Divide Modulo Functions sin sine cos cosine tan tangent exp exponential function et In natural log acos arc cosine asin arc sine atan arc tangent sinh hyperbolic sine cosh hyperbolic cosine cot
45. tered at the origin to test while searching for the zeros of f z y Click graph and a curve will be generated slowly The num sample points slider will determine how many points on the curve are calculated Notes on Symmetry There is no easy way to generate curves with any particular symmetry value unlike polar expressions The auto symmetry will attempt to detect symmetries Once again you can enter it manually if the auto detect fails but carefully consider if the auto symmetry was correct 19 4 5 Img Image Upload This one a crowd pleaser In this mode you can use simple image files to generate gear shapes Click the Design tab and then click the img tab to enter this design mode Begin by clicking the Image button You can upload images in most common formats jpg png bmp gif tiff etc Your image must contain a solid background color that is at least slightly different than the main contents of the image For this reason photographs are generally not suitable unless taken against a bright uniformly colored background Otherwise see the design mode Draw free draw and use a stencil image Ideally the main content of your image should be at the center Note in this view the standard pan view controls are disabled unless you click the pan zoom checkbox Left click on the image to set your gear center point The crosshairs will show where you selected Alternatively you can type in the desired gear center in pixel coordinates
46. the black display area Left click to add spokes After you e added 3 spokes you will see a curve generated Click again to add more spokes or right click to remove a highlighted spoke The spoke nearest the mouse is the one that is highlighted Click clear to remove all spokes and your stencil if one exists and start again Normal pan zoom controls are disabled for this view so click pan zoom to disable the draw controls and enable the usual view controls Uncheck to resume drawing While in this mode you can select 3 types of symmetry Only the radial option relates to the gear symmetry value which influences the rotation ratio Check horiz for horizontal symmetry This is eft right symmetry Any spoke you add or delete on the right will be duplicated on the left and vice versa Check vert for vertical symmetry This is op bottom symmetry Any spoke you add or delete on the top will be duplicated on the bottom and vice versa Check radial for radial symmetry You can set the number of divisions in the textbox beside it This is what determines the gear symmetry when determining rotation ratio in the Calculate Gear tab If your divisions value is n then each spoke you add or delete will be repeated at every 34 degrees So for example if you divisions value is 4 then each spoke will be repeated at every 360 90 degrees Using Stencils It is possible to upload a stencil into your drawing area so that you can trace the edges of an image This i
47. the next screen select Manually activate Gearify offline e You will be prompted to enter a product key Connect your flash drive or external device to your machine and open the gearify product key txt file you saved it earlier Copy the product key from this file and paste it into the Activation screen and click next e In the next screen you will be asked to either open or save the activation request Click Save the Activation Request file and save the file ActivationRequest xml to a flash drive or external device so you may transfer it to a machine with an internet connection e After you save you will see a dialog asking you to Send this file to Gearify Software to get the Activation Response file You certainly may do this but it is actually easier and faster for you to obtain the activation response file yourself Proceed to the next step to learn how Step 2 e Connect your flash drive or external device containing your ActivationRequest xml file to a machine with an internet connection e Go to www gearifysoftware com You will see a link on the main page that says No internet connection Manually activate or something to that effect Click this link e On the following screen you will be asked to either upload the ActivationRequest file or paste the contents into a text box I suggest clicking Browse selecting your Activa tionRequest xml file which you saved on your flash drive or external device and clicking Open e Once you h
48. tion of the displayed gears You may toggle between fixed and orbit mode for two separate rotation styles You can set the background color using the color box beside the Background label There are two control boxes to adjust each gears appearance You may toggle between a set of commonly used textures wood stone metal use an empty outline or a plainly filled gear and set the Color You may also upload a custom texture by clicking the Browse button and then selecting the custom texture option After doing so you may click the Adjust button to adjust the position orientation and scale of the texture When in this mode use the controls at the bottom of the view tab to toggle between Move Scale and Rotate Drag the mouse across the screen when each mode is active to move rotate or scale the texture You may also use the Flip Horizontal or Flip Vertical buttons to horizontally or vertically invert the image When you are done adjusting your texture click the Done adjusting button to return to viewing mode 32 7 2 Save Export To enter this view click the Save Export tab at the top of the interface There are two circumstances where you might want to export 1 You want to export just your known gear design 2 You want to export the result of a gear calculation If 1 simply enter the Save Export tab after your design is complete If2 enter the Save Export tab after your gear calculation is complete You have various options to determin
49. tooth 23 The total number of vertices directly effects gear calculation time If your calculations are taking too long consider reducing one or both of these values 5 3 Tooth Design Just like the base curve design section there a number of different design modes for creat ing tooth shapes and you can experiment with them simultaneously Whichever design tab is currently open contains the current tooth design An important feature is the add teeth button While in any particular tooth design mode clicking this button will cause the current tooth design to be used in generating a new tooth outline using your current base curve design and you will be returned to the active base curve design mode Another reason this is useful is that tooth calculation is automatically triggered at various times when designing base curves but certain adjustments such as manually adjusting the symmetry value do not trigger an automatic tooth recalculation For this reason you can always click the add teeth button to trigger recalculation of the tooth outline The Calculate Teeth tab contains 7 sub tabs Six of these tabs are for designing teeth and the last is for exporting your tooth designs so you can re use them later Listed below are all the sub tabs in Calculate Teeth tab e std Standard tooth design e f t Parametric tooth design Math savvy users only e draw Freedraw tooth design e img Image tooth design e dxf DXF tooth uploa
50. ual tooth designs for the left and right teeth The left tooth should be an open curve pointing upward and arching downward Like this N The right tooth should be an open curve pointing downward and arching upward Like this U Like so x0 y0 xl y1 x2 y2 5 3 7 export Exporting tooth designs Use the DXF and CSV buttons to browse to a file location and export the tooth designs When exporting to DXF you have the option of selecting which DXF version you would like to export to The resulting export will be split into two files If you save your file is MyTooth the files will look something like MyTooth_left dxf and MyTooth_right dxf The purpose of exporting individual teeth is so you can design teeth using any of the various design options and save them You can then re upload these files later in the csv txt and dxf tooth design modes 5 4 Import full tooth outline This tab allows you to upload a full tooth outline as either a DXF or CSV file As before CSV files are simply a list of coordinates separated by commas with one vertex per line The contents of the file should look like this x0 y0 xl y1 x2 y2 Click the Browse button to the right of the TXT CSV label to browse to a CSV file and upload it Likewise click the Browse button to the right of the DXF label to browse to a DXF file and upload it When uploading the DXF file you may first adjust the Num Dxf Sample Points value DXF files are composed of primitives s
51. uch as arcs and ellipse segments The number of dxf sample points is used to decompose these primitives into individual line segments 27 The number of points each primitive receives is proportional to the length of that primitive vs the total length of the outline curve So if you specify 1000 sample points and 1 10th of the length is composed of an ellipse segment 1000 10 100 vertices will be used to approximate that ellipse segment You can use your uploaded tooth outline in combination with any of the base curve design methods The currently open design tab in the Base Curve section under the Design tab will be the base curve that is used The tooth outline will be visible when designing your base curve so you can even use the Draw design mode and trace around the tooth outline to produce your base curve 28 Chapter 6 Gear Calculation 6 1 Calculation Parameters Once you have a base curve and tooth outline prepared click the Calculate Gear tab at the top of the user interface First you must set your Rotation Ratio The rotation ratio is displayed as a fraction The ratio is the number of rotations of the known gear the top number per rotations of the conjugate gear bottom number If you set a rotation ratio of 2 3 then the known gear will complete 2 rotations for every 3 rotations of the conjugate calculated gear Note you can only set the top number of the rotation ratio The bottom number is determined by the
52. when you modify a left tooth the right tooth will be modified as well This is because the left right tooth symmetry option is checked by default You can uncheck this to draw each tooth individually You may use stencil left and stencil right to upload background images to use as stencils so you may trace a design from a background image You may click Clear to erase your design and start fresh 25 Lastly to enable the standard zoom controls click the Pan Zoom checkbox Uncheck it to resume drawing Once you are satisfied with your design click add teeth and return to your active base curve design tab 5 3 4 img Image tooth design Click the browse button and select a tooth image For this mode you must have a specially formatted image to describe your tooth shape The image must have a solid background color that is distinct from the contents of the image This is the only instance where both the left and right teeth are designed together To save a thousand words the image describing the tooth shape should look something like this After uploading you may select the midpoint of the tooth it is centered in the image by default This is what separates the upper left tooth from the lower right tooth You will almost certainly want to increase the Vertices number above to increase the number of times the image is sampled Try to keep the upper and lower peaks of the curves depicted close to the upper and lower edges of the im
53. y see jagged or rippled artifacts on the conjugate gear after the calculation To correct these check the Extra High Accuracy option This will perform extra calculations to prevent these artifacts This is optional as it is often not needed for good results Once again this improves accuracy but slows the calculation speed Before you click Create Gear you have the option of selecting an auto save file to automat ically save the results when your calculation is complete Simply click Browse select a location and enter a file name See Save Export and Reopening Gearify files for more info on this Once you have set all the options described above click the Calculate Gear button Gearify will automatically save to your auto save file and transition to the View tab when the calculation is complete Lastly depending on the quality of your graphics card the gear calculation could actually be slowed by the number of lines being drawn during the calculation phase You can check Hide Display to prevent this info from being drawn and get a potential speed boost You are free to uncheck it and peek on the progress at any time Don t worry after the calculation is complete the display will automatically become visible once again 6 2 Gear Symmetry Throughout this document the gear symmetry value has been mentioned countless times Gear symmetry is more precisely radial symmetry If a gear has a symmetry value of n then the gear shape must repe
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