cycloidal-gear

// Cycloidal Gear
// A cycloidal gear is a gear with a continuous, curved tooth profile. They are used in watchmaking and high precision robotics actuation

// Set units
@settings(defaultLengthUnit = in)

// Create a function for the cycloidal gear
fn cycloidalGear(gearPitch, gearHeight, holeDiameter, helixAngle) {
  // Create a function to draw the gear profile as a sketch. Rotate each profile about the gear's axis by an helix angle proportional to the total gear height
  fn gearSketch(gHeight) {
    helixAngleP = helixAngle * gHeight / gearHeight
    gearProfile = startSketchOn(offsetPlane(XY, offset = gHeight))
      |> startProfileAt([
           gearPitch * 1.55 * cos(toRadians(helixAngleP)) + gearPitch * sin(toRadians(-helixAngleP)),
           gearPitch * 1.55 * sin(toRadians(helixAngleP)) + gearPitch * cos(toRadians(-helixAngleP))
         ], %)
      |> arc(angleStart = 90 + helixAngleP, angleEnd = -90 + helixAngleP, radius = gearPitch)
      |> tangentialArc(radius = gearPitch * 1.67, angle = 60)
      |> tangentialArc(radius = gearPitch, angle = -180)
      |> tangentialArc(radius = gearPitch * 1.67, angle = 60)
      |> tangentialArc(radius = gearPitch, angle = -180)
      |> tangentialArc(endAbsolute = [profileStartX(%), profileStartY(%)])
      |> close(%)
      |> hole(circle(center = [0, 0], radius = holeDiameter / 2), %)
    return gearProfile
  }

  // Draw sketches of the gear profile along the gear height and loft them together
  gearLoft = loft([
    gearSketch(0),
    gearSketch(gearHeight / 2),
    gearSketch(gearHeight)
  ])

  return gearLoft
}

// Call the cycloidal gear function
cycloidalGear(.3, 1.5, 0.297, -80)