Set 10 - Gears, Levers, Pulleys & Complex Machines

Set 10 - Description                                  Price: $2450.00 delivery 10 days from order

Cogworks Set 10 provides the necessary spark to get middle and high school students enthused about science and physics. Set10 is one of the new wave of tools being used to reinvigorate American school science education.  Grades 11 and 12 can be stretched by some of Set 10's more complex features.

Set 10's unique design features two triangular matrix boards mounted back to back via 3 aluminum tie rods, making a sturdy construction platform. This structure, which can be conveniently stored in the Set 10 case, easily assembles with the 30cm (12") long supplied tie rods.  The structure is essentially a three dimensional mechanical artistic canvas, ready to receive creative mechanical exploration.

Stub shafts are used to accurately locate pulleys and  gears, via a plethora ( approx 300 each side) of equi-spaced  holes and tapped inserts. The student simply screws the shaft into the precision hole via a hex brass nut at the base of the shaft.  The stub shaft in tightened by a special wooden wrench. The stub shafts allow gears and pulleys to be attached to the matrix board. The different length stub shafts are stored in the  Set 10 accessory tray. The stub shafts differ in length from 1 unit to 6 units, each shaft length unit allows gears, pulleys or spacers to be mounted. 1 unit equals 1 gear, pulley or spacer.  The gears, pulleys or spacers are retained by a stainless steel split shaft collar. The supplied tool easily clamps the collar to the precision stainless steel shaft via one quick turn.

All gears and pulleys use a Cogworks machined Delrin bearing which provides a very low coefficient of friction, no oil ever required!   The stub shafts are made from premium ground 303 stainless steel. All Set 10 hardware,  is machined in the Cogworks machine shop using precision Hardinge, Elmira, NY, HLV-H tool room lathes to guarantee accuracy. All wooden parts are made in the Cogworks precision woodworking shop. All parts are finished with a tough lacquer finish. The working face of the triangular matrix boards is sanded to 400 grit and finished with a FDA approved non-toxic mineral oil which provides a scratch resistant working surface.

Each gear and pulley is marked with an "engraved" chapter ring marked with degrees and radians. The rings are machined from  marker board allowing students to mark on the gears with fine point non-toxic dry erase markers. The option of putting reference marks on the actual gears can improve the learning process. The end of each stub shaft has an additional tapped hole, which allows  supplied reference pointers and other accessories to be easily attached to the system.

Each side of the Set 10 structure can be worked by independent students or student teams. To enhance collaborative projects and team building a unique Power Take Off  (PTO) system can connect both sides of the board. This can be achieved at the top dead center of the triangle or to the side by using different accessories. The PTO can be driven by gears or pulleys. The PTO mounting system features self aligning bearings so shaft binding is never an issue. Two PTO shafts and mounting hardware are included in Set 10.

Multiple Set 10 systems can be mechanically connected by using the torque beams to extend the hole matrix over to another Set 10 structure. The power can follow along the torque beam by either gearing or pulleys.

The set 10 case and accessory tray is made from Ash for strength. All joints are of dovetail construction, making it incredibly strong and durable.  The side covers slide vertically making access to the gears very easy. One side of the sliding cover is bonded with premium marker board laminate, that can be used as an educational marker board. Two sturdy carrying handle holes are cut into each side of the case.

Set 10 - Gears & Pulleys

Set 10 includes 6 different sizes of gears  and pulleys. Gears, pulleys and accessories are conveniently stored in the case. The complete inventory of gears and pulley sizes included in Set 10 is shown in the left hand column. The accessory tray holds all the hardware and tools required. When in use, we suggest the tray be pulled out and placed near the construction area. All hardware is corrosion resistant stainless steel and 360 brass.

Set 10 - Gear System

As mentioned previously, gears can be stacked on the stub shafts and spaced out as necessary. The gears can be mechanically locked together on the stub shaft via a connector. By not inserting a connector,  gears may move freely relative to each other.  Gears can be mixed with pulleys on the same shaft. Different length connectors are available in the Set 10 tool kit. Interference from other gear meshes can be accommodated by using the different length stub shafts, spacers and connectors. Many different types of gear boxes and techniques can be investigated.  For example, using only Qty 2 "4 unit" stubshafts the Qty 4 ~ 72 tooth gears and Qty 4 ~ 12 tooth gears a compact gearbox of  1296:1 can be set up !

The gear  torque beams can extend the stub shaft location matrix in space, therefore dramatically increasing the mechanical canvass area. Torque beams have the same hole spacing pattern as the triangular matrix board. Torque beams have an axial unit depth of 1.  To transfer power from elements on a torque beam use a brass 1 unit spacer on a stub shaft. This gives perfect alignment of pulley or gear components. Multiple torque beams can be built into a structure radiating out from the "mothership" triangular base structure. Custom length torque beams are available for special projects and exhibits.

Set 10 - Pulley System

As mentioned previously, pulleys can be stacked on the stub shafts and spaced out as necessary. The pulleys can be mechanically locked together on the stub shaft via a connector. Pulleys can be mixed with gears on the same shaft. Different length connectors are available in the Set 10 accessory kit. The pulley groove accommodates a 1/4" specially developed flexible rubber belt. Set 10 comes with 2 each of 4 different length belts. Each belt can flex at least +/- 3cm from it's static length. A belt making kit with a 100' roll of belting material is also available for special projects.

The gear  torque beams can extend the hole matrix in space which can dramatically increase the mechanical canvas area. Torque beams have the same hole spacing pattern as the triangular matrix board.

Set 10 - Exploded View

This view shows the set 10 gears & pulleys exploded from the case. Note the two matrix boards can be stored in one side of the case with the supplied 1/4" rubber belts.  The doors on both sides of the case slide vertically to easily lock all parts in place. The exploded view shows the real power of Set 10 with the vast array of gears, pulleys and mechanisms. Complex gear boxes & mechanisms can easily be built. Please ask about the special accessories for Set 10 such as; triangular gears, elliptical gears, wooden helical gears, the clock kit, automata kits. Custom mechanisms can also be purchased and adapted to the set 10 system. 

Torque investigation lab using a 1.5N brass weight counterbalanced by a spring balance. Stub shafts can easily be attached to torque beams via equi-spaced tapped holes. Brass weights are included in the Set 10 kit. The gear toque lab investigation runs through gear ratios from 1:1, 2:1, 3:1, 4:1, 5:1 & 6:1.  Torque beams can also be used as supports, the top torque beam attaches the spring balance to "earth"

Gears can then be put aside and the same lab done again using pulleys. In our survey of top science educators a tool that demonstrates the similarities of pulleys & gears was often requested. Set 10 meets this goal as it features a range of pulleys & gears with exactly the same pitch diameter.

Set 10 - Internal Accessory Kit ( Order : Set10-4i )

The internal accessory kit "Set10-4i" consists of a set of Qty 4  ground stainless steel  6mm shafts,  and associated hardware, with polished stainless steel pivots in each end. This allows any Set10 gear or pulley to be mounted "between the plates" or  between the triangular matrix boards. This method of mounting results in super low friction. The Set10 gears/pulleys are captured on the shaft with a "drive dog" collet arrangement. This collet is compressed by the standard Set10 split shaft collar. Internally mounted  gears and pulleys can be connected to mechanical arrangements on the outer side of the matrix boards via the PTO shafts. The internal accessory kit opens up another dimension in Set10 mechanical exploration. This internal shaft kit is the heart of the Set10 clock.  See the Set10 Accessories & Parts page for more information.

The internal shafts can easily be installed between the Set10 plates because of the use of a floating pivot bearing. The pivot bearing can be wound in to capture the shaft and set end float.