Mr. Cunningham.

Data Sheet 11 "Lantern Pinions and Epicycloidal Driving Wheels" in "Gears for Small Mechanisms" by W. O. Davis provides all the details necessary to design lantern pinions and their driving wheel, up to and including rack and contrate gears.

To answer your questions:

>1. What is ideal tooth profile to engage with a lantern pinion? Cycloidal, involute, or some other shape?

An Epicycloidal tooth form is suggested in the book mentioned above.

>2. Is there a recommended dimension for the diameter of a lantern pinion "flank" or cylinder as a percentage of module? Would I be better to match the maximum width of a pinion flank (giving me ample clearance), match the radius of curvature of the tip of a pinion flank, or go with some other dimension?

From Data Sheet 11, the pin diameter = 1.05 with 10 or fewer pins and 1.25 for more than 10 pins.

>3. I'm assuming I should locate the centers of the cylinders on the pitch center of the pinion -- is this correct?

Yes.

>4. Any other considerations when working with lantern gears?

Driving wheel tooth width = 1.57

" " dedendum = 1.2 for heavily stressed teeth.

" " dedendum = 1.4 for lightly stressed teeth.

" " dedendum has radial flanks

The addendum of the driving wheel tooth and the radius of the flank of the addendum is given in the table mentioned above, and depends upon the number of pins in the pinion, and the ratio between the pinion and the wheel. In addition, the table states "The tooth forms for driving wheels are rather taller than the teeth of wheels which engage radial flanked pinions. The gears are often formed by stamping, and a small tip rounding aids this operation. Where the pinion has 8 or fewer pins, this rounding should be very slight, in order to retain the maximum path of contact. Where the pinion has 12 or more pins, the rounding may be generous, such that the working height of the addendum is reduced to 1." Sorry, but the drawing with the table makes this clearer than I can describe.

RJG