1. Field of the Invention
This disclosure relates generally to mechanical and/or electro-mechanical power modulation devices and methods. More particularly, this disclosure relates to continuously and/or infinitely variable, planetary power modulating devices, and methods for modulating power flow in a power train or drive, such as power flow from a prime mover to one or more auxiliary or driven devices.
2. Description of the Related Art
Continuously variable transmissions (CVT) having spherical planets such as those generally described in U.S. Pat. No. 7,011,600 to Miller et al, U.S. Pat. No. 5,236,403 to Schievelbusch, or U.S. Pat. No. 2,469,653 to Kopp, typically have a rotatable support member or an idler component in contact with each spherical planet. In some systems, the idler is a generally cylindrical member located radially inward of each spherical planet. During operation of these types of CVTs, the spherical planets exert forces on the idler that generate high stress at the location contacting the spherical planets. The type of stress is commonly known as a hertzian contact stress. Fatigue life and/or durability of a rolling element, such as an idler, is a function of the hertzian stress exerted on the rolling element over time. High stress exerted on the idler component leads to lower fatigue life and lower efficiency performance of the CVT.
Thus, there exists a continuing need for devices and methods to improve the fatigue life of idler components. Embodiments of power modulating devices and/or drivetrains described below address one or more of these needs.
The systems and methods herein described have several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope as expressed by the claims that follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of Certain Embodiments” one will understand how the features of the system and methods provide several advantages over traditional systems and methods.
One aspect of the disclosure relates to a continuously variable transmission (CVT) having a longitudinal axis. In one embodiment, the CVT includes a group of spherical traction planets. Each traction planet has an axle about which it rotates. The axle is configured to tilt with respect to the longitudinal axis. The CVT includes an idler assembly in contact with each of the traction planets. In one embodiment, the idler assembly is located radially inward of each of the traction planets. The idler assembly has first and second rolling elements. The first and second rolling elements are configured to rotate at different speeds corresponding to the tilt of the traction planets.
Another aspect of the disclosure relates to a continuously variable transmission (CVT) having a group of traction planet assemblies arranged angularly about a longitudinal axis of the CVT. In one embodiment, the CVT includes a first carrier coupled to the each of the traction planet assemblies. The first carrier is provided with a number of radially offset slots. The first carrier is configured to guide the traction planet assemblies. The CVT also includes an idler assembly in contact with each of the traction planets. The idler assembly is located radially inward of each traction planet. The idler assembly has first and second rolling elements.
Yet another aspect of the disclosure relates to a continuously variable accessory drive system (CVAD). In one embodiment, the CVAD has a shaft arranged along a longitudinal axis of the CVAD. The CVAD includes a first traction ring coaxial about the longitudinal axis. The CVAD also includes a group of traction planets in contact with the first traction ring. The traction planets are arranged angularly about the longitudinal axis. In one embodiment, the CVAD includes a carrier operably coupled to the each of the traction planets. The carrier is provided with a number of radially offset guide slots. The CVAD also includes an idler assembly in contact with each of the traction planets. The idler assembly is located radially inward of each traction planet. The idler assembly has first and second rolling elements. The CVAD includes an alternator coupled to the shaft.
One aspect of the invention relates to an idler assembly for a continuously variable transmission (CVT) having a group of traction planet assemblies arranged about a longitudinal axis. Each traction planet assembly is operably coupled to a carrier having a number of radially offset guide slots. In one embodiment, the idler assembly includes first and second rolling elements in contact with each traction planet assembly. The first and second rolling elements are located radially inward of each traction planet assembly. The idler assembly also includes a bearing operably coupling the first rolling element to the second rolling element. The bearing is configured to balance axial force between the first and second rolling elements.
The preferred embodiments will be described now with reference to the accompanying figures, wherein like numerals refer to like elements throughout. The terminology used in the descriptions below is not to be interpreted in any limited or restrictive manner simply because it is used in conjunction with detailed descriptions of certain specific embodiments. Furthermore, embodiments of the disclosure can include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the embodiments described. Certain CVT embodiments described here are generally related to the type disclosed in U.S. Pat. Nos. 6,241,636; 6,419,608; 6,689,012; 7,011,600; 7,166,052; U.S. patent application Ser. Nos. 11/243,484; 11/543,311; 12/198,402, 12/251,325; and Patent Cooperation Treaty patent applications PCT/US2007/023315, PCT/IB2006/054911, PCT/US2008/068929, and PCT/US2007/023315, PCT/US2008/074496. The entire disclosures of each of these patents and patent applicationsare hereby incorporated herein by reference.
As used here, the terms “operationally connected,” “operationally coupled,” “operationally linked,” “operably connected,” “operably coupled,” “operably linked,” and like terms, refer to a relationship (mechanical, linkage, coupling, etc.) between elements whereby operation of one element results in a corresponding, following, or simultaneous operation or actuation of a second element. It is noted that in using said terms to describe certain embodiments, specific structures or mechanisms that link or couple the elements are typically described. However, unless otherwise specifically stated, when one of said terms is used, the term indicates that the actual linkage or coupling may take a variety of forms, which in certain instances will be readily apparent to a person of ordinary skill in the relevant technology. For description purposes, the term “axial” as used here refers to a direction or position along an axis that is parallel to a main or longitudinal axis of a transmission or variator. The term “radial” is used here to indicate a direction or position that is perpendicular relative to a longitudinal axis of a transmission or variator.
It should be noted that reference herein to “traction” does not exclude applications where the dominant or exclusive mode of power transfer is through “friction.” Without attempting to establish a categorical difference between traction and friction drives here, generally these may be understood as different regimes of power transfer. Traction drives usually involve the transfer of power between two elements by shear forces in a thin fluid layer trapped between the elements. The fluids used in these applications usually exhibit traction coefficients greater than conventional mineral oils. The traction coefficient (μ) represents the maximum available traction forces which would be available at the interfaces of the contacting components and is a measure of the maximum available drive torque. Typically, friction drives generally relate to transferring power between two elements by frictional forces between the elements. For the purposes of this disclosure, it should be understood that the CVTs described here may operate in both tractive and frictional applications. For example, in the embodiment where a CVT is used for a bicycle application, the CVT can operate at times as a friction drive and at other times as a traction drive, depending on the torque and speed conditions present during operation.
Embodiments disclosed here are related to the control of a variator and/or a CVT using generally spherical planets each having a tiltable axis of rotation that can be adjusted to achieve a desired ratio of input speed to output speed during operation. In some embodiments, adjustment of said axis of rotation involves angular displacement of the planet axis in a first plane in order to achieve an angular adjustment of the planet axis in a second plane, wherein the second plane is substantially perpendicular to the first plane. The angular displacement in the first plane is referred to here as “skew,” “skew angle,” and/or “skew condition”. For discussion purposes, the first plane is generally parallel to a longitudinal axis of the variator and/or the CVT. The second plane can be generally perpendicular to the longitudinal axis. In one embodiment, a control system coordinates the use of a skew angle to generate forces between certain contacting components in the variator that will tilt the planet axis of rotation substantially in the second plane. The tilting of the planet axis of rotation adjusts the speed ratio of the variator. The aforementioned skew angle, or skew condition, can be applied in a plane substantially perpendicular to the plane of the page of
One aspect of the torque/speed regulating devices disclosed here relates to drive systems wherein a prime mover drives various driven devices. In this sense, regulating is used to mean varying the transmission ratio to vary the torque or speed of the power being provided to the accessory to correspond with the operating requirements of the accessory being driven from the CVT. The prime mover can be, for example, an electrical motor and/or an internal combustion engine. For purposes of description here, an accessory includes any machine or device that can be powered by a prime mover. For purposes of illustration and not limitation, said machine or device can be a power takeoff device (PTO), pump, compressor, generator, auxiliary electric motor, etc. Accessory devices configured to be driven by a prime mover may also include alternators, water pumps, power steering pumps, fuel pumps, oil pumps, air conditioning compressors, cooling fans, superchargers, turbochargers and any other device that is typically powered by an automobile engine. As previously stated, usually, the speed of a prime mover varies as the speed or power requirements change; however, in many cases the accessories operate optimally at a given, substantially constant speed. Embodiments of the torque/speed regulating devices disclosed here can be used to control the speed of the power delivered to the accessories powered by a prime mover.
For example, in some embodiments, the speed regulators disclosed here can be used to control the speed of automotive accessories driven by a pulley attached to the crankshaft of an automotive engine. Usually, accessories must perform suitably both when the engine idles at low speed and when the engine runs at high speed. Often accessories operate optimally at one speed and suffer from reduced efficiency at other speeds. Additionally, the accessory design is compromised by the need to perform over a large speed range rather than an optimized narrow speed range. In many cases when the engine runs at a speed other than low speed, accessories consume excess power and, thereby, reduce vehicle fuel economy. The power drain caused by the accessories also reduces the engine's ability to power the vehicle, necessitating a larger engine in some cases.
In other situations, inventive embodiments of the torque/speed regulating devices disclosed here can be used to decrease or increase speed and/or torque delivered to the accessories for achieving optimal system performance. In certain situations, embodiments of the torque/speed regulating devices disclosed here can be used to increase speed to the accessories when the prime mover runs at low speed and to decrease speed to the accessories when the prime mover runs at high speed. Thus, the design and operation of accessories can be optimized by allowing the accessories to operate at one, substantially favorable speed, and the accessories need not be made larger than necessary to provide sufficient performance at low speeds. For example, the embodiments of the torque/speed regulating devices disclosed here can enable more power to be extracted from an accessory such as an alternator when the prime mover or engine is running at low idle speed. The accessories can also be made smaller because the torque/speed regulating devices can reduce speed to the accessories when the prime mover runs at high speed, reducing the stress load the accessories must withstand at high rpm. Because the accessories are not subjected to high speeds, their expected service life can increase substantially. In some cases, smoother vehicle operation results because the accessories do not have to run at low or high speed. Further, a vehicle can operate more quietly at high speed because the accessories run at a lower speed.
Embodiments of a continuously variable transmission (CVT), and components and subassemblies thereof, will be described now with reference to
Referring now to
In one embodiment, the CVT 10 is provided with an idler assembly 40 arranged radially inward of, and in contact with, each of the traction planets 16. The idler assembly 40 couples to a sleeve 42. The sleeve 42 is coaxial with, and surrounds, the shaft 30. In some embodiments, the sleeve 42 can be integral to the shaft 30. The sleeve 42 can be made of a different material than the shaft 30. For example, the sleeve 42 can be made of a material that has properties appropriate for a bearing race or a journal. In one embodiment, the idler assembly 40 includes a first rolling element 44 operably coupled to a second rolling element 46. The first rolling element 44 is radially supported on the sleeve 42 by a bearing 48. The bearing 48 can be a needle roller bearing, for example. The second rolling element 46 is radially supported by a bearing 50. The bearing 50 can be a needle roller bearing, for example. The second rolling element 46 is supported in the axial direction by a bearing 52. The bearing 52 can be a ball bearing, for example. The bearing 52 is coupled to a race 53. The race 53 is attached to the first rolling element 44 with, for example, a clip 54. The bearing 52 is positioned in a manner to balance the axial force applied to the first rolling element 44 with the axial force applied to the second rolling element 46.
During operation of the CVT 10, the first and second rolling elements 44, 46 rotate about the longitudinal axis 14. The first and second rolling elements 44, 46 each rotate at a speed corresponding to the tilt angle of the planet axle 18 with respect to the longitudinal axle 14. Under some operating conditions, for example when the planet axle 18 is substantially parallel to the longitudinal axis 14, the speed of the first rolling element 44 is substantially equal to the speed of the second rolling element 46. Under other operating conditions, the speed of the first rolling element 44 can be higher than the speed of the second rolling element 46. Under yet other operating conditions, the speed of the first rolling element 44 can be lower than the speed of the second rolling element 46. During operation of the CVT 10, the difference in speed between the first and second rolling elements 44, 46 is transmitted to the bearing 52. This is advantageous since the speed difference between the first and second rolling elements 44, 46 is typically small. It is well known that parasitic losses from bearings are related to the speed and load at which a bearing operates. Since the bearing 52 typically operates under relatively high axial loads, reducing the speed at which the bearing 52 operates serves to reduce the parasitic loss of the bearing 52.
Referring now specifically to
Turning now to
Referring now to
In one embodiment, the second carrier 21 is coupled to a clevis 94. The clevis 94 can be accessed through an opening (not shown) in the housing 36 to facilitate the coupling of the clevis 94 to an actuator (not shown). During operation of the CVT 10, a change in transmission ratio can be accomplished by rotating the second carrier 21 with respect to the first carrier 20. A rotation of the second carrier 21 can be accomplished by moving the clevis 94 with the actuator.
Referring now to
Passing now to
Referring now to
It should be noted that the description above has provided dimensions for certain components or subassemblies. The mentioned dimensions, or ranges of dimensions, are provided in order to comply as best as possible with certain legal requirements, such as best mode. However, the scope of the embodiments described herein are to be determined solely by the language of the claims, and consequently, none of the mentioned dimensions is to be considered limiting on the embodiments, except in so far as any one claim makes a specified dimension, or range of thereof, a feature of the claim.
The foregoing description details certain embodiments of the disclosure. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the disclosure can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the disclosure should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the disclosure with which that terminology is associated.
This application is a continuation of U.S. patent application Ser. No. 13/288,711, filed Nov. 3, 2011 and scheduled to issue on Nov. 18, 2014 as U.S. Pat. No. 8,888,643, which claims the benefit of U.S. Provisional Application No. 61/412,290, filed on Nov. 10, 2010. The disclosures of all of the above-referenced prior applications, publications, and patents are considered part of the disclosure of this application, and are incorporated by reference herein in their entirety.
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