The present invention relates to a series of elements of a belt of a continuously variable transmission provided on a vehicle, and a method of manufacturing the series of elements, and more particularly to techniques for improving durability of the elements and reducing a cost of manufacture of the elements.
There is known a belt of a belt-type continuously variable transmission, which is provided with annular rings each constituted by a plurality of annular endless band members laminated on each other, and a plurality of elements in the form of metallic plates supported by the annular rings and arranged in a direction of thickness thereof along an annulus of each of the annular rings, and which connects a pair of pulleys groove widths of which are variable. Patent Document 1 describes an example of such a continuously variable transmission belt. This Patent Document 1 discloses a technique for adjusting a gravity center of each of the elements such that a velocity (Vg) of the gravity center of the elements is held within a velocity range between a locking-edge velocity (Vr) of the elements and a velocity Vs of a radially outermost end of ring slots, in a radial direction of the annular rings, accommodating the rings, so as to prevent an inclination of the elements in linear portions (chord portions) of the belt extending between the pair of pulleys, so that the elements smoothly come into engagement with the pulleys.
Patent Document 1: JP-11-351335 A
Patent Document 1 describes a technique for reducing a geometric profile of an upper head portion of each of the elements, as one example of the techniques for lowering the gravity center of the element.
For lowering the gravity center of the element 200 (namely, for shifting the gravity center in the direction toward the body portion 202), a geometric profile of an outer part of the head portion 204 of the element 200 as seen in the radial direction of the belt is reduced as indicated by hatching lines. However, the reduction of the geometric profile of the head portion 204 results in reduction of a width of the ear sections 206, and consequent reduction of strength of the ear sections 206, giving rise to a possibility of fracture of the ear sections 206 at their proximal parts as indicated by cut-out lines in
The present invention was made in view of the background art described above. It is therefore an object of the present invention to provide a series of elements each constructed so as to permit an adjustment of its gravity center while preventing reduction of the strength of its ear sections, and a method of manufacturing the series of elements.
The object indicated above is achieved according to the present invention, which provides (a) an element for a continuously variable transmission belt, in the form of metallic plate supported by annular rings and arranged in a direction of thickness thereof along an annulus of each of the annular rings, (b) characterized in that the above-described element has a substantially trapezoidal body portion, and a substantially triangular head portion connected to an upper end of the above-described body portion, the above-described body portion and the above-described head portion cooperating to define therebetween ring accommodating slots for accommodating the above-described annular rings, and (c) the head portion of the element has a thickness which decreases as the head portion extends in a direction away from the above-described ring accommodating slots, and has a protruding section formed on one of opposite pressure surfaces thereof, and a recessed section which is formed in the other of the above-described opposite surfaces such that the recessed section is engageable with another of the above-described elements which is adjacent to the above-described each element.
According to the present invention, the element is formed such that its thickness decreases as the head portion extends in the direction away from the ring accommodating slots, so that the gravity center of the element is shifted toward the body portion as the mass of the head portion decreases. Since the gravity center of the element is shifted toward the body portion, a moment of rotation of the element during the power transmitting operation of the belt decreases to reduce the tendency of inclination of the element, for thereby preventing reduction of durability of the annular rings due to contact of the annular rings with the element caused by the inclination of the element. Further, the gravity center of the element 4 is shifted toward the body portion by reducing the volume in the direction of thickness of the element, without changing the geometric profile of the element, so that the head portion (ear sections) has a sufficiently high strength. The element having the sufficiently high strength can withstand a relatively high load acting thereon due to a large force exerted from the annular rings to the head portion (ear sections) in the radially outward direction when a relatively large torque acts on the continuously variable transmission belt. That is, the maximum permissible operating torque of the continuously variable transmission belt increases with an increase of the strength of the element (ear sections).
According to a preferred form of the present invention, the above-described head portion of the above-described element has a maximum thickness not smaller than a maximum thickness of the above-described body portion, so that a linear portion (chord portion) of the continuously variable transmission belt between a driving pulley and a driven pulley on the power transmitting side is protected against a waving motion, and the element is permitted to smoothly come into engagement with the driven pulley at its incoming point.
According to another preferred form of the invention, the above-described head portion of the above-described element has at least one slant surface, which reduces the mass of the head portion, so that the gravity center of the element can shifted toward the body portion.
According to a further preferred form of the invention, the head portion of the above-described element has at least one stepped surface, which reduces the mass of the head portion, so that the gravity center of the element can be shifted toward the body portion.
The object indicated above can also be achieved according to the present invention, which provides a method of manufacturing (a) an element for a continuously variable transmission belt, in the form of metallic plate supported by annular rings and arranged plurally in a direction of thickness thereof along an annulus of each of the annular rings, characterized in that (b) the above-described element has a substantially trapezoidal body portion, and a triangular head portion connected to an upper end of the above-described body portion, the above-described body portion and the above-described head portion cooperating to define therebetween ring accommodating slots for accommodating the above-described annular rings, (c) the head portion of the above-described element has a thickness which decreases as the head portion extends in a direction away from the above-described ring accommodating slots, (d) the above-described element is formed from a plate blank having a thickness smaller than maximum thicknesses of the above-described body portion and said head portion, and (e) the above-described element is manufactured with a fine blanking press operated to perform in a single stroke a squeezing process and punching process, such that a portion of the formed element which has a thickness larger than the thickness of the above-described plate blank is formed, in the squeezing process, of an excess material flown from a portion of the above-described plate blank which corresponds to a portion of the formed element which has a thickness smaller than the thickness of the above-described plate blank.
In the method of manufacturing the series of elements according to the present invention, the plate blank which is inexpensive is used to manufacture the element, and the element is formed at a reduced cost with the fine blanking press operated in a single stroke.
Embodiments of the present invention will be described in detail by reference to the drawings. It is to be understood that the drawings showing the embodiments are simplified or transformed as needed, and do not necessarily accurately indicate the dimensions and shapes of individual elements of the embodiments.
The above-described continuously variable transmission belt 10 has a pair of annular rings 22, and a plurality of elements (pieces) 24 in the form of a plurality of metallic plates supported by the pair of annular rings 22 and arranged in their direction of thickness along an annulus of each of the annular rings 22. Each of the annular rings 22 is constituted by a plurality of flexible annular band members of a hoop steel laminated on each other.
The annular band members of each annular ring 22 are formed from a highly tensile steel plate having a thickness of about 0.2 mm and laminated on each other in a radially outward direction of the annular ring 22. In the present embodiment, each annular ring 22 is constituted by nine annular band members laminated on each other.
Each of the elements 24 is a thick plate formed by punching from a plate member (steel plate member) having a thickness of about 1.8 mm. In the present embodiment, the continuously variable transmission belt 10 has about 400 elements 24.
The body portion 26 has a pair of contacting surfaces 30 formed at its opposite right and left end sections, for opposition to and contact with the pair of sheave surfaces 20 shown in
As shown in the side elevational view of
The head portion 28 of the element 24 has a thickness which decreases as the head portion 28 extends in the direction away from the ring accommodating slots 32. Described more specifically, the head portion 28 has a slant surface 50 of a predetermined inclination angle formed on the side of the first pressure surface 38, and another slant surface 52 of the predetermined inclination angle formed on the side of the second pressure surface 40. The inclination angle of the above-indicated slant surfaces 50, 52 is determined so that a gravity center G of the element 24 is located near the locking edge 36 in the direction of height of the element 24. Namely, the gravity center G is shifted toward the body portion 26 as a mass of the head portion 28 decreases with a decrease of a cross-sectional surface area of the head portion 28 in a cross-sectional plane parallel to the direction of thickness due to the provision of the slant surfaces 50, 52. For instance, an increase of the inclination angle of the slant surfaces 50, 52 causes a decrease of the mass (volume) of the head portion 28, and a consequent increase of a distance of shifting of the gravity center G toward the body portion 26. Thus, the location of the gravity center G of the element 24 is adjusted by adjusting the mass of the head portion 28 by changing the inclination angle of the slant surfaces 50, 52, so that the gravity center G is located near the locking edge 36. The head portion 28 has a maximum thickness A which is determined to be not smaller than a maximum thickness B of the body portion 26 (thickness at the locking edge 36). For example, a difference of the maximum thicknesses A and B is held within a range of about 0-0.01 mm.
There will be described an operation and advantages of the elements 24 constructed as described above.
At an outgoing point S2 of the driving pulley 14 indicated in
Further, the head portion 28 of the element 24 has the maximum thickness A determined to be not smaller than the maximum thickness B of the body portion 26, as indicated in
A method of manufacturing the element 24 will be described next. The element 24 is manufactured by a fine blanking press known in the art. The fine blanking press is a pressing machine constructed to perform a fine punching operation in a single stroke at a lower cost than conventional squeezing and punching operations in successive two strokes at respective two stations.
Initially, the squeezing process will be described by reference to
When the above-described third pressure surface 42 and slant surfaces 50, 52 are formed, a volume of the material of the plate blank 60 corresponding to a volume of a portion of the punch 64 indicated by hatching lines and a volume of a portion of the ejector 66 indicated by hatching lines flows into a space indicated by a hatched area V between the plate blank 60 and the ejector 66, so that the body portion 26 and head portion 28 having the thicknesses larger than the thickness of the plate blank 60. Namely, a portion of the finally formed element 24 which has a thickness larger than the thickness t of the plate blank 60 is formed of the excess material flown from a portion of the plate blank 60 which corresponds to a portion of the finally formed element 24 having a thickness smaller than the thickness t of the plate blank 60. It is noted that the punch 64 and ejector 66 are preliminary configured so that the maximum thickness A of the head portion 28 is not smaller than the maximum thickness B of the body portion 26.
In the next punching process shown in
The fine blanking press described above may be used to form the elements 24 having different thicknesses, from the same plate blank 60, by appropriately designing the dies 62 punch 64 and ejector 66 to change squeezing amount. By using the elements 24 having the different thicknesses, the circumferential length of the continuously variable transmission belt 10 can be suitably adjusted upon installation of the belt 10.
In the present embodiment described above, the element 24 is formed such that its thickness decreases as the head portion 28 extends in the direction away from the ring accommodating slots 32, so that the gravity center G of the element 24 is shifted toward the body portion 26 as the mass of the head portion 28 decreases. Since the gravity center G of the element 24 is shifted toward the locking edge 36, a moment of rotation of the element 24 during the power transmitting operation of the belt decreases to reduce the tendency of inclination of the element 24, for thereby preventing reduction of durability of the annular rings 22 due to contact of the annular rings 22 with the element 24 caused by the inclination of the element 24. Further, the gravity center G of the element 24 is shifted toward the body portion 26 by reducing the cross-sectional surface area of the head portion 28 in the cross-sectional plane parallel to the direction of thickness of the element 24, without reducing the geometric profile of the head portion 28 of the element 24, so that the head portion has a sufficiently high strength. The element 24 having the sufficiently high strength can withstand a relatively high load acting thereon due to a large force exerted from the annular rings 22 to the head portion 28 (ear sections 29) in the radially outward direction when a relatively large torque acts on the continuously variable transmission belt 10. That is, the maximum permissible operating torque of the continuously variable transmission belt 10 increases with an increase of the strength of the element 24.
The present embodiment is further configured such that the head portion 28 of the element 24 has the slant surfaces 50, 52, which reduce the mass of the head portion 28 to thereby shift the gravity center G of the element 24 toward the body portion 26 (locking edge 36).
The present embodiment is further configured such that the head portion 28 of the element 24 has the maximum thickness A not smaller than the maximum thickness B of the body portion 26, so that the linear portion W of the continuously variable transmission belt 10 between the driving pulley 14 and the driven pulley 16 on the power transmitting side is protected against deflection or curvature (a waving motion), and the element 24 is permitted to smoothly come into engagement with the driven pulley 16 at the incoming point S3.
The present embodiment is further configured such that the plate blank 60 which is inexpensive is used to manufacture the element 24, and the element 24 is formed at a reduced cost with the fine blanking press operated in a single stroke.
Another embodiment of this invention will be described. In the following description, the same reference signs as used in the preceding embodiment will be used to identify the corresponding elements, which will not be described.
The modified element 90 shown in
The modified element 100 shown in
The modified element 110 shown in
The modified element 120 shown in
Further modified elements having a combination of the slant surface and the stepped surface, for example, a slant surface on the side of the protruding section 46 and a stepped surface on the side of the recessed section 48, have substantially the same function and advantages as the modified elements described above. It is noted that the elements (80, 90, 100, 110, 120) shown in
As described above, according to the above-described embodiments, the gravity center G of the elements (80, 90, 100, 110, 120) constructed as described above can be located near the locking edge, so that these elements have substantially the same function and advantages as described above with respect to the preceding embodiment.
In the present embodiment, the head portion of the elements 100, 110, 120 has at least one stepped surface 104, 106, 114, 124, which reduces the mass of the head portion of the elements 100, etc., so that the gravity center G of the elements 100, etc. can be shifted toward the body portion 26.
While the embodiments of this invention have been described in detail by reference to the drawings, it is to be understood that the invention may be otherwise embodied.
In the illustrated embodiments, the gravity center G is located near the locking edge 36 by forming the slant surface or surfaces, and/or the stepped surface or surfaces in the head portion. However, the head portion may be otherwise configured as desired, so as to reduce its thickness and to reduce mass of the head portion without departing from the scope of the present invention.
It is to be understood that the foregoing embodiments and modifications have been described for illustrative purpose only, and that the present invention may be embodied with various other changes and improvements which may occur to those skilled in the art.
Number | Date | Country | Kind |
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2009-297692 | Dec 2009 | JP | national |
This application is a national phase application of International Application No. PCT/JP2009/071705, filed Dec. 26, 2009, the content of which is incorporated herein by reference.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2009/071705 | 12/26/2009 | WO | 00 | 6/25/2012 |