Patent Application
20060240936
Currently, in automotive propulsion systems and some stationary applications where fluctuating loads are encountered, torque transmission systems with a limited number of torque multiplication ratios are used. An operator or control mechanism must select the appropriate torque multiplication ratio to compensate for any difference between available torque and load conditions. Also, the number of torque multiplication ratios are limited, thus the engine providing torque must operate over a wide range of load conditions and rotational velocities. This adversely affects engine efficiency as most power generating systems operate most efficiently in a narrow range of load conditions and rotational velocities. Operator or control mechanism input is also required to select the proper torque multiplication ratio for changing load conditions.
While numerous continuously variable transmissions have been invented, including at least one self-regulating type, all have some serious drawback such as the generation of vibration or excessive friction or the lack of structural strength and are thus limited in the amount of torque that can be transmitted.
The two different torque transmission movements are represented by semi-circles composed of dashes with an arrow head at one point in said semi-circle which represents the angular direction of travel.
The juncture between the various moving components and thus the bearings which form the rotational axes of said components are represented by solid dots.
In
All shaded components are cylindrical with the viewer's line of sight at a right angle relative to the length axes of said cylinders. Illumination is from directly above, thus the bottom half of said cylinders are in shade. The demarcation between shaded and unshaded areas represent the diameter axis centers of said cylindrical components and demonstrates the distance and direction of offset between said components.
The throw radii of the four crankshafts are each one eighth of one inch and the difference in diameter between the planetary gears and ring gears is one quarter of one inch.
The two bearing supports (3) which support carrier shafts (16) on output shaft (11) are each inside one ring (12) and are thus not visible. One support (3) of each carrier crankshaft (cams 17) are also inside each ring (12) and are thus not visible. The said unseen supports (3) are identical in form and function as the visible supports (3).
With the exception of the two bearings (2) which support input shaft (4) in casing (1) and the two bearings (2) which support output shaft (11) in casing (1) all bearings (2) are inside outer components and are thus not visible. The numbered line (2) indicates one point on the outer circumference of each bearing (2).
In this system two external planetary gears (15) of equal lesser diameter drive two internal ring gears (13) of equal greater diameter by orbital and rotational movement.
Internal ring gears (13) are two hollow cylinders which have a common output shaft (11) which forms the rotational axis (B) and diameter axis center of gears (13). Each said cylinder has an internal ring gear (13) on the inner circumference which is intermeshed with one said external planetary gear (15).
During direct drive, when the torque exerted into planetary gears (15) equals the load opposing ring gear (13) rotation, planetary gears (15) orbit and rotate around axis (B) in the angular direction of torque input (X) at torque input velocity driving ring gears (13) at torque input velocity. Loads greater than torque input (X) inherently cause ring gears (13) to rotate at a lesser velocity than torque input (X) and said difference in velocity is proportional to the ratio of load over torque input.
To compensate for said difference in velocity, planetary gears (15) counter-rotate in the opposite angular direction of torque input (X) and said counter-rotation combines with torque input to drive planetary gears (15) in the angular direction of torque input around different axes.
At maximum load, planetary gears (15) counter-rotate in the opposite angular direction of torque input, one revolution per one full orbit in the angular direction of torque input (X). Thus planetary gears (15) with diameters equal to ninety percent of the diameters of ring gears (13) would compensate for ninety percent of torque input velocity leaving ten percent to drive ring gears (13). Such a system would have a maximum torque multiplication ratio of one to ten and a maximum angular velocity reduction of ten to one.
During direct drive, both planetary gears (15) are driven in orbit and rotation around output axis (B). Under maximum load, each planetary gear (15) is carried around a separate axis offset from axis (B).
Said two separate axes are provided by a carrier (shafts 16) which is mounted by bearings (2) on output shaft (11) between said two ring gears (13). Said carrier consists of two hollow shafts (16) which form a single integral unit. The diameter axis center of each shaft (16) is offset from the rotational axis (B) of said carrier provided by output shaft (11). The direction of said offset of each carrier shaft (16) is diametrically opposite the other relative to axis (B). Said carrier is free to remain stationary on output shaft (11) or to rotate in the direction of torque input at variable velocities up to torque input (X) velocity.
One of two carrier crankshafts (cams 17) is mounted by bearings (2) on each carrier shaft (16). Said carrier crankshafts each consists of two throw cams (17) which form a single integral unit. Each throw cam (17) is a short cylinder, the diameter axis center of which is offset from the rotational axis provided by the respective carrier shaft (16) to which it is mounted.
The direction of said offset of each cam (17) Is diametrically opposite to the other cam (17) relative to said rotational axis provided by shaft (16). Thus each said carrier crankshaft has two diametrically opposed throws (17). Said carrier crankshafts are free to remain stationary on carrier shafts (16) and travel in orbit around axis (B) (movement X) with shafts (16) or to rotate around shafts (16) (movement Y) when said carrier is stationary on axis (B) or a combination of said two movements (X and Y).
One length axis end of one connecting rod (10) is mounted by a bearing (2) on the circumference of one said throw cam (17) of each carrier crankshaft. One planetary gear (15) is mounted by bearing (2) on the other throw shaft (17) so that the diameter axis center of said gear (15) is offset from said cam (17). The direction of said offset is diametrically opposite the direction of offset of said carrier shaft (16), relative to axis “B”, to which each gear (15) is mounted, by each carrier crankshaft (17).
Connecting rods (10) transmit torque from the input axis (A) to output axis (B) and torque reaction from axis (B) to axis (A).
Said two movements (X and Y) are generated by the input axis (A) assembly of components. Said assembly consists of an input crankshaft and a secondary crankshaft. Said input crankshaft consists of two input axis shafts (4), a throw shaft (6), two radial arms (5), which connect the orbital throw shaft (6) with the rotational input shafts (4), and two counter-balances (7).
One length axis end of one input axis shaft (4) is connected to, and driven in rotation, by a torque source, thus driving said input crankshaft around axis (A).
A secondary crankshaft is mounted by bearings (2) on orbital throw shaft (6) and travels in orbit around axis (A) with shaft (6). Said secondary crankshaft is free to remain stationary on shaft (6) or to counter-rotate around shaft (6) is the opposite angular director of torque input (X).
Said secondary crankshaft consists of an axis shaft (8) and two throw cams (9). Axis shaft (8) is a hollow cylinder mounted by bearings (2) on throw shaft (6) so that the length axis of said cylinder is coincentric with the length axis of shaft (6).
Throw cams (9) are two short cylinders which are integral parts of axis shaft (8). The diameter axis center of each cam (9) is offset from the rotational axis (shaft 6) of axis shaft (8). The direction of said offset of each cam (9) is diametrically opposite the other cam (9) relative to said rotational axis, thus said secondary crankshaft has two diametrically opposed throws.
One length axis end of one connecting rod (10) is mounted by a bearing (2) on the circumference of each throw cam (9). Rods (10) transmit torque from throw cams (9) on input axis (A) to carrier crank throw cams (17) on output axis (B) and torque reaction from axis (B) back to axis (A).
During direct drive, when torque input equals load, carrier shafts (16) rotate around axis (B) at torque input (X) velocity carrying said carrier crankshafts (cams 17) in orbit and rotation around axis (B) thus driving planetary gears (15) in orbit and rotation around axis (B) (movement X). Thus movement (X) drives ring gears (13) at torque input (X) velocity.
During movement (X), said secondary crankshaft remains stationary on throw shaft (6) and said diameter axis centers of throw cams (9) orbit around axis (A) generating an orbital cranking movement (X) around input axis (A).
Under a maximum load over torque input ratio, said carrier (shafts 16) are stationary on axis (b) and each said carrier crankshaft (cams 17) rotates around one said axis offset from axis (B) provided by each carrier shaft (16) (movement Y). In this mode of operation, said secondary crankshaft (shaft 8, cams 9) counter-rotate one full counter-revolution in the opposite angular direction of torque input (X) per one full orbit of said secondary crankshaft in the angular direction of torque input (X). The two throw radii of cams (9) remain parallel to a fixed plane in space and transmit torque from input axis (A) to two separate axes offset from axis (A) (movement Y).
Secondary crankshaft (shaft 8, cams 9) are limited to one counter-rotation per one rotation of torque input (X) as movement (Y) is in the angular direction of torque input (X) and any greater counter-rotation would increase the velocity and distance of stroke of one connecting rod (10) and decrease the velocity and distance of stroke of the other rod (10) between axis (A) and (B). This would drive each said carrier crankshaft (cams 17) at a different velocity which is impossible as each said carrier crankshaft is engaged equally with a single load.
Said throw radii of cams (9) act as the two radial arms of a lever with throw shaft (6) being the fulcrum. Torque reaction exerted against each cam (9) combines with torque input (X) from shaft (6) to drive the other cam (9) in the angular direction of torque input during both movements (X) and (Y). Thus a continuous feed back loop is created between input axis (A) and output axis (B).
The point at which torque is exerted into axis (B) is between axis (B), which acts as the fulcrum of a lever, and ring gears (13), which are the load. As axis (B) is fixed and said load is free to rotate around axis (B), load bearing ring gears (13) react to torque input by rotating around axis (B) at an angular velocity proportional to the load opposing ring gear (13) rotation relative to the torque exerted into the radial arm of said lever formed by the radii of ring gears (13).
Specifications
The following factors are considered in the design of this invention.
Structural Strength
All moving components are supported by two bearings (2) and all torsional loads on said components are between said bearing (2) supports. The exception being the two planetary gears (15) which are each supported on one carrier throw cam (17) by one bearing (2). The support provided by said single bearing (2) is directly aligned with the torsional load to which each planetary gear (15) is subjected.
Mass Balancing
To prevent the generation of vibration due to asymmetric mass distribution around axis (A), the mass of all components which rotate on axis (A) is balanced on axis (A) by counter-balances (7). The mass of planetary gears (15) is balanced on axis (B) by the mass of connecting rods (10) which is diametrically opposed to the mass of gears (15) relative to axis (B).
Friction
All moving components are supported by ring type roller or ball bearings (2) which generate very little friction.
Inertia
The mass of the moving components and the radius of orbit of said mass around the various axes is minimized to reduce the radius of travel of said mass. This minimizes the inertia of said mass during changes in angular velocity of said moving components and thus any negative effect said inertia has on performance and efficiency.
Overall Mass, External Dimensions and Cost
This invention consists of ten moving components and eighteen bearings and is light weight, compact and inexpensive to manufacture.
Specifications
While there are many methods to construct this device, the model described herein is the most ideal mechanical embodiment.
1. Stationary Casing
Said casing (1) encloses all the moving components in a lubricating oil bath and provides a stationary mount for the input shaft (4) and output shaft (11).
2. Bearings
Said bearings (2) are ring shaped roller or ball type bearings (2) which eliminate friction between the various moving components.
3. Bearing Supports
Said supports (3) are hollow cylinders which are integral parts of said moving components and each contain a bearing (2) which supports each said moving component. Said supports (3) of secondary crankshaft (8, 9) carrier crankshafts (17) and carrier (16) are each detachable from these said components to allow assembly of other components to these components.
4. Input Axis Shafts
Said axis shafts (4) are two short cylinders which are integral parts of the input crankshaft. One length axis end of each shaft (4) is supported by a bearing (2) in one opposite end wall of casing (1). One length axis end of one shaft (4) is connected to, and driven in rotation around the cylindrical length axis (A) of shafts (4) by a torque source.
5. Radial Arms
Said arms (5) are integral parts of said input crankshaft and connect one length axis end of each rotational input shaft (4) with one length axis end of the orbital throw shaft (6).
6. Throw Shaft
Said shaft (6) is an integral part of said input crankshaft. The length axis of shaft (6) is parallel to the rotational and length axes (A) of input shafts (4) and travels in an orbit around axis (A) with input crankshaft rotation. Shaft (6) is composed of two pieces to allow assembly of other components to shaft (6). One piece of said secondary crankshaft consists of one input shaft (4), one radial arm (5) and one part of throw shaft (6). One said part of shaft (6) is a hollow cylinder. The second said part of shaft (6) is a solid cylinder which has a diameter equal to the inner diameter of said hollow cylinder. After assembly of said other components to said outer hollow cylinder, said solid cylinder is inserted inside said hollow cylinder to form a single integral crankshaft.
7. Counter-Balances
Said counter-balances (6) are each an integral part of one input shaft (4) and are attached to each shaft (4) so that the mass of both counter-balances are diametrically opposite to radial arms (4). Counter-balances (6) are of sufficient mass and radius of orbit around input axis (A) so as to generate a centrifugal force equal to the centrifugal force generated by throw shaft (6) and components mounted on shaft (6).
8. Secondary Crank Axis Shaft
Said secondary axis shaft (8) is a hollow cylinder, each length axis end of which is supported by a bearing (2) and support (3) on throw shaft (6) and is free to counter-rotate on shaft (6).
9. Secondary Crank Throw Cams
Said secondary cams (9) are two short cylinders which are integral parts of secondary axis shaft (8). The diameter axis center of each cam (9) is offset from the rotational axis (shaft 6) of axis shaft (8). The distance of said offset is equal to the throw radius of said input crankshaft. The direction of said offset of each cam (9) is diametrically opposite the direction of offset of the other cam (9) relative to said rotational axis (shaft 6) of said secondary crankshaft. Thus shaft (8) and cams (9) form a crankshaft with two diametrically opposed throws.
10. Connecting Rods
Said rods (10) are each an elongated bar. One length axis end of each rod (10) is mounted by a bearing (2) and support (3) on the circumference of one throw cam (9). Rods (10) transmit torque from input axis (A) to output axis (B).
11. Output Axis Shaft
Said output shaft (11) is a cylinder, each length axis end of which is supported by a bearing (2) in each opposite end wall of casing (1). Shaft (11) rotates on it's cylindrical length axis (B) and one length axis end is connected to a load which is driven in rotation. Output shaft (11) is composed of two pieces to allow assembly of other components to shaft (11). One said piece of shaft (11) is a hollow cylinder with splines on the inner circumference. The other said piece is a solid cylinder with spline slots on the circumference. Said solid cylinder has an outer circumference equal to the inner circumference of said hollow piece and said solid piece is inserted into said hollow piece after assembly of said other components to shaft (11).
12. Rings
Said rings (12) are two hollow cylinders which are integral parts of output shaft (11) which forms the rotational axis (B) and diameter axis center of rings (12).
13. Internal Ring Gears
Said ring gears (13) are two internal gears, each one of which is located on the inner circumference of each ring (12).
14. Ring Support Discs
Said discs are integral parts of output shaft (11) and support rings (12) on shaft (11).
15. External Planetary Gears
Said planetary gears (15) are two external gears, each one of which is intermeshed with one internal ring gear (13).
16. Carrier Shafts
Said shafts (16) are two hollow cylinders which form a single integral unit. One length axis end of each cylinder is joined to the other and each length axis end of said unit is supported by bearings (2) and supports (3) on output shaft (11) between said two ring gears (13). The diameter axis center of each shaft (16) is offset from the rotational axis (B) of said shafts (16). The distance of said offset is equal to said throw radius of said input crankshaft or the throw radii of secondary throw cams (9). The direction of said offset of each shaft (16) is diametrically opposite the direction of offset of the other shaft (16) relative to output axis (B). Said carrier (16) is subject to torque input and torque reaction and rotates on axis “B” in the angular direction of torque input over a range from zero to torque input velocity.
17. Carrier Crank Throw Cams
Said carrier throw cams (17) are four short cylinders which form two separate integral units with two cams (17) each. Each said unit is mounted by bearings (2) and supports (3) on one carrier shaft (16). The diameter axis center of each cam (17) of each said unit is offset from the rotational axis (shaft 16) of each said unit. The distance of said offset is equal to said throw radius of said input crankshaft. The direction of said offset of each cam (17) of each said unit is diametrically opposite to the direction of offset of the other cam (17) relative to the rotational axis (shaft 16) of said unit. Thus each said unit forms a crankshaft with two diametrically opposed throws.
One length axis end of one connecting rod (10) is mounted by a bearing (2) and support (3) on the circumference of one carrier throw cam (17) of each said unit formed by two cams (17).
One planetary gear (15) is mounted by a bearing (2) on the other throw cam (17) of each said unit. The diameter axis center of each planetary gear (15) is offset from said diameter axis center of the cam (17) to which each gear (15) is mounted. The distance of said offset is equal to the distance of said offset of each carrier shaft (16) from axis (B). The direction of said offset of each gear (15) is diametrically opposite, relative to axis (B), the direction of said offset of the shaft (16) to which each gear (15) is mounted by said carrier crankshaft (cams 17).
During direct drive when torque input equals load, said carrier (shafts 16) rotates on axis (B) at torque input velocity in the angular direction of torque input. Said carrier crankshafts (cams 17) orbit axis (B) with carrier shaft (16) rotation driving planetary gears in orbit and rotation around axis (B). Thus movement (X) drives internal ring gears (13) and output shaft (11) at torque input (X) velocity in the angular direction of torque input (X).
Loads greater than torque input inherently cause output shaft (11) and ring gears (13) to rotate at a lesser velocity than torque input. Said difference in velocity is proportional to said load over torque input ratio. To compensate for said difference in velocity, said carrier (shafts 16) rotates on axis (B) at a lesser velocity than torque input (X) thus carrying said carrier crankshafts (cams 17) around axis (B) at a lesser orbital velocity than torque input (X).
Under a maximum load over torque input ratio, said carrier (shafts 16) is stationary on axis (B) and said carrier crankshaft (cams 17) orbit around axis (B) is zero. In this mode of operation (movement Y), each said carrier crankshaft (cams 17) rotates around the carrier shaft (16) to which it is mounted.
As the diameter axis center of each planetary gear (15) is offset from the cam (17) to which it is mounted; and said offset is diametrically opposite to the direction of offset of the respective carrier crankshaft of said cam (17), relative to axis (B), planetary gears (15) orbit around axis (B) during both movements (X and Y).
During movement (Y), the diameter axes of planetary gears (15) remain parallel to a fixed plane in space while each gear (15) is carried around an axis offset from axis (B). This is the equivalent of planetary gears (15) counter-rotating in the opposite angular direction of torque input (X) one full counter-revolution per one full orbit of planetary gears (15) around axis (B) in the angular direction of torque input (X). of ring gears (13) would compensate for ninety percent of torque input velocity. Such a system will have a maximum torque multiplication ratio of one to ten and a maximum angular velocity reduction of ten to one.
Movements (X) and (Y) are generated by said secondary crankshaft (shaft 8, cams 9). During direct drive, said secondary crankshaft remains stationary on throw shaft (6) and throw cams (9) orbit input axis (A). Under maximum load, said secondary crankshaft counter-rotates around throw shaft (6) one full counter-revolution in the opposite angular direction of torque input (X) per one full orbit of shaft (6) and said secondary crankshaft around axis (A). The throw radii of the two diametrically opposed throws of cams (9) remain parallel to a fixed plane in space and transmit torque to two separate axes offset from axis (A) (movement Y). Said secondary crankshaft cannot counter-rotate more than one counter-revolution per one orbit as to do so would increase the velocity and distance of stroke of one connecting rod (10) between axis (A) and (B) and decrease the velocity and distance of stroke of the other connecting rod (10) between axis (B). Thus each rod (10) transmits torque from axis (A) to axis (B) and torque reaction from axis (B) to axis (A) and forms a continuous feed back loop.
The point at which torque is exerted into the axis (B) assembly of components is between axis (B) and ring gears (13). Axis (B) acts as a fulcrum of a lever with ring gears (13) being the load and the radii of gears (13) being the radial arm of said lever. Said radii react to torque input by rotating around axis (B) at an angular velocity equal to torque input relative to the load opposing ring gear (13) rotation around axis (B).
Alternate Method of Construction
Same as described except that one planetary gear and one ring gear is used.
Said internal ring gear is a hollow cylinder with an internal ring gear on the inner circumference and an output axis shaft which forms the diameter axis center and rotational axis of said cylindrical ring gear.
Said external planetary gear is intermeshed with said ring gear and consists of a gear, a hollow cylindrical shaft which forms the diameter axis center of said planetary gear and two throw cams. The diameter axis center of each said throw cam is offset from the diameter axis center of said hollow shaft. The direction of said offset of each throw cam is diametrically opposite the direction of offset of the other throw cam relative to the diameter axis center of said hollow shaft.
One length axis end of one connecting rod is mounted by a bearing and bearing support on the circumference of each said planetary gear throw cam.
A carrier is mounted by bearings and bearing supports on said output axis shaft. Said carrier consists of two hollow cylindrical shafts which form a single unit. Each said carrier shaft is offset from the rotational axis of said carrier (said output axis shaft) and provides a rotational axis offset from said output shaft. Each said offset axis is diametrically opposite the other relative to said output axis.
Each length axis end of said planetary gear hollow shaft is supported on one carrier shaft by a carrier crankshaft. Each said carrier crankshaft is a short hollow cylindrical shaft, each length axis end of which is supported by a bearing and bearing support on one of the two said carrier shafts. The diameter axis center of each said cylindrical crankshaft is offset from the rotational axis of said bearings which support it on said carrier shaft so that said diameter axis center travels in orbit around said carrier shaft during carrier crankshaft rotation on said carrier shaft. Said offset is equal in distance to the throw radius of the input crankshaft.
As described, during direct drive, said carrier rotates around said output shaft axis carrying said planetary gear in orbit and rotation around said output axis.
Under maximum load, said carrier is stationary on said output shaft and each said carrier crankshaft rotates around the respective carrier shaft to which it is mounted carrying said planetary gear in orbit around two separate axes offset from said output axis.
One counter-balance is attached to one bearing support of each said carrier crankshaft so that the mass of said counter-balance is diametrically opposite to the direction of said offset of said carrier crankshaft offset shaft relative to the rotational axis of said carrier crankshaft.
Said two counter-balances are of sufficient mass and radius of orbit so as to generate a centrifugal force equal to the centrifugal force generated by said planetary gear, connecting rod ends and throw cams which orbit or rotate on axis (B).
Alternate Method of Construction
Said alternate method of construction is the same as described except that two lesser diameter external planetary gears intermesh with a larger diameter external central sun gear. The rotational axes of said two planetary gears, is parallel to the rotational axis of said central sun gear and output shaft. Said planetary gears drive said sun gear around the output shaft diameter center of said sun gear by two different rotational movements or a combination of said movements.
During direct drive, said planetary gears orbit and rotate around said sun gear output shaft diameter center at torque input velocity. During maximum torque multiplication, each said planetary gear rotates around each diameter center of the gear shaft which forms the rotational axis of each said planetary gear, at torque input velocity. Planetary gears with a diameter equal to ninety percent of the diameter of said central sun gear would have a maximum torque multiplication ratio of one to ten and a maximum output shaft angular velocity reduction of ten to one.
Said planetary gears are supported on said output shaft by two gear carriers. Said carriers are two elongated bars, which are mounted by bearings on said output shaft, one on each side of said central sun gear. The mid-length axis center of each said carrier is mounted on said output shaft so that the length axis ends of both said carriers orbit around said output shaft. Both said planetary gears are supported by said carriers so that each length axis end of each rotational axis shaft of both said planetary gear are supported by a bearing located in each length axis end of each said carrier.
One of two connecting rods is mounted by a bearing on each said throw cam so that the inner circumference of the end ring of said connecting rod is supported by a bearing on the circumference of said throw cam. Said throw cam drives the length axis of said connecting rod in rotation around said output shaft axis center during direct drive when said tertiary carrier crankshafts orbit around said output shaft axis or; each said throw cam drives each said connecting rod length axis in rotation around said diameter center of one said tertiary crankshaft carrier during maximum torque multiplication.
Each said rotational axis shaft of said planetary gears contains a crankshaft with a single throw cam or throw shaft offset from said axis shaft. Said crankshaft is located on one length axis end of each said rotational axis shaft, on opposite ends. The throw radius of both said crankshafts is equal to one half said throw radius of said input throw cam or one half said distance of offset of said diameter centers of said tertiary carrier crankshaft from said output shaft rotational axis center. Thus, one hundred and eighty degrees of said planetary gear crankshaft rotation would create a linear stroke equal in length to said distance of offset of said tertiary carrier crankshaft diameter center from said output shaft diameter center. Thus, said planetary gears are limited to one rotation around each individual planetary gear rotational axis per one planetary gear orbit around said output shaft.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11107975 | Apr 2005 | US |
| Child | 11342035 | Jan 2006 | US |
