This application is a secondary application of Mexican Patent Application Serial No. MX/a/20131002354 filed Feb. 28, 2013, hereby incorporated herein by reference in its entirety.
The present invention refers generally to mechanical transmissions, and more specifically to speed reducers and amplifiers.
The worm and gear speed reducer is one of the most frequently used when a large speed reduction is required. However, it has limitations: low load capacity and poor efficiency. The low load capacity is inherent to the geometry since the pitch cylinder of the worm has only one point of tangency with the pitch cylinder of the gear and, therefore, very few teeth in contact. The low efficiency is due to the sliding contact between the worm and the gear with the resulting great loss of energy due to friction. The sliding contact also gives rise to rubbing that gives rise to wear. Furthermore, in some applications, the heat generated by friction is such that a cooling system is required and this involves a greater complication and higher manufacturing and maintenance costs.
During the preceding centuries several patents were granted referring to concepts to increase the load capacity of the worm and gear reducers by increasing the contact surfaces. The best known concepts to achieve this goal have been, on the one hand, a gear configuration with the circumferential toothed surface concave shaped so as to partially envelop or wrap the worm, and on the other hand, a worm with a concave silhouette which partially envelops the gear. Also, gear and worm assemblies are used with double enveloping arrangements, that is, which simultaneously incorporate both configurations. All of these schemes have contributed to noticeably raise the load capacity, but are still limited. It is clear that of this does not solve the inefficiency problem.
In 1897, the concept of a worm and chain speed reducer described in U.S. Pat. No. 595,508 by Wolander appeared, which refers to a speed reducer similar to a worm and gear, such as is shown in
U.S. Pat. No. 418,328, published in December 1889 by Willett refers to a mechanism which drives a boat by means of pedals which include an angular speed amplifier, made up of a chain equipped with small wheels that drives a worm, such as is shown in
U.S. Pat. No. 642,430 published in January 1900 by Corcoran and DE 3305551 C2 published in September 1990 by Reguzzi, such as are shown in
On the other hand, the patents: U.S. Pat. No. 626,515 published in June 1899, by Whitney and U.S. Pat. No. 747,463 published in December 1903, by Moore, such as are shown in
In the past few decades there has been a general, great interest, in energy savings. Particularly, in the case of worm and gear speed reducers, patents have been granted, and applications continue to be filed which involve concepts to render them more efficient. Therefore there are patents, for example, U.S. Pat. No. 4,023,433 published on May 9, 1977, by Schutz, such as can be seen in
Other patents which could be considered generally relevant in prior art, as far as the roller screw which is applied in the second embodiment of the present invention, are patents U.S. Pat. No. 2,683,379, published in July 1954, by Strandgren, and U.S. Pat. No. 8,082,818, published in December 2011, by Sugitani. However, these patents do not describe a reducer. The conventional roller screw is driven by a tube which has an internal thread, and in the case of the inverted roller screw, said tube is driven by the screw. However, for the sake of simplicity, the inverted roller screw which is used in the second embodiment of the present invention will be simply called “roller screw”. This term refers to an assembly, which basically consists of a worm provided with threaded planetary rollers, and placed within an internally threaded tube. The threaded planetary rollers roll between the worm and the threaded tube, and upon turning they displace said tube on a straight line. In this invention, the internally threaded tube is substituted by a plurality of nuts which are mounted on the links of a chain transmission.
The present invention refers to a transformation of a worm and gear reducer to significantly increase both the efficiency and the load capacity. The gear is substituted by a chain transmission carrying nuts. In a first embodiment of this invention, the worm is substituted by a ball screw. In a second embodiment, the worm is substituted by an inverted roller screw.
The efficiency is increased because the sliding contact between the worm and the gear is substituted by the rolling contact between the ball screw and the nuts, or between the roller screw and the nuts. The load capacity is increased because the contact of very few teeth in the worm and gear is substituted by the contact of many nuts that envelop a large surface of the ball screw, or of the roller screw. This is possible because said contact takes place on a straight stretch of the chain, which can be as long as desired.
As opposed to the worm and gear, this invention can also function as an amplifier because the low friction of the ball screw as well as of the roller screw, allows it to function as such.
In both embodiments, the nuts envelop most of the cylindrical surface of the ball screw, or that of the roller screw, and thus the contact surface is much greater than in the case of the worm and gear, as well as all the other prior art patents which have been described.
Just as in the case of the worm and gear, one turn of the ball screw or of the roller screw, produces a very small fraction of a turn in the sprockets of the transmission chain, there is a great reduction of angular displacement and, thus, a great speed reduction. In both embodiments, an additional reduction may be obtained by using the differential screw principle, in the case of the first embodiment by using a differential ball screw, such as that described in U.S. Pat. No. 5,899,114 published in May 1999 by Dolata, and in the case of the second embodiment by using a differential roller screw, such as that described in patents U.S. Pat. No. 3,406,584 published in October 1968 by Roantree and FR 2951514 B1, published in March 2012 by Baudasse.
In the invention being described in the present document, advantage is taken of the geometry of the configuration to increase the contact surface and thus increase the load capacity, given that the ball screw and the roller screw can be as long as desired.
As has already been pointed out, in reducers which involve a worm, efforts are being made to overcome the limitations regarding load capacity and efficiency, but the concepts which have been proposed imply reducers which overcome effectively one, and not both limitations in the same reducer.
Therefore, an objective of the present invention is to provide a high efficiency speed reducer/amplifier.
Another objective of this invention is to provide a speed reducer/amplifier with a high load capacity.
An additional objective of this invention is to provide a speed reducer/amplifier with an increased reduction or amplification ratio.
Yet another objective of the present invention is to provide a reducer/amplifier which includes all the objectives mentioned previously, simultaneously in a single unit.
The particular features and advantages of the present invention, as well as other objectives of the invention, will become apparent in the following description and its accompanying figures:
a is a conventional perspective view of the ball screw of the first embodiment, with the re-circulation conduits for the balls, showing the external tubes separated from the screw.
b is a detailed view of one end of the ball worm, without the balls, showing the exit and return conduits for the balls.
c is a conventional perspective of a detailed view of one end of the worm with balls, and with the outer tube in operating position.
a is a conventional perspective view of the ball retainer trough of the first embodiment. The ball retainer trough which is shown has a semi-circular channel shape to be used with nuts like those in
b shows the ball retainer trough to be used with the nuts, like those of
a Referring to the first embodiment, this is a conventional perspective view of a chain link, and of the nut fastened unto the same.
b shows separately a chain link and a nut.
c referring to the first embodiment, shows a variant of the nut which envelops the ball screw in an arc greater than 180° with a gap that barely allows the shaft of the ball screw to pass through.
d shows the geometric relations between the gap λ of the nut, the angle θ of the threaded surface of the nut and its conjugate angle φ.
a is a conventional perspective view, from a first side, which shows a nut mounted in position on a chain link.
b is
Nuts: the term “nut”, in the case of the present invention, does not have the usual meaning referring to a fastening device and known in prior art, instead it refers to the components through which the rotating motion of the drive screw, ball or roller, is converted into the linear displacement of the chain.
A motor (not shown) is coupled to shaft (31) and makes both it and ball worm (32) rotate about their common geometric axis,
The ball worm (32) is equipped with recirculation balls (35) which, when rolling describe a helicoid trajectory and propel the nuts (34) of the chain (40). The balls (35) roll between the helicoid thread (36) of the ball worm (32) and the helicoid thread (37) of the nuts (34) thus forcing the nuts to be displaced in a straight line, as can be seen in
The nuts (34) have a λ wide gap (46),
c shows a variant of the nuts (34) in which said nuts envelop the ball screw (32) in an arc greater than 180°, since it is only required that the gap (46) of the nuts (34) be sufficiently wide to avoid an interference between the nuts (34) and the shaft (31) of the ball worm (32).
Because of the gap (46) in the nuts (34), the thread (37) in the same is not continuous but rather, intermittent. The ball retainer trough (42) serves as a bridge which prevents the balls from falling when they cross the gap (46). Said ball retainer trough (42) is a channel whose cross section is a circular arc which subtends an angle ψ=φ−α where α is the clearance (38) between the nuts (34) and the ball retainer (42),
Referring to
It is pertinent to point out that the cylindrical surface of the ball worm (32) covered by the balls which transmit the load is S=θrL, where r is the radius of the ball worm and L is the length of the ball worm.
Referring to
The chain and sprockets are of the roller type they may be single or multiple strand according to the requirements. The chain and sprockets may be either roller type or inverted tooth type, also known as silent chain.
In order to axially align the nuts (34), and also in order to prevent the possibility of a small rotation which could occur between the adjacent nuts due to the looseness between the components of the chain (40), the nuts (34) have a protruding shape (52) on one of its sides, and a recessed shape (53) on the other side,
It may be convenient that sprockets (48) and (49) have different diameters so as to have two different output speeds, one from each shaft (50) and (51) respectively. Of course, the sprockets may have identical diameters, because there may be some applications which require this to be so.
When this first embodiment is used as a reducer, the shaft (31) is the input shaft and the shafts (50) and (51) are the output shafts. When this embodiment is used as an amplifier, one of the shafts (50) or (51) is the input shaft, and the shaft (31) is the output shaft.
It is preferred that the chain (40) have one nut (34) fastened to each link (39), however it is possible to have nuts (34) fastened to alternate links (39), or in each 3rd, 4th, . . . or nth, link (39). The length of the nuts (34) is equal to np, where p is the chain pitch, given that on the straight stretch of the chain there are no spaces between the nuts.
Both the ball worm (32) and the nuts (34) may have a single thread, or they may have a rapid advance thread, that is, one with multiple threads.
The chain (40) may be a roller chain or an inverted toothed chain (also known as silent chain), or even, a toothed belt could conceivably substitute the chain. In the case that the chain (40) and the corresponding output sprockets (48) and (49), are of the roller type, the chain may be single or multiple, i.e., double, triple etc. depending on the load capacity.
In other variants, the chain (40) may drive 2, 3, or more output sprockets with their respective shafts, in order to have various reduction ratios, or, in order to drive different loads (for instance, machines).
In other variations, a ball worm (32) may drive two chain transmissions (40) at the same time, thus eliminating the bending moment which is acting on the ball worm (32) when only one chain transmissions (40) is used.
Since there is rolling contact between the worm (32), the balls (35) and the nuts (34) the friction is much lower than that of the worm and gear reducer, where there is sliding contact. Additionally, the contact surfaces may be as great as desired, and in any case, much greater than in the case of the worm and gear.
For these reasons, the reducer/amplifier being referred to in this first embodiment of the present invention has both a load capacity and an efficiency which are much greater than those of a worm and gear reducer, and much greater than in all of the devices referred to in the patents mentioned previously.
A greater reduction may be obtained by using a differential ball screw.
Similar to the first embodiment and referring to
The nuts (3) are fastened onto the links (7) of the chain (8), by fastening means known in the art such as could be screws or rivets (not shown) or, said nuts (3) may be integral with the links (7).
The nuts (3) have a λ wide gap (6),
Similarly to the first embodiment, and in order to align the nuts (3) axially, and so as to prevent the possibility of a small rotation which could occur between the adjacent nuts due to the looseness between the components of the chain (8), the nuts (3) have a protruding shape (15) on one of its ends, and a recessed shape (16) on the other end, both centered on the longitudinal axis of the threaded cylindrical surface,
In this second embodiment, shown in
In view that the nuts (3) are fastened unto the chain (8), upon the displacement of the nuts (3), the chain (8) is also displaced. This produces an angular displacement of the output sprockets (9) and (10). The output sprockets (9) and (10) turn together with their respective shafts (11) and (12) because they are either keyed or splined together, or they may be integral with each other. The shafts (11) and (12) are output shafts, and are supported on bearings (not shown). Generally, it is convenient that the output sprockets have different diameters so as to have two different reduction ratios, one from each output shaft (11) and (12). Of course, the output sprockets may have identical diameters, because there may be some applications which require this to be so.
When this second embodiment of the invention is used as a reducer, the shaft (2) is the input shaft and the shafts (11) and (12) are output shafts. When this embodiment of the invention is used as an amplifier, one of the shafts (11) or (12) (or both) is the input shaft, and the shaft (2) is the output shaft.
It is preferred that the chain (8) have a nut (3) fastened unto each link (7), however, it is possible to have nuts fastened unto alternating links, or at every 3rd, 4th, . . . or nth link. The length of the nuts (3) is equal to np, where p is the chain pitch, because there are no spaces between the nuts on the straight stretch of the chain.
It is possible that both the roller screw (1) and the nuts (3) have a single thread or a rapid advance thread, that is, one with multiple threads.
The chain (8) can be either a roller chain, or a silent chain or any other suitable chain or it could conceivably be a toothed belt or some other kind of belt. The roller chain (8) and the sprockets (9) and (10) may be single or multiple: double, triple, etc. according to the different requirements.
In other variations, the chain (8) may drive 2, 3, or more output sprockets with their respective shafts, in order to have various reduction ratios. For example, the variant in
In other variations, a roller screw (1) may drive two chain transmissions at the same time, see
As has already been pointed out, in this second embodiment of the invention, the roller screw (1) acts as a worm driver and its threaded planetary rollers (4) roll between the worm (5) and the nuts (3) and drive said nuts in a straight line. At the ends of the worm (5), there are gears (13), which are integral to the worm (5) itself,
Since there is rolling contact between worm (5) and the threaded planetary rollers (4) and also between said planetary rollers and the nuts (3) friction is much lower and thus efficiency is greater than that of a worm and gear reducer. Because this higher efficiency this embodiment may be used in reverse form as an amplifier, without decreasing the amplification ratio, which is impossible in the case of the worm and gear.
Additionally, the contact surface of a threaded planetary roller (4) is much greater than the contact surface of a row of balls (with a length comparable to that of a planetary roller), and as a consequence the load capacity of this second embodiment is greater by one order of magnitude than that of the first embodiment. As was already pointed out, the load capacity of the first embodiment is much greater than that of the worm and gear. Additionally, the life of the roller screw is 15 times greater than that of the ball screw of the first embodiment.
The effectiveness of the roller screw, insofar as the increase in both the load capacity and the efficiency, has been amply proven in its application on commercial actuators by different manufacturers.
A greater reduction can be achieved by using a differential roller screw.
Insofar as this invention has been described in terms of its two embodiments and several variations, there are alterations, permutations and equivalents which lie within the scope of this invention. It should also be emphasized that there may be many alternative ways to implement the devices and methods of the present invention. Therefore, it is assumed that the following claims shall be interpreted so as to include all such alterations, permutations and equivalent as long as they lie within the spirit and scope of the present invention.
Number | Date | Country | Kind |
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MX/A/2013/002354 | Feb 2013 | MX | national |