CONTINUOUSLY VARIABLE TRANSMISSION WITH UNIFORM INPUT-TO-OUTPUT RATIO THAT IS NON- DEPENDENT ON FRICTION
20190003564 ยท 2019-01-03
Inventors
Cpc classification
F16H29/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H19/043
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H2035/003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H21/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H53/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H35/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16H29/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H53/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H21/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H19/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H29/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
This invention is an all gear infinitely variable transmission that is non-dependent on friction. It can me be used in high torque applications. It offers a steady and uniform output for a steady and uniform input. It allows a co-axial input and output thereby by using a planetary gear system the output can be made continuous from forward to reverse. This uses a scotch-yoke mechanism to convert rotational motion to a linear reciprocating motion. The linear distance of this reciprocating motion-stroke is changed by altering the crankpin location of the scotch-yoke mechanism. This reciprocating motion is converted to a rocking motion by using a rack and pinion and later converted to a unidirectional motion via a One-Way-Bearing. A set of non-circular gears are used to achieve a steady and uniform output. It employs a very simple mechanism to change the ratio between the input and output of the transmission.
Claims
1. An infinitely variable transmission wherein: At least one Scotch-Yoke-Module which consists of: a) an Input-Disk having a radial slot with a length extending in a substantially radial direction, disposed between a Ratio-Cam-Disk comprising a non-radial slot extending at least partially in a non-radial direction, and a slotted Cross-Rack-Holder comprising a first slot for receiving a Crank-Pin, a longitudinal axis of the first slot being orthogonal to a longitudinal axis of a Rack coupled with the slotted Cross-Rack-Holder that is restricted to move only along a substantially straight line that is substantially orthogonal to the first slot, a Crank-Pin engaged in the slot on the Input-Disk, the first slot of the Cross-Rack-Holder, and the slot of the Ratio-Cam-Disk 18, and extending parallel to a longitudinal axis of the Input-Disk, b) at least one Rectifier-Module that includes: the Rack, a Pinion, a Shaft-Pinion, a One-Way-Bearing or a Ratchet-Mechanism or a Computer-Controlled-Clutch, and an Output-Gear or an Output-Sprocket and c) an Angular-Velocity-Modifier-Module comprising at least one Non-Circular-Gear and an Input-Shaft, arranged such that a uniform rotation of at least one Driving-Non-Circular-Gear rotates at least one Driving-Non-Circular-Gear about its longitudinal-axis causes a non-uniform angular velocity of the Input-Disk about its longitudinal-axis which via the slot of the Input-Disk causes the Crank-Pin to reciprocate the Rack substantially orthogonal to its slot at a constant velocity and slowing down to a stop followed by an acceleration in the opposite direction to a constant reciprocating the Rack coupled there to rock the Pinion and this rocking movement of the Pinion is converted to unidirectional rotation of an Output-Gear or an Output-Sprocket via at least one of a One-Way-Bearing, a Ratchet-Mechanism, or a Computer-Controlled-Clutch; where the driven non circular gear further functions as a carrier of a planetary gear system, housing at least one free to spin planet gear that is attached to a gear cam that meshes with a stationary ring gear or a stationary sun gear operably engaging the gear cam with a shaft cam that is mounted on the Input-Shaft to compensate for any deviation in the desired rack movement in the functional region.
2. The infinitely variable transmission of claim 1, wherein the Ratio-Cam-Disk and the Input-Disk are positioned adjacent and coaxial to one another, and are controllable to rotate synchronously or non-synchronously by a Synchronous-Control-Mechanism and when they rotate substantially synchronously, a distance between the Crank-Pin and a central axis of the Input-Disk is maintained at a substantially constant distance, where this distance ranges from zero to the length of the radial slot of the Input-Disk, and any non-synchronous rotation will alter the distance between the Crank-Pin and the central axis of the Input-Disk by a Crank-Pin-Displacement-Mechanism; wherein the Synchronous-Control-Mechanism comprises two sets of an axially connected pair of Intermediate-Circular-Gears, wherein for each axially connected pair of Intermediate-Circular-Gears, the circular gears of the pair are dissimilar in size, and one of the gears from one of the sets is configured to radially connect to the Input-Disk and one of the gears from the other of the sets is configured to radially connect with the Ratio-Cam-Disk, where the Input-Disk and the Ratio-Cam-Disk have gear profile with substantially identical pitch curve on their circumference/perimeter, and wherein each longitudinal axis of the Intermediate-Circular-Gear is parallel to the axis of the Input-Disk, and further wherein the axes of the Intermediate-Circular-Gears are movable along a slot, thru a lever or cable, that is at a substantially constant distance from the longitudinal axis of the Input-Disk. wherein the Input-Disk and Ratio-Cam-Disk rotate substantially synchronously when the axes of the Intermediate-Circular-Gears remain substantially stationary, otherwise the Input-Disk and the Ratio-Cam-Disk rotate non-synchronously. wherein the driven non-circular-gear is paired with a cam which pushes the lever or cable via a spring to assist the lever or cable movement.
Description
DETAILED DESCRIPTION OF THE INVENTION
Summary of the Invention
[0221] To briefly describe this invention is an Infinitely Variable Transmission (IVT). Unlike existing CVT designs, this particular design does NOT depend on friction to transmit power. Most of the CVTs that exist today depend on friction to transmit power and therefore cannot be used where there is a need to transmit high power at low speed. Due to this advantage, it is possible to use this invention where high torque transmission is required. Co-axial input and output can be achieved with this layout.
List of Components
[0222] 1) Frame-Main-Housing
[0223] 2) Frame-Cross-Rack-Holder-Guide
[0224] 3) Frame-Telescopic-Guide
[0225] 4) Shaft-Input
[0226] 5) Bearing-Input-Shaft
[0227] 6) Shaft-Intermediate-Gear
[0228] 7) Bearing-Intermediate-Gear-Shaft
[0229] 8) Driving-Non-Circular-Gear
[0230] 9) Driven-Non-Circular-Gear
[0231] 10) Intermediate-Circular-Gear-C1
[0232] 11) Intermediate-Circular-Gears-C2-C3
[0233] 12) Intermediate-Circular-Gears-C4-C5
[0234] 13) Bearing-Collar
[0235] 14) Bearing-Circular-Gear-C2-C3
[0236] 15) Bearing-Circular-Gear-C4-C5
[0237] 16) Input-Disk
[0238] 17) Bearing-Input-Disk
[0239] 18) Ratio-Cam-Disk
[0240] 19) Bearing-Ratio-Cam-Disk
[0241] 20) Intermediate-Circular-Gears-C4a-C5a
[0242] 21) Shaft-Carrier
[0243] 22) Bearing-Carrier-Shaft
[0244] 23) Lever-Ratio-Changing-Planetary-Mechanism
[0245] 24) Sleeve-Input-Disk
[0246] 25) Collar-Stationary-Differential
[0247] 26) Bearing-Stationary-Differential-Collar-Spur-Gear-Shaft
[0248] 27) Shaft-Stationary-Differential-Collar-Spur-Gear
[0249] 28) a) Small-Bevel-Gear-Stationary-Differential-Collar [0250] b) Large-Bevel-Gear-Stationary-Differential-Collar
[0251] 29) Spur-Gear-Stationary-Differential-Collar
[0252] 30) Spacer-Spur-Gears
[0253] 31) Collar-Dynamic-Differential
[0254] 32) Bearing-Dynamic-Differential-Collar-Spur-Gear-Shaft
[0255] 33) Shaft-Dynamic-Differential-Collar-Spur-Gear
[0256] 34) a) Small-Bevel-Gear-Dynamic-Differential-Collar [0257] b) Large-Bevel-Gear-Dynamic-Differential-Collar
[0258] 35) Spur-Gear-Dynamic-Differential-Collar
[0259] 36) Universal-Joint
[0260] 37) Spiral-Fluted-Collar
[0261] 38) Shaft-CVT-Output
[0262] 39) Compression-Spring
[0263] 40) Thrust-Bearing
[0264] 41) Lever-Ratio-Changing-Spiral-Flute-Mechanism
[0265] 42) Crank-Pin
[0266] 43) Dummy-Crank-Pin
[0267] 44) Cross-Rack-Holder
[0268] 45) Sleeve-Primary-Telescopic
[0269] 46) Sleeve-Secondary-Telescopic
[0270] 47) Pinion
[0271] 48) Shaft-Pinion
[0272] 49) Bearing-Pinion
[0273] 50) Computer-Controlled-Clutch/One-Way-Bearing/Ratchet-1\riechanism
[0274] 51) Output-Gear/Output-Sprocket
[0275] 52) Shaft-Power-Link
[0276] 53) Bearing-Power-Link-Shaft
[0277] 54) Power-Link-Sprocket/Power-Link-Gear
[0278] 55) Dummy-Rack
[0279] 56) Wheel-Vibration-Cancellation-JVIechanism
[0280] 57) Collar-Wheel-Vibration-Cancellation-Mechanism
[0281] 58) Input-Shaft-For-Miter/Bevel-Gears
[0282] 59) Miter/Bevel-Gear
[0283] 60) Clutch-Park/Neutral/Reverse
[0284] 61) Miter/Bevel-Gear-Differential-Output-Shaft
[0285] 62) Intermediate-Gear-Non-Circular-Gear-Connector
[0286] 63) Guide-Intermediate-Gear-Non-Circular-Gear-Connector
[0287] 64) Rack
[0288] 65) Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear
[0289] 66) Shaft-Auxiliary-Input
[0290] 67) Sliding-Collar-Auxiliary-Input-Shaft
[0291] 68) Link
[0292] 69) Shaft-Crank-Pin
[0293] 70) Collar-Crank-Pin-Shaft
[0294] 71) Retainer-Crank-Pin
[0295] 72) Spur-Gear-Crank-Pin-Rack
[0296] 73) Rack-Crank-Pin
[0297] 74) Shaft-Notched-Input
[0298] 75) Disk-Input-Modified
[0299] 76) Ratio-Cam-Disk-Modified
[0300] 77) Cam-Gear
[0301] 78) Cam-Input-Shaft
[0302] 79) Stationary Sun Gear
[0303] 80) Spring-Force-Compensation
[0304] 81) Cam-Spring
[0305] 82) Shaft-Cam
[0306] The working of this CVT can be described by the following simple sequential operations. [0307] a) A Crank-Pin 42 (
[0311] The Cross-Rack-Holder 44 is restricted such that it can move only in the direction that is normal to its slot. A Rack 64 is fastened to the Cross-Rack-Holder 44, such that the Rack 64 is parallel to the Cross-Rack-Holder's 44 direction of movement. In the alternative construction, the Shaft-Crank-Pin 69 is orthogonal to the Shaft-Input 4. The revolution of the Crank-Pin 42 about the longitudinal axis 1021 of Input-Disk 16 is translated to pure linear back and forth movement or reciprocating movement of the Rack 64. This mechanism is commonly known as Scotch-Yoke-Mechanism in the industry. The distance of this linear back and forth movement (stroke) is directly proportional to the radial distance of the Crank-Pin 42 from the longitudinal axis 1021 of the Input-Disk 16. Since the work done is constant, which is a product of force applied multiplied by the distance traveled (F*stroke), for a smaller stroke, the force applied is greater and for a longer stroke, the force applied is smaller. [0312] c) The Rack 64 is linked to a Pinion (
[0314] One main purpose of this invention is to achieve a CONSTANT AND UNIFORM output angular velocity when the input angular velocity is constant and uniform. However, using the steps described above, this is NOT achieved, as the output is sinusoidal. By modifying the rate of change of angular displacement of the Input-Disk 16, a uniform steady output can be achieved. By using a set of Non-Circular-Gears, the Driving-Non-Circular-Gear 8 (
[0315] The design construction is grouped in to modules/mechanism for easier understanding: Detailed description of Assembly, Sub-assembly of components/Modules and their functions: [0316] a) Angular-Velocity-Modifier-Module (
[0326] The Input-Disk 16 has a radial slot, with optionally geared profile 1010 on its perimeter. The
[0327] Ratio-Cam-Disk (
[0354] By this arrangement the dynamic flow train is as described below [0355] I. The Large-Bevel-Gear-Stationary-Differential-Collar 28b spins Small-Bevel-Gear-Stationary-Differential-Collar 28a. [0356] II. The Small-Bevel-Gear-Stationary-Differential-Collar 28a spins the Shaft-Stationary-Differential-Collar-Spur-Gear 27. [0357] III. The Shaft-Stationary-Differential-Collar-Spur-Gear 27 spins the Spur-Gear-Stationary-Differential-Collar 29. [0358] IV. The Spur-Gear-Stationary-Differential-Collar 29 spins Spur-Gear-Dynamic-Differential-Collar 35. [0359] V. The Spur-Gear-Dynamic-Differential-Collar 35 spins Shaft-Dynamic-Differential-Collar-Spur-Gear 33. [0360] VI. The Shaft-Dynamic-Differential-Collar-Spur-Gear 33 thru the Universal-Joint 36 spins the Small-Bevel-Gear-Dynamic-Differential-Collar 34a. [0361] VII. The Small-Bevel-Gear-Dynamic-Differential-Collar 34a spins the Large-Bevel-Gear-Dynamic-Differential-Collar 34b. [0362] VIII. The Large-Bevel-Gear-Dynamic-Differential-Collar 34b spins the Ratio-Cam-Disk 18. Since the two large bevel-gears, the two small bevel-gears, and the spur-gears are identical and same size respectively, when the Collar-Dynamic-Differential 31 is stationary, the angular velocity of the Ratio-Cam-Disk 18 is synchronized with the Input-Disk 16. While the Collar-Dynamic-Differential 31 is being rotated with respect to the Collar-Stationary-Differential 25, there will be a relative angular displacement between the Input-Disk 16 and the Ratio-Cam-Disk 18. [0363] 4) Link Mechanism: [0364] The Shaft-Auxiliary-Input 66 has a cross section with a circular hole in the middle and a non-circular shape for the exterior perimeter. This is paired with a Sliding-Collar-Auxiliary-Shaft 67 with a matching orifice, which is co-axially placed allowing axial movement while restricting rotational motion with respect to each other. A Thrust-Bearing 40 is co-axially placed in contact with one end of the Sliding-Collar-Auxiliary-Shaft 67 and the Sliding-Collar-Auxiliary-Shaft 67 has a pivot 1028 on the other end. One end of a Link 68 is attached to the pivot 1028 and the other end of the Link 68 is either attached to the Crank-Pin 42, as shown in (
[0365] A Cross-Rack-Holder 44, Input-Disk 16, Driven-Non-Circular-Gear 9, Intermediate-Circular-Gears 12 and 20, Crank-Pin 42, Ratio-Cam-Disk 18 , and a Ratio-Changing-Mechanism is used for Two Rectifier-Modules 1001 are used in one Scotch-Yoke-Module (
[0366] Two Racks 64 are placed on the Cross-Rack-Holder 44 with a phase shift of 180.
[0367] Another identical assembly of Scotch-Yoke-Modules (
[0368] ASSEMBLY CONFIGURATIONS: Two assembly configurations are discussed here using the above-mentioned modules and a Gear-Changing-Mechanism.
[0369] Namely: [0370] 1) Sequential configuration and [0371] 2) Siamese configuration.
[0372] The main difference is how the modules and the Gear-Changing-Mechanisms are arranged and the space and the envelope it occupies. The sequential configuration has a smaller foot print but taller than the Siamese configuration. The choice depends on the available envelope for the CVT Sequential Configuration (
[0373] As shown in
TABLE-US-00001 Type of From To connection Input-Shaft Driven-Non-Circular-Gear Axial, Rigid Driven-Non-Circular-Gear Driving-Non-Circular-Gear Radial Driving-Non-Circular-Gear Intermediate gear 1 Axial, Rigid Intermediate gear 1 Intermediate gear 2 Radial Intermediate gear 2 Intermediate gear 3 Axial, Rigid Intermediate gear 3 Intermediate gear 4 Radial Intermediate gear 4 Intermediate gear 5 Axial, Rigid Intermediate gear 5 Input-Disk Radial
[0374] While the working of the CVT can be accomplished just with Intermediate-Circular-Gears-C1 10, Intermediate-Circular-Gears-C4-C5 12 and Intermediate-Circular-Gears-C4a-C5a 20, the Intermediate-Circular-Gears-C2-C3 11 are used to achieve 1:1 ratio between the Driving-Non-Circular-Gear 8 to Input-Disk 16, if the ratio between the Driving-Non-Circular 8 gear and the Driven-Non-Circular gear 9 is not 1:1 or 1:1 where I is an integer or depending on the relationship between the Driving-Non-Circular-Gear 8 and the Driven-Non-Circular-Gear 9.
[0375] Two Rectifier-Modules 1001 are placed next to the Cross-Rack-Holder 44 as shown in
[0376] The Cross-Rack-Holder 44 is free to move only along the direction of the Rack 64 and its movement is restricted by a Frame-Cross-Rack-Holder-Guide 2. A set of telescopic-sleeves, Sleeve-Primary-Telescopic 45 and Sleeve-Secondary-Telescopic 46 are placed on either side of the Cross-Rack-Holder 44. This will decrease the overall size needed for the Cross-Rack-Holder 44 and the Frame-Main-Housing 1. A prong placed on either side of the Cross-Rack-Holder 44 and another on the Sleeve-Secondary-Telescopic 46, to pull and extend the telescopic sleeves and the telescopic sleeves are collapsed by the body of the Cross-Rack-Holder 44. These telescopic-sleeves are caged-in by a Frame-Telescopic-Guide 3 (
[0377] A Power-Link assembly (
[0378] The main purpose of the Power-Link assembly is to link the output from each rectifier-module so that they are connected in sequence with a set overlap and there is a continuous output. The power-link assembly consists of a Shaft-Power-Link 52 that is mounted on two bearings that are placed on the Frame-Telescopic-Guide 3. A gear or sprocket is placed on the Shaft-Power-Link's 52 each ends. The power from the Shaft-Pinion 48 is transmitted to the Shaft-Power-Link 52 through this gear or sprocket. Siamese configuration (
[0379] Here the construction is identical to the Sequential configuration except as noted below. In this alternative assembly configuration, the Scotch-Yoke-Module
TABLE-US-00002 Type From To of connection Input-Shaft Driven-Non-Circular-Gear Axial, Rigid Driven-Non-Circular-Gear Driving-Non-Circular-Gear Radial Driving-Non-Circular-Gear Intermediate gear 1 Axial, Rigid Intermediate gear 1 Intermediate gear 2 Radial Intermediate gear 2 Intermediate gear 3 Axial, Rigid Intermediate gear 3 Intermediate gear 4 Radial Intermediate gear 4 Intermediate gear 5 Axial, Rigid Intermediate gear 5 Input-Disk Radial
Arrangement of Transmission of Power From Engine/Power Source to Input-Disk 16:
[0380] By using a set of non-circular gears, the Driving-Non-Circular-Gear 8 (
[0381] Driven-Non-Circular-Gear 9 (
[0382] The Intermediate-Circular-Gear-C1 10 is mounted on the Shaft-Intermediate-Gear 6, with a direct connection to the Driven-Non-Circular-Gear 9. The Intermediate-Circular-Gears-C2-C3 11 (
[0383] Reason behind the need for a circular gear between the non-circular gears when the pitch-curve 1006 interferes/multiple contacts at the same instant: This also can be eliminated by having multiple layers for the non-circular gears.
[0384] From the equations for the non-circular gear pitch-curves 1006, it can be seen that the radius of the Driven-Non-Circular-Gear 9 is lower than the Shaft-Input 4 it is mounted on over a wide region and reaches zero at two locations. In addition, there is a potential that, due to the shape of the pitch-curve 1006, the Driven-Non-Circular-Gear 9 and the Driving-Non-Circular-Gear 8 may have multiple contact points at a given time. This can be eliminated by inserting an Intermediate-Gear-Non-Circular-Gear-Connector 62 between the two non-circular gears. This increases the distance between the two non-circular gears and eliminates the issue of multiple contact point at any given time.
Crank-Pin-Displacement-Mechanism:
[0385] Two concepts are used namely 1) Axis at slot intersection and 2) Axis on Rack.
[0386] Crank-Pin Axis at slot intersection: This can be achieved by rotating the Ratio-Cam-Disk 18 which has a slot with a certain profile. When the Ratio-Cam-Disk 18 is rotated with respect to the Input-Disk 16 this profile forces the Crank-pin 42 to move in radial direction of the disk's longitudinal axis. This is because the longitudinal axis of the Crank-pin 42 intersects the slot Input-Disk 16 and the slot in the Ratio-Cam-Disk 18. When the Crank-pin 42 is closer to the longitudinal axis 1021 of the Input-Disk 16 the stroke is shorter and since the work done is constant, the force is increased. Similarly, with the Crank-pin 42 is farther from the longitudinal axis 1021 of the Input-Disk 16, the stroke is longer and since the work done is constant, the force is decreased. The challenge here is to have the Ratio-Cam-Disk 18 and the Input-Disk 16 spinning synchronized during normal operation however, and when the ratio change is desired, the Input-Disk 16 and the Ratio-Cam-Disk 18 should have a relative angular velocity. By using one of the three mechanisms described below, a relative angular velocity between the Input-Disk 16 and the Ratio-Cam-Disk 18 can be achieved, when desired.
[0387] Crank-Pin Axis on the Rack: This method to change the location of the Crank-Pin 42 is shown in
Concept Behind Using TelescopicSleeve to Enable Compact Design:
[0388] For this design to work the length of the input slot of the rack assembly has to be a value equal to 2*stroke+Input-Shaft diameter+2* minimum material thickness+2* the distance to reach the rack guide. This entire length has to be guided by the rack guide. Since the rack guide also has to accommodate the travel of the Rack 64, the opening portion of the rack guide should have a width at least as the diameter of the Input-Disk 16 or it will be out of reach when the Rack 64 travels to one side to the extreme. The telescopic-guide extends the support and as a result, the overall length of the rack assembly can be reduced by the distance to reach the rack guide. This also makes it possible for the Frame-Main-Housing Ito be shorter by that distance. Prongs are provided in the design of the rack assembly and in the Sleeve-Secondary-Telescopic 46 to extend the telescopic-sleeves. The body of the Cross-Rack-Holder 44 collapses the telescopic-sleeves.
Concept Behind Use/Working Function of Retainer-Crank-Pin 71:
[0389] The Crank-Pin 42 is much smaller than the Shaft-Input 4. Since both the slots cross each other, there is a potential that the Crank-Pin 42 can slip in to the Input-Shaft slot. This is eliminated by using a Retainer-Crank-Pin 71 (
Concept of Overlap of Power Transmission:
[0390] To ensure smooth transition from one Rectifier-Module 1001 to the next, for a brief period both the Rectifier-Modules 1001 are active and engage when the output from both of them reach a constant and uniform value. The overlap between each pair of adjacent Rectifier-Modules is substantially identical (
Modules and Their Assembly Layout and Constraints:
[0391] All the four Rectifier-Modules 1001 share one common Shaft-Input 4 and one common Driving-Non-Circular-Gear 8. Two of the Rectifier-Modules 1001 share a common Input-Disk 16 and a Gear-Changing-Mechanism. The Racks 64 are placed at 90 phase shift to the next. To accommodate this, the Driven-Non-Circular-Gear 9 is oriented at 45 with the Driven-Non-Circular-Gear 9 phased at 45 relative to the other Driven-Non-Circular-Gear 9. Also due to the fact the Non-Circular-Gears are symmetric it can be also oriented at 135. This adds up to a 90 phase shift between Racks 64.
Concept of Power Transfer/Link Between Modules:
[0392] When the Rectifier-Modules 1001 operate in sequence, they must be linked before the power is transferred to the Wheel-System 1022. This is achieved by using a Shaft-Power-Link 52 that has Output-Gear/Output-Sprocket 51 to link the output from each Rectifier-Module 1001 such that it has a continuous power to the Wheel-System 1022. The power is also transferred in sequence. The Rectifier-Modules 1001 are oriented such that their Non-Circular-Gears are in functional region 1017 in sequence with overlap 1016 (
Reverse Gear Mechanism:
[0393] The output from the Shaft-CVT-Output 38 or the Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is coupled with Input-Shaft-For-Miter/Bevel-Gears 58. The output of these Miter/Bevel-Gear 59 will therefore rotate in opposite directions. The Miter/Bevel-Gear-Differential-Output-Shaft 61 of this differential-mechanism is placed co-axial to the output Miter/Bevel-Gear 59 with clearance so that it is free to spin independently with respect to the output Miter/Bevel-Gear 59. Two collars with a clutch are placed on the Jviiter/Bevel-Gear-Differential-Output-Shaft 61 allowing them to move axially. These can be made to link with either of the output Miter/Bevel-Gear 59, which rotate in opposite direction. When one of the collars is made to link via the Clutch-Park/Neutral/Reverse 60, by means of clutch, with a particular output Miter/Bevel-Gear 59 and the Miter/Bevel-Gear-Differential-Output-Shaft 61 will rotate in a particular direction. It will reverse its direction if the link is swapped to the other Miter/Bevel-Gear 59.
Neutral Gear Mechanism:
[0394] When the collars are not in link via the Clutch-Park/Neutral/Reverse 60 with any of the Miter/Bevel-Gear 59, the collar and the e Miter/Bevel-Gear-Differential-Output-Shaft 61 is not restricted and, therefore, they are free to spin in any direction and function as a neutral gear.
Park Mechanism:
[0395] When the collars are in link via the Clutch-Park/Neutral/Reverse 60 with both the Miter/Bevel-Gear 59, the collar is restricted from spinning and the Miter/Bevel-Gear-Differential-Output-Shaft 61 is totally restricted and, therefore, they are restricted to spin in any direction and functions as a parking gear.
Feature and JVIechanism to Compensate Vibration:
[0396] 1. Dummy-Crank-Pin 43: The Crank-Pin 42 is placed off-center when the Input-Disk 16 revolves. This imbalance will result in vibration. To compensate this, a Dummy-Crank-Pin 43 is placed at same distance 180 apart. This is moved by the same Ratio-Cam-Disk 18 that moves the Crank-Pin 42. This movement is identical to the movement of the Crank-Pin 42. The cam slots are made identical at 180 apart.
[0397] 2. Dummy-Rack 55 for counter oscillation: As the Input-Disk 16 rotates the Cross-Rack-Holder 44 has an oscillatory motion which will result in vibration. It is cancelled by having an appropriate mass oscillating in the opposite direction. This is achieved by attaching a Wheel-Vibration-Cancellation-Mechanism 56 in contact with the Rack 64, which will spin back and forth. Bringing an appropriate mass in contact with the Wheel-Vibration-Cancellation-Mechanism 56 at 180 apart will compensate for this vibration.
Co-Axial Input-Output Option Feature:
[0398] When co-axial input and output is desired, this can be achieved by adding a Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 which has an internal gear, namely a ring gear placed co-axial with Shaft-Input 4. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 will radially connect with all the Output-Gear I Output-Sprocket 51 and the Power-Link-Sprocket/Power-Link-Gear 54, directly or via an intermediate gears or planet gears of a planetary gear system.
Converting CVT to an IVT (Infinitely-Variable-Transmission):
[0399] Having a co-axial input and output allows the CVT to function as a IVT. This can be achieved by adding a Planetary-Gear-System with a Sun-Gear, Ring-Gear and Planets supported by Carriers, and linking with Shaft-Input 4, the Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65.
[0400] The following are the options to achieve this: [0401] a) The Shaft-Input 4 is directly linked to the Sun-Gear of the planetary-Gear-System with following 2 sub-options [0402] a. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Carrier of the Planetary-Gear-System and Ring-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022 [0403] b. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is linked to the Ring-Gear of the Planetary-Gear-System and the Carrier functions as the final output or wheel system 1022. [0404] b) The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Sun-Gear of the Planetary-Gear-System with following 2 sub-options. [0405] a. The Shaft-Input 4 is directly linked to the Carrier of the Planetary-Gear-System and the Ring-Gear of the Planetary-Gear-System and the Ring-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022. [0406] b. The Shaft-Input 4 is directly linked to the Ring-Gear of the Planetary-Gear-System and the Carrier functions as the final output or wheel system. [0407] c) The Shaft-Input 4 is directly linked to the Ring-Gear of the planetary-Gear-System with following 2 sub-options [0408] a. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Carrier of the Planetary-Gear-System and Sun-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022. [0409] b. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is linked to the Sun-Gear of the Planetary-Gear-System and the Carrier functions as the final output or wheel system 1022. [0410] d) The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Ring-Gear of the Planetary-Gear-System with following 2 sub-options. [0411] a. The Shaft-Input 4 is directly linked to the Carrier of the Planetary-Gear-System and the Carrier of the Planetary-Gear-System and the Sun-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022. [0412] b. The Shaft-Input 4 is directly linked to the Sun-Gear of the Planetary-Gear-System and the Carrier functions as the final output or wheel system 1022. [0413] e) The Shaft-Input 4 is directly linked to the Carrier of the planetary-Gear-System with following 2 sub-options [0414] a. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Ring-Gear of the Planetary-Gear-System and Sun-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022. [0415] b. The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is linked to the Sun-Gear of the Planetary-Gear-System and the Sun-Gearr functions as the final output or wheel system 1022. [0416] f) The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is directly linked to the Carrier of the Planetary-Gear-System with following 2 sub-options. [0417] a. The Shaft-Input 4 is directly linked to the Ring-Gear of the Planetary-Gear-System and the Ring-Gear of the Planetary-Gear-System and the Sun-Gear of the Planetary-Gear-System functions as the final output or wheel system 1022. [0418] b. The Shaft-Input 4 is directly linked to the Sun-Gear of the Planetary-Gear-System and the Ring-Gear functions as the final output or wheel system 1022.
[0419] In other words, The Co-Axial-Output-Element-With-Internal-Gear/Planetary-Gear 65 is connected to one of the three elements, either a Ring-Gear, a Carrier, or a Sun-Gear of a Planetary-Gear-System. The Shaft-Input 4 is connected to one of the remaining two elements of the Planetary-Gear-System. The third remaining element of the Planetary-System functions as the final output or wheel system 1022. This converts the CVT to an IVT.
Concept of Temporary Storage of Power in a Flywheel:
[0420] When the power from the engine or power source is not transmitted to the final output or the wheel system, the power can be transferred to a flywheel system 1023 temporarily and transferred back to Shaft-Input 4 and then to the final output or the wheel system 1022 or directly to the final output or wheel system 1022 when desired.
Compensating for Deviation in Rack Movement with Cams:
[0421] It is beneficial to have smooth and gradual transitions in the rack movement profile to improve the life of the transmission. As shown in
[0430] It may not always be possible to generate perfect non-circular gears to meet the above desired Rack 64 movement. If the pitch curves 1006 of the Non-Circular-Gears 8 & 9 do not to achieve this desired Rack 64 movement, a Cam-Spring 81 and a planetary system can be used to compensate for any deviations from the desired Rack 64 movement profile. To achieve this, a Stationary Sun Gear 79 with respective to the frame is placed co-axial with the Driven-Non-Circular-Gear 9 as shown in
Development of Mathematical Model:
[0431] The main aim is to determine a mathematical formula for the pitch-curves 1006 of the non-circular gears such that v.sub.rack (linear velocity of the Rack 64) is constant. Pitch-curves 1006 are needed to develop non-circular gears.
[0432] The pitch curves for the Driving-Non-Circular-Gear 8 and Driven-Non-Circular-Gear 9, when expressed using Cartesian coordinates (X.sub.1, Y.sub.1) and (X.sub.2, Y.sub.2) respectively, as a function of an angle are,
where () is a solution to a piece-wise differential-equation that uses a Sine function
Where the boundary conditions are:
Or a differential equation using a Cosine function
With the boundary conditions below:
Where is angular displacement of the Driving-Non-Circular-Gear 8 [0433] is the angular position of the Driven-Non-Circular-Gear 9 [0434] .sub.1.sub.
to .sub.1.sub.
are non-functional regions [0435] k.sub.i is an unknown constant that needs to be solved for using the boundary conditions for the Input-Disk 16 ith rotation [0436] the constant of integration also needs to be solved for using boundary conditions [0437] is the cutoff angle between the first functional and non-functional regions [0438] N is the number of times the Input-Disk 16 rotates when the Driven-Non-Circular-Gear 9 rotates once [0439] n is the number of times the Driven-Non-Circular-Gear 9 rotates when the Driving-Non-Circular-Gear 8 rotates once [0440] i refers to the ith rotation of the Input-Disk 16 starting with i=0 and going up to i=N*n1
[0441] In our simple design, the following parameters were used:N=2, n=2. So using the Sine function
And the boundary conditions are:
Using the Cosine function we get
Where the boundary conditions are:
In the most general form, () is a solution to a piece-wise differential-equation
function of any linear or nonlinear curve connecting the points
function of any linear or nonlinear curve connecting the points (.sub.2.sub.
function of any linear or nonlinear curve connecting the points (.sub.4.sub.
k.sub.i if
function of any linear or nonlinear curve connecting the points (.sub.1.sub.
function of any linear or nonlinear curve connecting the points (.sub.3.sub.
Where the boundary conditions are
Where
[0449] is the angular displacement of the Driving-Non-Circular-Gear [0450] is the angular displacement of the Driven-Non-Circular-Gear [0451] i refers to the i-th revolution the Input-Disk from 0 to N*n1 with the 1.sup.st rotation being i=0; [0452] N is the number of times the Input-Disk spins when the Driven-Non-Circular-Gear spins once; The value of N will depend on the radii of the intermediate circular gears. [0453] n is the number of times the Driven-Non-Circular-Gear spins when the Driving-Non-Circular-Gear spins once; [0454] the regions where the piece-wise function is constant are functional regions and the regions where the piece-wise function is not constant are non-functional regions which can be linear or non-linear functions of ; [0455] .sub.1.sub.
[0459] The piece-wise function can be set up for a 1 whole cycle of the rack movement function or multiple cycles, or part of a cycle (only if using symmetric rack movement function). Reflection techniques can be used to get the complete pitch curve for the driving and driven non-circular gears. [0460] t.sub.n+1.sub.
Compensating for Force Required to Move the Crank Pin to Change Input to Output Ratio:
[0465] It will take a large amount of force to be applied on the Lever-Ratio-Changing-Planetary-mechanism 23 to move the Crank-Pin 42 since it is opposing the load from the output. This force is dependent on the torque required to overcome the load on the output by the Input-Disk 16, the angle of the input slot to the direction of Rack 64 movement and the distance of the Crank-Pin 42 to axis of rotation of the Input-Disk 16. The direction and magnitude of this force changes as shown in the graph in
[0466] Here, [0467] the force acting on one Angular-Velocity-Modifier-Module is R.sub.fcos (.sub.a()) and [0468] the other Angular-Velocity-Modifier-Module is R.sub.fsin (.sub.b()) [0469] and the sum is [0470] R.sub.fcos (.sub.a())+R.sub.fsin(.sub.b()), [0471] where [0472] R.sub.f is the force experienced by the Rack 64 of the respective module at any given time. (.sub.a()) and (.sub.b()) are angles of rotation () of the two Driven-Non-Circular-Gears 9 which are functions of the rotation of the Driving-Non-Circular-Gear (). A graph showing this force as a function of the angular displacement of the Driving-Non-Circular-Gear 8 is shown in
[0473] The two Spring-Force-Compensation 80 are attached the operating Lever-Ratio-Changing-Planetary-Mechanism 23 acting on the Cam-Input-Shaft 78 (as shown in
[0474] Springs with a spring constant that it close to the the average value of the force required when the Crank-Pin 42 is at its two extreme positions, over the distance of the two extreme position can be chosen.