AUTOMATIC POOL CLEANER GEAR MECHANISM

Abstract

A Gear change and gear change biasing mechanism for use in an automatic swimming pool cleaner in slightly off-set paths to cover a mostly square area, a fourth larger turn 46 will steer cleaner to a different area of pool indicated by arrow 47 where the pattern will repeat itself.

Claims

1. In an automatic pool cleaner comprising a first gear 11 and a second gear 12, a mechanism for changing between the first gear and the second gear, the mechanism comprising: an oscillatable gear carrying assembly moveable between a first position wherein the first gear 11 is engaged to a worm 10 and a second position wherein the second gear 12 is engaged to the same worm; an actuating arrangement for selecting one of said positions by initiating movement of the gear carrying assembly to urge the assembly towards the selected one of said positions; the first gear and the second gear being mounted on the oscillitable assembly and when the first gear is engaged, the cleaner is driven to move in a first direction and when the second gear is engaged the cleaner is driven in another direction.

2. The mechanism as claimed in claim 1 where the first gear 11 and second gear 12 within the oscillatable gear carrying assembly is always engaged to one another by means of a third gear 20, the third gear being mounted in a fixed axially oriented position to form a pivot point for the oscillatable gear carrying assembly when rotated to position to engage either the first or second gears with the worm, the relationship of rotation between the worm and first and second gears to be determined so that when under operation torque or friction applied to the third gear 20 either the first or second gear will be biased to a swift and fully engaged position with the worm after first or initial contact is made with the worm.

3. The mechanism as claimed in claim 1 where the worm has a left and right hand directional thread; so that when the first gear engages to one type thread on the worm the cleaner is driven to move in a first direction and when the first gear disengages and second gear engages the opposite type of thread the cleaner is driven to move in another direction.

4. The mechanism as claimed in claim 2 where the worm has a left and right hand thread; so that when the first gear engages to one type thread on the worm the cleaner is driven to move in a first direction and when the first gears disengages and the second gear engages the opposite type of thread the cleaner is driven to move in another direction.

5. The mechanism as claimed in claim 2, comprising two oscillatable assemblies positioned on the same axial position so that one side of the cleaner may reverse in relation to the other when one oscillatable assembly is actuated towards a different position of rotation than the other.

6. The mechanism as claimed in claim 5 where both oscillatable assemblies are actuated to any of said position by a single cam device to form a fixed timed relationship between the two oscillatable assemblies in a manner where the cleaner will always follow a predetermined path.

7. The mechanism as claimed in claim 6 where the cam will incorporate a predetermined pattern with at least one reverse direction and at least one steering direction, where a steering action will immediately be followed by a reversing of direction of the cleaner.

8. The mechanism as claimed in claim 2 where the fourth gear 6 is engaged to a fifth gear 2, where the mesh tolerance between the fourth and fifth gears is variable.

9. The mechanism as claimed in claim 8 where the fifth gear 2 is mounted circumferentially to a roller or wheel arrangement.

10. The mechanism as claimed in claim 9, where the roller incorporates a drive pulley with at least one tooth to coincide with at least one formation on an endless track, where the endless track when positioned on the pulley has an outside circumference smaller than the outside diameter of the roller.

11. The mechanism as claimed in claim 5 where one assembly will provide input to one side of the cleaner and the other assembly to the opposite side of the cleaner, where a fourth gear 6 in either assembly will be meshed with a fifth gear 2 where the mesh tolerance between the fourth and fifth gears can be varied, where the fifth gear is mounted circumferentially to a set of drive wheels, rollers or pulleys at both sides of the cleaner, where the pulleys have at least one tooth, where a track with at least one inside formation will provide drive to a second set of drive wheels, rollers or pulleys positioned opposed the first set of rollers, wheels or drive pulleys.

12. The mechanism as claimed in claim 11, where the gear mounted circumferentially with the worm is molded from a flexible material

13. A device for cleaning a submerged surface in a fluid comprising a drive mechanism, where the drive mechanism is connected to a fluid in and outlet, where movement of fluid through the in to outlet will allow a drive mechanism to provide rotational input to a worm, where an oscillatable gear carrying assembly will include a first and a second gear, where the first and second gears will be permanently meshed with a third gear where the third gear is mounted on a fixed axial position in relationship to the cleaner body, where the first and second gear together with the oscillatable assembly will rotate around the fixed axial position of the third gear, whereby a means to pivot the gear carrying assembly around the axially fixed position of the third gear axis will allow the first and second gear to alternatively engage and disengage with the worm, where the third gear forms a fixed axially orientated position for output drive to the rest of a drivetrain, where the pool cleaning device will move in one direction when the first gear is engaged to the worm while the second gear is disengaged and an opposed direction when the second gear is engaged to the worm while the first gear is disengaged from the worm; whereby the orientation of rotation of the gears is such that when friction or load applied to the third gear the gear carrying assembly will upon initial contact with the worm bias the relevant first or second gears to pivot towards a fully engaged position with the worm.

14. A device as claimed in claim 13 whereby the worm will have a left and right hand type thread where the first gear will engage to one type thread to rotate in an opposed direction to the second gear when the second gear engages to the opposed type thread.

15. An automatic cleaner comprising a mechanism FIG. 10-10.3, where a first input gear 48 and a second input gear 49 is permanently engaged to each other, where the first input gear 48 and the second gear 49 is positioned in an axial fixed orientation, where a third gear 50 and a fourth gear 51 within an oscillatable gear carrying assembly 53 is permanently engaged (meshed) to one another by means of a fifth gear 52, the fifth gear being mounted in an axially oriented fixed position to form a centrally positioned pivot point for the oscillatable assembly 53, when either of the third or fourth gears together with the oscillatable assembly is rotated around an axis of the fifth gear 52 to engage with a first or second input gear; the direction of movement of the cleaner to be in one direction when the first gear 48 is engaged to the third gear 50 and another direction when the first gear 48 disengages and the second gear 49 engages the fourth gear 51; the relationship of rotation between first input gear 48 and the second input gear 49 to the third gear 50 and fourth gear 51 to be determined so that when torque or friction applied to the fifth gear 52 either the third or the fourth gear together with the oscillatable assembly will be instantly biased to a fully engaged position with the first or second input gear when first or initial contact is made with the first input gear 48 or the second input gear 49.

16. In a swimming pool cleaner a single worm gear mated with a worm, where the worm has 2 types of directional thread, where the worm gear can be moved by an actuating mechanism in a linear fashion from a first position where the worm gear is mated to one type of thread on the worm to a second position where the worm gear will be mated to an opposed type of thread on the worm, when the worm gear will rotate in one direction when mated to one type of thread on the worm and to another direction when mated to the other type of thread on the worm.

17. A Device as claimed in claim 16 where 2 single worm gears are mated with two dual thread worms at opposed sides of the cleaner so when one worm gear engages a different thread pattern on one worm and the opposed worm gear engages the opposed type of thread on the other worm the one worm gear will rotate in an opposite direction of the other worm gear.)

18. A device as claimed in claim 5 whereby a cleaning path will simulate parallel cleaning paths whereby a short turn will precede a reverse of direction change; where at least one of the turns will be of longer duration to allow a turn of larger degree of no more than 360 degree to precede a direction change to allow the cleaner to proceed to a different area within the pool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] 1.) FIG. 1 depicts an isometric view showing the drive module and roller configuration.

[0031] 2.) FIG. 2 depicts a side on and isometric view of the power module with outer cover removed, to show the drive unit and relationship between the various parts

[0032] 3.) FIG. 3 to FIG. 3c depicts a side on and isometric view gear carrier oscillatable assembly with integrated cam follower and stops including a series of processes for engage and disengagement

[0033] 4.) FIG. 4 depicts a close up view of the oscillatable gear carrying assembly end stop cap

[0034] 5.) FIG. 5 depicts a Removable back plate

[0035] 6.) FIG. 6, 7, 8. 9 depicts variations of worm reversing mechanisms.

[0036] 7.) FIGS. 10 to 10.3 depicts a variant of a biasing mechanism in conjunction with normal type gears

[0037] 8.) FIG. 11 depicts a preferred pattern for cleaning

DETAILED DESCRIPTION OF THE DRAWINGS

[0038] In FIG. 1 the turbine driven power module 5 provides drive output through two gears 6 situated at a left side 1A and right side 113 of the power module, direction of rotation of gears 6 on each side can independently or together be reversed from a clockwise to anticlockwise direction and vice versa. A Gear 6 on each side engage with a gear 2 in line with each roller, gear 2 is coupled to rollers 1 which in turn is coupled to track pulleys 3, track 4 provide drive between rollers 1 and rollers 8 positioned opposed rollers 1. Rollers 1 and 8 is split in the middle 7, so each side of rollers and track combination can individually be driven by the power module 5 without interference from one another. Depending on the direction of rotation of gear 6 on each side therefore the cleaner can steer to either side or change direction in a straight line.

[0039] The relationship between gear 6 and gear 2 is such that the tolerance of the meshing between the gears 6 and 2 can be varied, in the preferred embodiment the design had been optimized to allow sufficient flex between the drive module 5 and chassis with rollers 1 and 8 so most type of debris will be able to pass between gears 2 and 6 when in operation. The rotational direction between gear 2 and gear 6 is also such that towards the direction of movement of the cleaner debris will be pushed away from the gears instead of drawn in.

[0040] For the preferred embodiment the arms 9 FIG. 1 is shaped like a bow to allow flexing between the upper and lower segments while making the cleaner sturdy under normal operation. Gear 2 can also be molded from a flexible material.

[0041] When gears 6 on both sides of power module 5 rotate in the same direction the pool cleaner will be driven to move either forward, or reverse in a straight line depending on the direction of rotation.

[0042] When gear 6 on only one end of the power module 5 is reversed the track 4 and roller combination on the affected side will also reverse rotation, in turn this will allow the cleaner to steer due to one side going forward and one reversing. This procedure will repeat itself on either side at predetermined intervals determined by the centrally positioned cam 15 FIG. 2. The preferred cam 15 design is such that one of the gears 6 will reverse rotation slightly before or after the opposed gear 6 so a steering effect occurs before or after a reverse or forward directional change.

[0043] FIG. 2 depicts the drive module 5 with cover removed, turbine 19 will rotate when suction or pressure applied, a gear 21 coupled to turbine 19 engages with a spur gear 2A that forms an integrated part of worm 10, this in turn will cause worm 10 to rotate. Worm has opposed directional threads, as shown in FIG. 2 and FIG. 3. Gears 11 and 12 is a single gear with two integrated types of teeth profiles, one set to mesh with the worm 10 and another profile to mesh with a third gear 20. The thread pattern on worm gear 11 and 12 that engages the worm has opposed teeth profiles to mate with the worm's dual opposed thread.

[0044] In FIG. 2, the two worms 10 will provide input to the output gears 6 by means of alternative engagement with a first worm gear 11 and a second worm gear 12 in two gear carrying assemblies to provide steering or reversing functions at both sides of the cleaner. Worm gear 11 is engaged with worm 10 and will rotate in direction shown by arrows 22, a third gear 20 will therefore rotate in the opposite direction as shown by arrows 23. The gear carrying assembly FIG. 3 is designed so at least one of the worm gears 11 or 12 will be engaged with the worm 10 while the other is disengaged, for a brief moment however when engage and or disengagement takes place both worm gears 11 and 12 will be disengaged from the worm 10. Worm gear 12 direction is not applicable in FIG. 2 as during this phase it will function as an idler gear.

[0045] In FIG. 3 one of the gear carrying assemblies is depicted in greater detail, it consists of a first worm gear 11 and a second worm gear 12, cam follower 14 and end stop cap 18. The assembly is held together by 2 internal shafts (not shown) between cam follower 14 and stop cap 18 that also function as the axles for worm gears 11 and 12. Cam follower 14 has a centrally positioned hole to coincide with the fixed axle 26 as a means to allow rotation of the complete assembly on the shaft 26. The complete gear carrying assembly therefore will be able to rotate freely around the axle 26 and a third output gear 20 as shown by the arrow 25 in FIG. 3. In turn output gear 20 can also rotate freely on the shaft 26 in terms it receives input from the two worm gears 11 and 12.

[0046] As depicted in FIG. 3A when worm gear 11 is engaged with worm 10 and worm gear 12 disengaged, rotation of gear 11 will be as depicted by arrows 27 and in turn gear 20 as by arrows 28. Due to the rotational relationship as shown by arrows 27 and 28, between the worm 10, worm gear 11 and 12, and gear 20, as soon as either worm gear 11 or 12 make initial contact with worm 10 as shown in greater detail in FIG. 3B the mating worm gear will due to frictional forces of the drivetrain on gear 20 be biased to a swift fully engaged position with the worm 10. To illustrate this arrow 31 in FIG. 3B indicate the direction the gear carrier assembly with worm gears will rotate should gear 20 have a slight amount of friction applied to it when initial contact made with worm 10. In practice it has been found that friction from the drivetrain is sufficient to create sufficient load on gear 20 to enable the carrier assembly with worm gears to swiftly toggle to the fully engaged position with worm 10 as shown in FIG. 3C to reverse rotation as shown by arrows 31 and 32. In FIG. 3C now worm gear 11 will have the function of an idler gear. Arrows 29 and 30 indicate the direction of force on the gear carrying assembly when worm gears 11 or 12 are engaged. Apart from the rotational relationship there are no devices needed to keep the worm-gears 11 or 12 engaged to worm 10. Due to the positive biased engagement the end cap stops 18, shown in greater detail in FIG. 4, will prevent worm gears 11 or 12 from meshing too tight with worm 10.

[0047] The engage and disengagement of worm gears 11 and 12 are by means of actuating mechanism comprising a cam 15 FIG. 2 providing input to cam followers 13 and 14 on 2 gear carrying assemblies.

[0048] Cam 15 rotates from input provided by worm 16 with integrated worm gear 17 in turn engaged with worm 10. At predetermined intervals cam followers 13 and 14 will be biased by the cam profile to either engage or disengage worm gear 11 or 12 with worm 10 depending on the position of the cam followers 13 and 14 in relation to the cam 15. By engaging and disengaging the worm gears 11 and 12 either side of the unit can be made to steer or change direction, the duration of such steering and or direction change will be determined by the specific cam design. Cam 15 will only be in contact with follower 13 and 14 during the engage or disengagement phase, as soon the gear carrying assembly toggled to the fully engaged position due to the biasing influence determined by the rotational relationship between the worm gears 11 and 12, worm 10 and gear 20 there will be no further surface contact between cam 15 and cam follower 13 or 14. Due to the positive biased engagement from the rotational relationship between the gears 11, 12 and worm 10 around gear 20 external stops 18 FIG. 4 within the gear carrying assembly will prevent too tight mesh between gear 11, 12 and worm 10.

[0049] In FIG. 5 the removable back plate 33 is shown for ease of removal for debris.

[0050] In FIG. 6 a variation of the relationship of a single thread worm 6A to worm gears 11 and 12 are shown, in this embodiment a first worm gear 11 and a second worm gear 12 is positioned at opposite sides of a single directional thread worm, integrated in worm 6A is a spur gear 6B. By using the biasing mechanisms described an oscillatable assembly 37 can be rotated in direction as depicted by arrows 36. When worm gear 11 engages the single tread worm 6A it will rotate in direction as shown by arrows 34 when worm rotates in direction of arrows 35. When the cam actuating mechanism rotate the assembly 37 to disengage worm gear 11 and engage worm gear 12, the rotational direction will be reversed as shown by arrows 38. Not shown here is the addition of a third meshed gear to function as a biasing mechanism and output gear similar to gear 20 to allow the positive engagement toggle effect to the worm.

[0051] FIG. 7 depicts an alternative version where the worm gears 11 and 12 stay in a fixed position while a single thread input worm 6A is shifted between the two worm gears 11 and 12 in direction of arrows 39. The arrows 34 and 38 depict the direction of rotation when worm gears 11 or 12 engage the worm.

[0052] FIG. 8 depicts a version where a dual thread worm similar to worm 10 can slide laterally in direction of arrows 41 and only a single worm gear 11 will alternatively engage with either thread direction to reverse rotation as shown by arrows 40 and 42.

[0053] FIG. 9 depicts yet another variant where in this case the input worm 10 stays in position while a single worm gear 11 can shift in a linear fashion between two opposed threads as shown by arrows 43. Worm gear 11 will now change rotational direction as depicted by arrows 40 and 42.

[0054] In FIG. 10 a variation of the gear carrying and toggle effect biasing mechanism is shown with a normal gear type such as spur or helical. A first Gear 48 Is permanently engaged with a second gear 49, either gear 48 or 49 can be the driven input gear. Gear 48 and 49 is axially mounted in a fixed position so they can rotate but not pivot away from their respective positions.

[0055] An oscillatable gear carrying assembly 53 consist of a third gear 50 and a fourth gear 51 permanently engaged with a fifth gear 52. Fifth gear 52 is axially mounted to a fixed position and also forms the central pivot and mounting point for the gear carrying assembly 53 so that the gear carrying assembly 53 can together with gear 50 and 51 rotate around the axis of the fifth gear 52.

[0056] Gear 52 also functions as a non oscillatable output gear for the rest of the drivetrain.

[0057] During operation and as shown in FIGS. 10 to 10.3 the rotation of gear 48 and 49 will always be in direction of arrows D and E. Oscillatable assembly 53 can rotate freely around axis of gear 52 in directions as shown by arrows F. A cam mechanism for actuating assembly 53 to rotate around the center pivot point of axis of gear 53 is not shown but is similar as described for the other embodiments. In FIG. 10 the third gear 50 and fourth gear 51 is stationary as they are not engaged with rotating first gear 48 or second gear 49. During operation as soon a cam mechanism (not shown) bias the gear carrying assembly 53 to the initial contact position as shown in FIG. 10.1 gear 51 will engage with driven input gear 49, as soon initial contact is made as seen in close up view FIG. 10.1 A, the rotational relationship between input gears 48 and 49 to gears 50 and 51 within the oscillatable assembly around gear 52 will create a swift toggle effect in direction of arrows G to a fully engaged position as shown in FIG. 10.2 and close up view 10.2 B. As in the other embodiments this toggle effect is achieved due to friction from the drivetrain on gear 52. Gear 52 will now rotate in direction H.

[0058] To illustrate the procedure for the toggle effect mechanism based on gear rotational relationship in FIG. 10.3 C a close up of the third gear 50 relationship with fifth gear 52 shows how if gear 52 would be prevented from turning, when gear 50 rotates in direction of arrows J the assembly 53 will together with the gear 50 be biased upwards to a direction indicated by arrow K which is towards the first input gear 48. Gear 52 will now rotate in direction of arrows L. Under normal condition gear 52 will not be prevented from turning but in tests it has shown that the friction of the drivetrain on gear 52 is sufficient to display a behavior similar to as if the gear 52 Is held stationary in terms of creating a swift toggle effect in the direction indicated by arrows K. For the same reason the continuous friction on gear 52 from the drivetrain will keep either gear 50 or 51 engaged to either gear 48 or 49 respectively. In FIG. 10.1 where gear 51 is engaged to gear 49 the relationship is the same to create the toggle effect and positive engagement without need for holding the gear engaged by any other means. As in the other embodiments due to the positive engagement stops (not shown) within the gear carrying assembly will prevent gear mesh between gear 48 and 50 and 49 with 51 from being too tight.

[0059] FIG. 11 illustrates the preferred cleaning path simulating a broom-sweep pattern that has been found to be very efficient to clean a pool of any size, as can be seen the path indicated by arrows 45 depicts a slight steering function with every direction change, this will allow the cleaner 44 to move in slightly off-set paths to cover a mostly square area, a fourth larger turn 46 will steer cleaner to a different area of pool indicated by arrow 47 where the pattern will repeat itself.