Pulley assembly for segmented pulley transmission and actuator system thereof

Abstract

A pulley assembly (120) for engaging an annular member (118) includes a first pulley (124), a second pulley (126), and at least one transition segment group (128, 130), the at least one transition segment group including one or more transition segments (152, 162a, 162b), the one or more transition segments being independently movable between an engagement region and a disengagement region to transition the annular member (118) between the first pulley (124) and the second pulley (126). An actuator system (122) includes a support structure (220), an actuator subassembly (222, 226) secured to the support structure (220), and a stator (224, 228). The actuator subassembly (222, 226) includes a follower (250) and a slide plate (248), the slide plate being movable in a circumferential direction between an advanced position and a retracted position in response to an electromotive force generated on the slide plate (248) by the stator (224, 228). When the slide plate (248) moves between the advanced position and the retracted position, the follower engages the cam surface (262) of the slide plate (248) to move in the axial direction between the extended position and the retracted position.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 642,979, filed on March 14, 2018, and entitled "Electrical System Features, Screw Drive Configurations, and Advanced Geometry Designs in Pulley Segment and Support Surface Designs in Synchronous Segmented Interchange Pulley Transmission Systems," the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to transmissions, and more particularly to a pulley assembly and actuator system thereof for a segmented pulley transmission. Background Art

[0004] Transmissions are well known and can be used to vary the gear ratio between rotating elements. Potential applications for transmissions are very wide and include motor vehicles, human powered vehicles, marine vehicles and heavy machinery such as pumps, turbines, mixers, winches, centrifuges and shredders.

[0005] Clutchless multi-ratio transmissions allow the transmission ratio between rotating elements to be changed while the transmission is under load. Certain mechanical problems may affect clutchless multi-ratio transmissions that limit their widespread use; specifically, in practical applications, the ability of such transmission systems to operate effectively and efficiently at high speeds or high loads. In addition, ratcheting, slippage, and tensioning problems may limit the commercial viability of such transmissions by reducing their reliability, reducing their efficiency, and increasing wear. Therefore, synchronized segmented interchange pulley transmission systems (SSIPTS) have been developed to reduce or alleviate at least some of these mechanical problems.

[0006] For example, U.S. Pat. No. 8,753,236 to Wong et al. discloses a SSIPTS in which a pulley assembly is mounted on a shaft. The pulley assembly includes: a core pulley having a first set of mating features on its outer peripheral surface; and a pulley segment group, the pulley segment group including a plurality of pulley segments, the plurality of pulley segments being slidably mounted in the pulley assembly and arranged in a ring concentric with the core pulley. The pulley segments can be individually actuated in and out of the pulley assembly. The pulley segments have a second set of mating features on the outer peripheral surface that mates with the first set of mating features. The annular drive member has corresponding mating features on the inner surface for engaging the first set of mating features of the core pulley and the second set of mating features of the pulley segments in the engaged position. The contact between the annular drive member and the core pulley defines a contact area. When the pulley segments are outside the contact area, the actuator actuates the pulley segments between the engaged position and the non-engaged position.

[0007] Wong's U.S. Patent No. 9,816,598 discloses a key pulley segment for SSIPTS, which is the first or last segment in the pulley segment arranged to engage with the annular member. The first or last key segment teeth that engage or disengage the annular member, respectively, are shortened or fully pruned, and the pulley segment adjacent to the key segment is elongated so that a portion of the tooth profile extends toward the key segment. The shortened one or more teeth and the elongated adjacent segment together allow many pulley segments to be designed as key segments. The fully pruned teeth are designed to create a support surface for the annular member on the key segment. The elongated adjacent segment may have an extension that slidably cooperates with the support surface of the key segment to receive radial support therefrom. Multiple pulley segments from different pulley segment groups may be connected or configured to move together in a unified stack. The unified stack may be moved by a cam or roller cam system. The cam mounted on the base engages the roller outside the contact area and moves the individual segments of the unified stack into or out of engagement via the roller arm. The rollers may be actuated into and out of engagement with the cams by electromagnets that may be fixedly mounted in an array.

[0008] Although the contributions of known segmented pulley transmissions are commendable, improvements and alternatives are generally needed. It is therefore an object of the present invention to provide a novel pulley assembly for a segmented pulley transmission and a novel actuator system therefor. Summary of the invention

[0009] It should be understood that this summary is provided to introduce some concepts in a simplified form, which concepts will be further described in the detailed description of the following embodiments. This summary is not intended to limit the scope of the claimed subject matter.

[0010] Therefore, in one aspect, a pulley assembly for engaging an annular member of a segmented pulley transmission is provided, the pulley assembly comprising: a first pulley rotatable about a rotation axis and having an outer peripheral surface for engaging the annular member; a second pulley configured to concentrically surround the first pulley and having an outer peripheral surface for engaging the annular member, the second pulley comprising a group of second pulley segments independently movable between an engagement region and a disengagement region; and at least one transition segment group comprising one or more transition segments independently movable between an engagement region and a disengagement region to transition the annular member between the first pulley and the second pulley, the at least one transition segment group defining at least one transition surface for engaging and transitioning the annular member between the first pulley and the second pulley.

[0011] In one or more embodiments, the at least one transition segment set may be inserted between the first pulley and the second pulley when located in the engagement region with the first pulley and the second pulley.

[0012] In one or more embodiments, the at least one transition segment group may include a first transition segment group configured to transition the annular member from the first pulley to the second pulley, and the at least one transition surface may include a first transition surface defined by the first transition segment group. The first transition surface may have a front portion that is substantially aligned with a first adjacent portion of the first pulley. The first transition surface may have a rear portion that is substantially aligned with a first adjacent portion of the second pulley. The first transition segment group may include only a single first transition segment.

[0013] In one or more embodiments, the at least one transition segment group may include a second transition segment group configured to transition the annular member from the second pulley to the first pulley, and the at least one transition surface may include a second transition surface defined by the second transition segment group. The second transition surface may have a front portion that is substantially aligned with a second adjacent portion of the second pulley. The second transition surface may have a rear portion that is substantially aligned with a second adjacent portion of the first pulley. The second transition segment group may include a plurality of second transition segments.

[0014] In one or more embodiments, at least one of the transition surfaces may extend from an adjacent first pulley to an adjacent second pulley over a partial rotation about the axis of rotation.At least one of the transition surfaces may follow a smooth generally spiral path about the axis of rotation.

[0015] In one or more embodiments, the pulley assembly may further include an actuator system coupled to a set of second pulley segments and at least one transition segment set, wherein the actuator system is configured to independently move the set of second pulley segments and at least one transition segment set between an engagement region and a disengagement region. The actuator system may be configured to independently move the set of second pulley segments and at least one transition segment set between an engagement region and a disengagement region using an electromotive force.

[0016] According to another aspect, a method for shifting an annular member on a pulley assembly during rotational operation of the pulley assembly is provided, the method comprising: engaging the annular member with a starting pulley of the pulley assembly; positioning a transition segment group of the pulley assembly in an engagement region, the transition segment group extending between the starting pulley and a destination pulley of the pulley assembly; rotating the pulley assembly to engage the annular member with the transition segment group; transitioning the annular member from an adjacent starting pulley to an adjacent destination pulley over a portion of a rotation of the pulley assembly about its rotational axis; positioning the destination pulley in the engagement region; rotating the pulley assembly to engage the annular member with the destination pulley; disengaging the annular member from the starting pulley; and disengaging the annular member from the transition segment group.

[0017] In one or more embodiments, the step of transitioning the annular member may occur only on a portion of the rotation of the pulley assembly about the axis of rotation. During the step of transitioning the annular member from an adjacent starting pulley to an adjacent destination pulley, the transition segment group may provide support to the annular member. The destination pulley may include a plurality of segments circumferentially surrounding the starting pulley, and positioning the destination pulley in the engagement region may include: when positioned in the non-contact region of the pulley assembly, sequentially moving each of the segments into the engagement region. The method may also include: moving the transition segment group out of the engagement region after disengaging the annular member from the transition segment group, and moving a different transition segment group into the engagement region to prepare for a subsequent shifting event.

[0018] In one or more embodiments, the starting pulley may include a plurality of segments circumferentially surrounding the destination pulley, and the step of rotating the pulley assembly to engage the annular member with the transition segment set may include: sequentially moving each of the segments out of the engagement region when positioned in the non-contact region of the pulley assembly. The method may also include moving the transition segment set out of the engagement region after a partial rotation of the pulley assembly and before a full rotation of the pulley assembly.

[0019] According to another aspect, an actuator system for moving discrete rotating elements of a working system is provided, the actuator system comprising: a support structure that can be rotatably fastened to the working system about a rotation axis; an actuator subassembly that is fastened to the support structure and comprises: a slide that can be moved between an advanced position and a retracted position in a substantially circumferential direction about the rotation axis relative to the support structure in response to an electromotive force generated on the slide by a temporary magnetic field, the slide defining a cam surface; and a follower that can engage with the cam surface to move between an extended position and a retracted position in a substantially axial direction when the slide moves between the advanced position and the retracted position, the follower being fastened to one or more of the discrete rotating elements of the working system; and a stator that can be fixedly fastened to the working system in a position close to the actuator subassembly, the stator being selectively energized to generate a temporary magnetic field to move the slide between the advanced position and the retracted position.

[0020] In one or more embodiments, the actuator subassembly may further include a back plate located near the slide plate to increase the electromotive force generated by the temporary magnetic field on the slide plate. The back plate may be fastened to the support structure and may extend in a generally circumferential direction. The back plate may pass through the slide plate.

[0021] In one or more embodiments, the support structure may include a pair of guides, and the slide board may be slidably fastened between the pair of guides to guide the slide board in a generally circumferential direction when the slide board moves between the advanced position and the retracted position. The slide board may include a slide board base and a reaction plate fastened to the slide board base, and the reaction plate may be formed of a conductive but magnetically inert material to increase the electromotive force generated on the slide board. The support structure may include at least one stopper to prevent movement of the slide board in a generally circumferential direction at the advanced position and the retracted position. The slide board may include at least one buffer for impacting the stopper to prevent movement of the slide board in a generally circumferential direction at the advanced position and the retracted position.

[0022] In one or more embodiments, the stator may include a stator body and at least one winding that can be selectively energized to generate a temporary magnetic field. The follower may include a protrusion that can engage with the cam surface to move the follower between the extended position and the retracted position when the slide plate moves between the advanced position and the retracted position.

[0023] In one or more embodiments, the discrete rotating elements of the working system are segments of a set of second pulley segments and at least one transition segment set of the pulley assembly as described in any of paragraphs eight to twelve.

[0024] According to another aspect, a method for moving a discrete rotating element of a working system is provided, the method comprising: energizing a stator to generate a temporary magnetic field; using an electromotive force induced by the temporary magnetic field to move a slide between a retracted position and an advanced position; engaging a follower with a cam surface of the slide to move the follower between an extended position and a retracted position; and fastening the follower to the discrete rotating element of the working system to move the discrete element with the follower.

[0025] In one or more embodiments, the stator can be fixed to the working system, the slide plate and the follower can be rotatably fastened within the working system, and energizing the stator can include selectively energizing the stator when the slide plate rotates near the stator. The slide plate can be moved in a generally circumferential direction between a retracted position and an advanced position, and the follower can be moved in an axial direction between an extended position and a retracted position. The method can also include using a back plate adjacent to the slide plate to increase the electromotive force.

[0026] According to another aspect, a segmented pulley transmission is provided, comprising: a housing; a first rotatable member secured within the housing; a pulley assembly as described in paragraphs 8 to 12, coupled to the first rotatable member; an actuator system as described in paragraphs 16 to 20, connected to the pulley assembly and configured to move at least one segment of the pulley assembly; a second rotatable member secured within the housing and spaced apart from the first rotatable member; and an annular member coupling the first rotatable member and the second rotatable member and extending between the first rotatable member and the second rotatable member.

[0027] In one or more embodiments, the housing may include a substantially closed shell or a substantially open support structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Embodiments will now be described more fully with reference to the accompanying drawings, in which:

[0029] Figure 1 is a cross-sectional view of a segmented pulley transmission;

[0030] Figure 2 yes Figure 1 A right front side view of a pulley assembly of a segmented pulley transmission and an actuator system thereof;

[0031] Figure 3 yes Figure 2 a right front side view of the pulley assembly;

[0032] Figure 4 yes Figure 2 A front view of a pulley assembly;

[0033] Figure 5 yes Figure 2 a front right side view of the pulley assembly and actuator system of FIG. 1 , showing the annular member engaged with the first pulley;

[0034] Figure 6a to Figure 6g yes Figure 2 a front right side view of a pulley assembly and actuator system of FIG. 1 showing a sequence for transitioning an annular member from a first pulley to a second pulley;

[0035] Figure 7 yes Figure 2 a front right side view of the pulley assembly and actuator system of FIG. 1 showing the annular member engaged with the second pulley;

[0036] Figures 8a to 8i yes Figure 2 a front right side view of a pulley assembly and actuator system of FIG. 1 showing a sequence for transitioning the annular member from the second pulley to the first pulley;

[0037] Fig. 9 yes Figure 2a reverse right rear side view of the pulley assembly and actuator system;

[0038] Fig.10 yes Figure 2 a reverse right rear side view of the pulley assembly and actuator system of FIG. 1 with a pair of back plates hidden for visibility; and

[0039] Figures 11a to 11c yes Figure 2 A cross-sectional view of a pulley assembly and actuator system showing a sequence of segments for retracting the pulley assembly, with shielding elements hidden for visibility. DETAILED DESCRIPTION

[0040] When reading in conjunction with the accompanying drawings, the following detailed description of the aforementioned overview and certain embodiments will be better understood.As used herein, the element or feature quoted in the singular and before the word "one" or "an" should be understood as not necessarily excluding multiple elements or features.In addition, the reference to "an example" or "an embodiment" is not intended to be interpreted as excluding the existence of additional examples or embodiments of the element or feature also combined with the narration of this example or an embodiment.In addition, unless explicitly stated to the contrary, "comprising", "having" or "including" an element or feature or multiple elements or features with a specific characteristic example or embodiment may further include additional elements or features without the specific characteristic.In addition, it will be understood that the terms "comprising", "having" and "including" refer to "including but not limited to", and the terms "comprising", "having" and "including" have equivalent meanings.

[0041] As used herein, the term "and / or" may include any and all combinations of one or more of the associated listed elements or features.

[0042] It will be understood that when an element or feature is referred to as being "on," "attached to," "connected to," "coupled to," "in contact with," etc., another element or feature, the element or feature may be directly on, attached to, connected to, coupled to, or in contact with the other element or feature, or there may be intermediate elements. Conversely, when an element or feature is referred to as being, for example, "directly on," "directly attached to," "directly connected to," "directly coupled to," or "directly in contact with" another feature element, there are no intermediate elements or features.

[0043] It will be appreciated that spatially relative terms such as "below," "beneath," "lower," "above," "above," "upper," "front," "rear," etc. may be used herein to easily describe the relationship of an element or feature to another element or feature as depicted in the figures. However, the spatially relative terms may encompass different orientations in use or operation in addition to the orientation shown in the figures.

[0044] Reference to "example" herein means that one or more features, structures, elements, components, characteristics and / or operating steps described in conjunction with the example are included in at least one embodiment and / or implementation of the subject matter of the present disclosure. Therefore, the phrases "example", "another example" and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. In addition, the subject matter characterizing any one example may, but need not, include the subject matter characterizing any other example.

[0045] References to "configured" herein refer to the actual state of construction of an element or feature that is substantially related to the physical characteristics of the element or feature preceding the phrase "configured."

[0046] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as labels and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. In addition, reference to a "second" item does not require or preclude the existence of lower-numbered items (e.g., "first" items) and / or higher-numbered items (e.g., "third" items).

[0047] As used herein, the terms "approximately" and "about" refer to an amount close to the stated amount that still performs the desired function or achieves the desired result. For example, the terms "approximately" and "about" can refer to an amount within an engineering tolerance that is readily understood by a person skilled in the art.

[0048] Now turn to Figure 1 , a segmented pulley transmission is shown and generally identified by the reference numeral 110. In this example, the segmented pulley transmission 110 is a synchronized segmented interchange pulley transmission system (SSIPTS). The segmented pulley transmission 110 includes a housing 112, a fixed pulley 114, an idler pulley 116, an annular member 118, a pulley assembly 120, and an actuator system 122. The segmented pulley transmission 110 may also include or be coupled to a driven shaft and a drive shaft. Although Figure 1 The annular member 118 in the embodiment is shown as a schematic diagram having mating features on only a portion thereof, but the annular member 118 includes mating features across its entire inner surface. In other embodiments, it will be understood that the segmented pulley transmission 110 may include various types of annular members, such as chains or belts, having various types of mating features, such as teeth or holes.

[0049] The housing 112 at least partially surrounds the fixed pulley 114, the idler pulley 116, the annular member 118, the pulley assembly 120 and the actuator 122. In this embodiment, the housing 112 is a generally closed housing. Although in other embodiments, the housing 112 can be a generally open support structure, such as a support frame. The fixed pulley 114 is rotatably fastened in the housing 112 and is configured to be fixedly fastened to the driven shaft or the drive shaft. The pulley assembly 120 is rotatably fastened in the housing 112 and is configured to be fixedly fastened to the other of the driven shaft and the drive shaft. Therefore, the pulley assembly 120 can be used as a driven pulley or a driving pulley in the segmented pulley transmission 110. In other embodiments, both the driven pulley and the driving pulley of the segmented pulley transmission 110 can include a pulley assembly 120 connected to a corresponding actuator system 122 to provide an additional transmission ratio for the segmented pulley transmission 110. The annular member 118 engages with the fixed pulley 114 and the pulley assembly 120 and rotationally couples the fixed pulley 114 and the pulley assembly 120. The annular member 118 also engages the idler pulley 116 (such as Figure 1 The idler pulley 116 is configured to take up the slack in the annular member 118. The annular member 118 rotationally couples the idler pulley 116 to the fixed pulley 114 and the pulley assembly 120. The actuator system 122 is secured within the housing 112 and coupled to the pulley assembly 120.

[0050] Figure 2 Shown separately are the pulley assembly 120 and actuator system 122 of the segmented pulley transmission 110. The pulley assembly 120 is connected to a rotatable portion of the actuator 122, and the actuator 122 is configured to move the segments of the pulley assembly 120 into and out of the area where, during a rotating operation, the segments will engage the annular member 118, as will be described.

[0051] Figure 3 and Figure 4A pulley assembly 120 is shown. The pulley assembly 120 is configured to engage the annular member 118 of the segmented pulley transmission 110 during rotational operation of the pulley assembly 120 in the direction indicated by arrow AA. The pulley assembly 120 includes a first pulley 124, a second pulley 126, a first transition segment set 128, and a second transition segment set 130. The first pulley 124 and the second pulley 126 are configured for continuous rotational operation with the annular member 118 (i.e., during a complete rotation of the pulley assembly 120, the first pulley 124 or the second pulley 126 will continuously engage the annular member 118). In contrast, the first transition segment set 128 and the second transition segment set 130 are configured for temporary rotational operation with the annular member 118 (i.e., during a complete rotation of the pulley assembly 120, neither the first transition segment set 128 nor the second transition segment set 130 will continuously engage the annular member 128). In this embodiment of the pulley assembly 120, the first pulley 124 and the second pulley 126 are defined as being directly adjacent because there is no pulley between them. That is, only the first transition segment set 128 and the second transition segment set 130 are engaged between the first pulley 124 and the second pulley 126, and the first transition segment set 128 and the second transition segment set 130 are not configured for continuous operation and are therefore not pulleys. In this embodiment, the first pulley 124 is the core pulley of the pulley assembly 120, that is, the centermost or smallest diameter pulley of the pulley assembly 120. However, in other embodiments, the first pulley 124 can be another pulley of the pulley assembly 120, such as an intermediate pulley located between other pulleys of the pulley assembly 120.

[0052] The first pulley 124 is rotatable about and concentric with an axis of rotation 132 of the pulley assembly 120 and is configured to engage the annular member 118 of the segmented pulley transmission 110. The first pulley 124 includes an outer peripheral surface 134 for engaging the annular member 118. The outer peripheral surface 134 is generally circular and may include a plurality of mating features 136, such as teeth, for engaging corresponding mating features on the annular member 118. The first pulley 124 also includes an inner peripheral surface 138 that is configured to be mounted on the actuator system 122, such as by press-fitting the first pulley 124 into the actuator system 122. The inner peripheral surface 138 is generally circular and may include a plurality of inner mating features 140, such as keys, for engaging corresponding mating features on the actuator system 122. Although the inner circumferential surface 138 of the first pulley 124 is configured to be mounted on the actuator system 122, it should be understood that in other embodiments, the inner circumferential surface 138 can be configured for direct mounting on a rotatable element of the segmented pulley transmission 110, such as an axle of the segmented pulley transmission 110.

[0053] The second pulley 126 is rotatable about and concentric with the rotation axis 132 and is configured to engage with the annular member 118 of the segmented pulley transmission 110. The second pulley 126 includes an outer peripheral surface 142 for engaging the annular member 118. The outer peripheral surface 142 is generally circular and may include a plurality of mating features 144, such as teeth, for engaging corresponding mating features on the annular member 118. The second pulley 126 includes a plurality of second pulley segments 146a to 146e. Each of the second pulley segments 146a to 146e defines a portion of the outer peripheral surface 142 and includes a subset of the plurality of mating features 144. Each of the second pulley segments 146a to 146e is configured to be coupled to the actuator 122 and independently movable between an engagement region and a disengagement region.

[0054] In the context of the present disclosure, an "engagement zone" is a zone where elements of the pulley assembly 120 will engage the annular member 118 during rotational operation of the pulley assembly 120 when the elements are not obscured or blocked by other elements of the pulley assembly 120. Conversely, a "disengagement zone" is a zone where elements of the pulley assembly 120 will not engage the annular member 118 during rotational operation of the pulley assembly 120, regardless of their exposure or the position of other elements of the pulley assembly 120. Thus, in the present embodiment, it should be understood that the first pulley 124 is permanently located within the engagement zone in that the first pulley 124 is axially immovable and will always engage the annular member 118 if not blocked by other elements during rotational operation of the pulley assembly 120. In other embodiments, the first pulley 124 is movable between the engagement zone and the disengagement zone.

[0055] Thus, each of the second pulley segments 146a-146e is movable within the engagement region to a respective engaged position wherein the segment is in line with the annular member 118. Similarly, each of the second pulley segments 146a-146e is movable within the disengagement region to a respective disengagement position wherein the segment is not in line with the annular member 118 and will clear the annular member 118 during rotational operation of the pulley assembly 120. Each of the second pulley segments 146a-146e is independently movable between its respective engaged position and its disengagement position.

[0056] The first transition segment set 128 is configured to transition the annular member 118 from engaging the first pulley 124 to engaging the second pulley 126 during the rotational operation of the pulley assembly 120. During this transition, the first transition segment set 128 engages and at least partially supports the annular member 118. The first transition segment set 128 extends circumferentially around the rotation axis 132 for only a portion of the rotation. Therefore, the first transition segment set 128 extends the entire circumference around the first pulley 124. The first transition segment set 128 is between the first pulley 124 and the second pulley 126, and includes a first transition surface 148 for engaging the annular member 118 of the segmented pulley transmission 110 and transitioning the annular member 118 from the first pulley 124 to the second pulley 126. The first transition surface 148 may include a plurality of mating features 150, such as teeth, for engaging corresponding mating features on the annular member 118. The first transition segment set 128 includes a single first transition segment 152. The first transition segment 152 defines the first transition surface 148. The first transition section 152 is independently movable between the engagement region and the disengagement region and is inserted between the first pulley 124 and the second pulley 126 when in the engagement region with the first pulley 124 and the second pulley 126. Thus, the first transition section 152 has an engagement position in the engagement region, wherein the first transition section 152 is aligned with the annular member 118. Similarly, the first transition section 152 is movable to a corresponding disengagement position in the disengagement region, wherein the first transition section 152 is not aligned with the annular member 118 and will avoid the annular member 118 during rotational operation of the pulley assembly 120. The first transition section 152 is independently movable between its corresponding engagement position and disengagement position.

[0057] The first transition surface 148 follows a smooth, generally spiral path about the axis of rotation 132. In the present embodiment, the path of the first transition surface 148 follows a continuously increasing radius over the circumferential length of the first transition surface 148. The first transition surface 148 extends from the adjacent first pulley 124 to the adjacent second pulley 126 over only a partial rotation about the axis of rotation 132, and is configured to extend the transition of the annular member 118 from the first pulley 124 to the second pulley 126. It will be appreciated that extending the transition can reduce the intermittent forces generated during the transition and can result in a smoother transition of the annular member 118 between the pulleys 124, 126. The first transition surface 148 includes a leading portion 154 and a trailing portion 156. The leading portion 154 is configured to initially engage the annular member 118 when transitioning the annular member 118 from the first pulley 124 to the second pulley 126, and the trailing portion 156 is configured to eventually engage the annular member 118 when transitioning the annular member 118 from the first pulley 124 to the second pulley 126. Thus, the leading portion 154 of the first transition surface 148 is generally aligned with an adjacent portion of the outer peripheral surface 134 of the first pulley 124 (such as a rotationally leading portion of the outer peripheral surface 134 of the first pulley 124). While the trailing portion 156 of the first transition surface 148 is generally aligned with an adjacent portion of the outer peripheral surface 142 of the second pulley 126 (such as a portion of the outer peripheral surface 142 defined by the second pulley segment 146a that follows rotationally). It will be appreciated that the rotationally following second pulley segment 146a is the initial segment of the second pulley 126 to engage the endless member 118 of the segmented pulley transmission 110 during the transition of the endless member 118 from the first pulley 124 to the second pulley 126 .

[0058] In the context of the present disclosure, it will be understood that a "smooth" path is a path that does not cause the ring member 118 to bend more than a specified amount. For example, when the ring member is a chain, the specified amount can be the maximum allowable bending angle between the links in the ring member, or when the ring member is a belt, the specified amount can be the minimum allowable bending radius. Similarly, it will be understood that in the context of the present disclosure, surfaces or portions of surfaces are "substantially aligned" with each other when arranged so that the ring member 118 forms a transition that does not cause the ring member 118 to bend more than a specified amount when engaged therebetween.

[0059] The second transition segment set 130 is configured to transition the annular member 118 from engaging the second pulley 126 to engaging the first pulley 124 during the rotational operation of the pulley assembly 120. During this transition, the second transition segment set 130 engages and at least partially supports the annular member 118. The second transition segment set 130 extends axially around the rotation axis 132 for only a portion of the rotation. Therefore, the second transition segment set 130 extends the entire circumference around the first pulley 124. The second transition segment set 130 is between the first pulley 124 and the second pulley 126, and includes a second transition surface 158 for engaging the annular member 118 of the segmented pulley transmission 110 and transitioning the annular member 118 from the second pulley 126 to the first pulley 124. The second transition surface 158 may include a plurality of mating features 160, such as teeth, for engaging corresponding mating features on the annular member 118. The second transition segment set 130 includes a pair of second transition segments 162a, 162b. Each of the second transition segments 162a, 162b defines a portion of the second transition surface 158. Each of the second transition segments 162a, 162b is independently movable between an engagement region and a disengagement region. The second transition segments 162a, 162b are inserted between the first pulley and the second pulley when they are in the engagement region with the first pulley 124 and the second pulley 126. Therefore, each of the second transition segments 162a, 162b is movable to a corresponding engagement position in the engagement region, wherein the segment is in line with the annular member 118. Similarly, each of the second transition segments 162a, 162b is movable to a corresponding disengagement position in the disengagement region, wherein the segment is not in line with the annular member 118 and will avoid the annular member 118 during the rotation operation of the pulley assembly 120. Each of the second transition segments 162a, 162b is independently movable between its corresponding engagement position and its disengagement position.

[0060] The second transition surface 158 follows a smooth, generally spiral path about the axis of rotation 132. In the present embodiment, the path of the second transition surface 158 follows a continuously decreasing radius over the circumferential length of the second transition surface 158. The second transition surface 158 extends from the adjacent second pulley 126 to the adjacent first pulley 124 over only a partial rotation about the axis of rotation 132, and is configured to extend the transition of the annular member 118 from the second pulley 126 to the first pulley 124. It will be appreciated that extending the transition can reduce intermittent forces generated during the transition and can result in a smooth transition of the annular member 118 between the pulleys 124, 126. The second transition surface 158 includes a leading portion 164 and a trailing portion 166. The leading portion 164 is configured to initially engage the annular member 118 when transitioning the annular member 118 from the second pulley 126 to the first pulley 124, and the trailing portion 166 is configured to eventually engage the annular member 118 when transitioning the annular member 118 from the second pulley 126 to the first pulley 124. Thus, the leading portion 164 of the second transition surface 158 is generally aligned with an adjacent portion of the outer peripheral surface 142 of the second pulley 126 (such as a portion of the outer peripheral surface 142 defined by the rotationally preceding second pulley segment 146 e), and the trailing portion 166 of the second transition surface 158 is generally aligned with an adjacent portion of the outer peripheral surface 134 of the first pulley 124 (such as a rotationally trailing portion of the outer peripheral surface 134 of the first pulley 124). It will be appreciated that the rotationally preceding second pulley segment 146 e is the last pulley segment of the second pulley 126 to disengage the endless member 118 of the segmented pulley transmission 110 during the transition of the endless member 118 from the second pulley 126 to the first pulley 124 .

[0061] As will be described herein, during rotational operation of the pulley assembly 120, the second pulley segments 146a-146e, the first transition segment 152, and the second transition segments 162a, 162b may be moved into and / or out of the engagement region by the actuator system 122 to adjust the transmission ratio of the segmented pulley transmission 110 under load.

[0062] Figure 5 Schematic diagram of a pulley assembly 120, an actuator system 122, and an annular member 118 are shown. The annular member 118 engages a first pulley 124 of the pulley assembly 120. It will be appreciated that the annular member 118 may also engage additional elements of the segmented pulley transmission 110, such as the fixed pulley 114 and the idler pulley 116 ( Figure 5 It will also be understood that, although a schematic diagram of the annular member 118 is shown with mating features on only a portion thereof, the annular member 118 includes mating features across its entire inner surface.

[0063] During rotational operation of the pulley assembly 120, the annular member 118 will contact and engage the pulley assembly 120 within an angular region defined as the contact zone. Conversely, the annular member 118 will not contact or engage the pulley assembly 120 within an angular region defined as the non-contact zone (NCZ). Thus, the pulleys / transition segments 146a to 146e, 152, 162a, 162b of the pulley assembly 120 can move into or out of the engagement zone when positioned in the non-contact zone without interfering with the annular member 118 and when the segmented pulley transmission 110 is under load. It will be appreciated that the non-contact zone will vary depending on which pulley / transition segment of the pulley assembly 120 is engaged with the annular member 118.

[0064] By sequentially moving the pulleys / transition segments of the pulley assembly 120 into or out of the engagement region while positioned in the non-contact region, the annular member 118 may transition from engaging one pulley (the “starting pulley”) in the pulley assembly 120 to engaging another pulley (the “destination pulley”) in the pulley assembly 120 without interrupting the continuous rotational operation of the segmented pulley transmission 110 and without interrupting the load on the segmented pulley transmission 110. In this embodiment, the starting pulley may be the first pulley 124 and the destination pulley 126 may be the second pulley 126, or vice versa.

[0065] The transition of the annular member 118 from the starting pulley to the destination pulley is generally referred to as a "shift event". A shift event that results in a higher gear ratio between the driven pulley and the driving pulley of the segment pulley transmission 110 is referred to as an "upshift event". A shift event that results in a lower gear ratio between the driven pulley and the driving pulley of the segment pulley transmission 110 is referred to as a "downshift event". During a shift event, the annular member 118 will sequentially engage the starting pulley, one of the transition segment groups, and the destination pulley. The time period that the annular member 118 transitions from engaging only the starting pulley to engaging only the destination pulley is referred to as the transition period, and the degree of rotation of the pulley assembly 120 during the transition period is referred to as the transition range. It will be understood that the transition segment groups 128, 130 provide support for the annular member 118 during at least a portion of the shift event. Thus, including a transition segment set in a shift event may increase the transition period and transition range for the shift event, which may help reduce forces caused by the shift event and may help smooth the transition of the annular member 118 between the starting pulley and the destination pulley.

[0066] Figure 6a to Figure 6g 1 and 2 illustrate a sequence of shift events that transition the annular member 118 from engaging the first pulley 124 to engaging the second pulley 126 during rotational operation of the pulley assembly 120. It will be appreciated that the annular member 118 is hidden in these figures for visibility. Figure 5As shown in FIG, prior to a shifting event, the annular member 118 is engaged with the first pulley 124. Thus, the second pulley segments 146a to 146e, the first transition segment 152, and the second transition segments 162a, 162b are all in the disengagement region.

[0067] exist Figure 6a , the first transition segment 152 moves into the engagement region when positioned in the non-contact region of the pulley assembly 120. As the pulley assembly 120 rotates, the first transition segment 152 will enter the contact region and will engage the annular member 118 with the first transition surface 148. The front portion 154 of the first transition surface 148 will initially engage the annular member 118 to smoothly transition the annular member 118 from the first pulley 124 to the first transition segment set 128. As the pulley assembly 120 rotates further, the remaining portion of the first transition surface 148 will engage the annular member 118 to smoothly transition the annular member 118 from the adjacent first pulley 124 to the adjacent second pulley 126.

[0068] exist Figure 6b , the second pulley segment 146a moves into the engagement region when positioned in the non-contact region of the pulley assembly 120. As the pulley assembly 120 rotates, the second pulley segment 146a will rotationally follow the first transition segment 152 into the contact region and will engage the annular member 118. The outer peripheral surface 142 defined by the second pulley segment 146a will follow the trailing portion 156 of the first transition segment 152 and engage the annular member 118 to smoothly transition the annular member 118 from the first transition segment set 128 to the second pulley segment 146a of the second pulley 126.

[0069] exist Figure 6c to Figure 6f In the steps shown in , the remaining second pulley segments 146b to 146e are sequentially moved into the engagement region when they are respectively positioned in the non-contact region of the pulley assembly 120. As the pulley assembly 120 rotates, the remaining second pulley segments 146b to 146e will rotationally follow the second pulley segment 146a into the contact region and will engage the annular member 118. Once all of the second pulley segments 146a to 146e are in the engagement region, the pulley assembly 120 can continue to operate with the annular member 118 engaging only the second pulley 126, and the shifting event from the first pulley 124 to the second pulley 126 is completed. Figure 7 As shown in FIG. 1 , after the shift event, the annular member 118 will engage the second pulley 126. Optionally, the shift event may include other steps, such as steps to prepare for the next shift event.

[0070] exist Figure 6gAt the step shown in , the first transition section 152 moves out of the engagement area. This step may be performed in preparation for a subsequent shifting event, or may be performed as part of a preceding shifting event. In the present embodiment, the first transition section 152 moves out of the engagement area when positioned in the non-contact area. In other embodiments, because the first transition section 152 is obscured or blocked by the second pulley 126 when in the contact area and will not engage or interfere with the annular member 118, the first transition section 152 may move out of the engagement area when positioned in the contact area or bridging the contact area and the non-contact area. It will be understood that this step may occur once the first transition section 152 is rotated out of engagement with the annular member 118. Therefore, this step may occur at Figures 6c to 6f occurs before the steps shown in are completed, or may occur after that.

[0071] It will be appreciated that during a shift event, the annular member 118 may simultaneously engage all three of the first pulley 124, the second pulley 126, and the first transition segment set 128, or the annular member 118 may simultaneously engage only one of the first pulley 124 and the second pulley 126 and the first transition segment set 128. Figure 6a to Figure 6g The steps of the shift events shown in may occur completely consecutively without any overlap, or may partially overlap in time.

[0072] Figure 7 The pulley assembly 120, the actuator system 122 and Figure 5 Schematic diagram of the annular member 118 in FIG. The annular member 118 is engaged with the second pulley 126 of the pulley assembly 120.

[0073] Figures 8a to 8i 1 and 2 illustrate a sequence of shift events that transition the annular member 118 from engaging the second pulley 126 to engaging the first pulley 124 during rotational operation of the pulley assembly 120. It will be appreciated that the annular member 118 is hidden in these figures for visibility. Figure 7 As shown in FIG, prior to a shift event, the annular member 118 is engaged with the second pulley 126. Figure 5 As shown in FIG. 1 , after a shift event, the annular member 118 will engage the first pulley 124. During a shift event, the annular member 118 may simultaneously engage all three of the first pulley 124, the second pulley 126, and the second transition segment set 130, or the annular member 118 may simultaneously engage only one of the first pulley 124 and the second pulley 126 and the second transition segment set 130. It will be appreciated that during a shift event, the annular member 118 may simultaneously engage all three of the first pulley 124, the second pulley 126, and the second transition segment set 130. Figures 8a to 8i The steps of the shift events shown in may occur completely consecutively without any overlap, or may partially overlap in time.

[0074] exist Figure 8a and Figure 8b At the step shown in , the second transition sections 162a, 162b are sequentially moved into the joining area. It will be understood that in other embodiments, the second transition sections 162a, 162b can be moved into the joining area simultaneously. As described herein, Figure 8a and Figure 8b The steps shown in the figure can be performed as part of a shift event from the second pulley 126 to the first pulley 124, or can be performed in preparation for or before the shift event. In the present embodiment, because the second transition segments 162a, 162b are shielded or blocked by the second pulley 126 when in the contact region and do not engage or interfere with the annular member 118, the second transition segments 162a, 162b move into the engagement region when positioned in the contact region or bridging the contact region and the non-contact region.

[0075] exist Figure 8c to Figure 8g , the second pulley segments 146a to 146e are sequentially moved out of the engagement area when they are respectively positioned in the non-contact area of ​​the pulley block 120. Therefore, as the pulley block 120 rotates, the second pulley segments 146a to 146e will avoid and will not engage the annular member 118. In contrast, the second transition segments 162a, 162b of the second transition segment group 130 will enter the contact area and will engage the annular member 118. The front portion 164 of the second transition surface 158 will initially engage the annular member 118 following a portion of the outer peripheral surface 142 defined by the second pulley segment 146e to smoothly transition the annular member 118 from the second pulley 126 to the second transition segment group 130. As the pulley assembly 120 rotates further, the remaining portion of the second transition surface 158 will engage the annular member 118 to smoothly transition the annular member 118 from the adjacent second pulley 126 to the adjacent first pulley 124. As the pulley assembly 120 rotates still further, the first pulley 124 will engage the annular member 118. The portion of the outer peripheral surface 134 of the first pulley 124 that rotationally follows the second transition segment set 130 will follow the trailing portion 166 of the second transition surface 158 to initially engage the annular member 118 to smoothly transition the annular member 118 from the second transition segment set 130 to the first pulley 124.

[0076] exist Figure 8h and Figure 8iAt the step shown in , the second transition sections 162a, 162b are sequentially moved out of the engagement area when they are respectively positioned in the non-contact area of ​​the pulley assembly 120. Therefore, as the pulley assembly 120 rotates, the second transition sections 162a, 162b will avoid and not engage the annular member 118. Once the second transition sections 162a, 162b are moved out of the engagement area, the pulley assembly 120 can continue to operate with the annular member 118 engaging the first pulley 124, and the shifting event from the second pulley 126 to the first pulley 124 is completed.

[0077] Fig. 9 and Fig.10 An actuator system 122 and a pulley assembly 120 are shown. The pulley assembly 120 is secured to the actuator system 122, and the actuator system 122 is configured to move the pulley / transition segments 146a to 146e, 152, 162a, 162b of the pulley assembly 120 between an engagement region and a disengagement region. The actuator system 122 includes a support structure 220, a first actuator subassembly 222, a first stator 224, a second actuator subassembly 226, and a second stator 228. As described herein, the actuator system 122 and the pulley assembly 120 may be secured within a segmented pulley transmission 110.

[0078] The support structure 220 is rotatable and is configured to support and couple the first actuator subassembly 222 and the second actuator subassembly 226 to a rotatable element in the segmented pulley transmission 110, such as a driven shaft or a drive shaft (not shown). In the present embodiment, the support structure 220 is also configured to support and couple the pulley assembly 120 to a rotatable element of the segmented pulley transmission 110. In other embodiments, the pulley assembly 120 or a portion thereof (such as the first pulley 124) may be directly coupled to a rotatable element of the segmented pulley transmission 110. The support structure 220 includes a hub 230, a pair of retaining rings 232, and a plurality of support rods 234 fastened between the hub 230 and the retaining rings 232.

[0079] The hub 230 is configured to be secured to the shaft of the segmented pulley transmission 110 and supports the first actuator subassembly 222 and the second actuator subassembly 226. The hub 230 includes a circular disk having an actuator side 236 and an opposing pulley side 238. A central passage 240 is defined within the hub 230 and extends from the actuator side 236 to the pulley side 238. The central passage 240 is configured to securely receive the shaft of the segmented pulley transmission 110 and is concentric with the axis of rotation 132. The hub 230 is also configured to secure the first pulley 124 of the pulley assembly 120 to the shaft of the segmented pulley transmission 110. Thus, as shown in FIG. Figure 8iAs shown in , the hub 230 includes an axial protrusion 242 extending from the pulley side 238 of the hub 230 and is configured to secure the first pulley 124. In some embodiments, the first pulley 124 can be press-fit onto the hub 230. The hub 230 includes a pair of guides 244 on its actuator side 236. As will be described below, the guides 244 are configured to slidably secure the slides of the first actuator subassembly 222 and the second actuator subassembly 226 and guide the slides in a generally axial direction. Fig.11a As shown in , the guide 244 may include a raceway defined in the actuator side 236 of the hub 230, or may include other suitable guide features, such as tracks or ridges.

[0080] The retaining ring 232 supports the first actuator subassembly 222 and the second actuator subassembly 226 and is secured to the hub 230 via a support rod 234. The retaining ring 232 is positioned on a side of the actuator subassemblies 222, 226 opposite the hub 230. Each of the retaining rings includes a guide 246 that is aligned with a corresponding one of the guides 244 in the hub 230. As described below, the guide 246 is configured to slidably secure the slides of the first actuator subassembly 222 and the second actuator subassembly 226 and guide the slides in a generally circumferential direction. Fig.11a , the guide 246 may include a raceway defined in the actuator side 236 of the hub 230, or may include other suitable guide features, such as tracks or ridges. Although multiple retaining rings are shown, it will be understood that in other embodiments, the support structure 220 may include a single retaining member that extends across both the first actuator subassembly 222 and the second actuator subassembly 226 and secures both the first actuator subassembly and the second actuator subassembly. The single retaining member may be a single retaining ring extending across the two actuator subassemblies 222, 226, or may be a single retaining plate. In such embodiments, the single retaining member may include two guides 246.

[0081] A support rod 234 that secures the retaining ring 232 to the hub 230 extends from the actuator side 236 of the hub 230 to the retaining ring 232 and is secured therebetween by fasteners or the like. The support rod 234 may further extend through the hub 230 and may be slidably engaged with a pulley / transition section of the pulley assembly 120, such as Fig.11a Thus, the support rod 234 can be configured to guide the pulley / transition section of the pulley assembly 120 as it moves between the engagement region and the disengagement region. Fig.11a20 and 21. A single support rod 234 is shown extending from the retaining ring 232 through the hub 230 and to the pulley / transition section of the pulley assembly 120, but in other embodiments, separate support rods 234 may extend from the retaining ring 232 to the hub 230 and from the hub 230 to the pulley / transition section of the pulley assembly 120. Although a support rod 234 is shown and described, in other embodiments, a different suitably shaped support member, such as a support beam or bar, may be used to secure the retaining ring 232 to the hub 230. In other embodiments, the retaining ring 232 may be secured directly to the hub 230 via an integrally formed support member.

[0082] The first actuator subassembly 222 and the second actuator subassembly 226 are configured to move the pulley / transition segments 146a to 146e, 152, 162a, 162b of the pulley assembly 120 into and out of the engagement area. Specifically, the first actuator subassembly 222 is configured to move the transition segments 152, 162a, 162b of the transition segment groups 128, 130. The second actuator subassembly 226 is configured to move the pulley segments 146a to 146e of the second pulley 126. The first actuator subassembly 222 and the second actuator subassembly 226 are fastened to the support structure 220, and each of the actuator subassemblies 222, 226 includes a plurality of slide plates 248, a plurality of followers 250, a plurality of connecting rods 252, and a back plate 254. The first actuator subassembly 222 and the second actuator subassembly 226 are functionally identical. However, the second actuator subassembly 226 is circumferentially larger than the first actuator subassembly 222 and surrounds the first actuator subassembly 222. Therefore, the second actuator subassembly 226 includes a greater number of slide plates 248, followers 250, and connecting rods 252 than the first actuator subassembly 222.

[0083] Each of the slide plates 248 can be moved in a generally circumferential direction about the rotation axis 132 between respective retracted positions (in Fig.11a ) and the corresponding forward position (in Fig.11c224, 228). It will be appreciated that the generally circumferential direction may extend completely circumferentially, or may extend partially circumferentially and include a radial component. Each of the slide plates 248 is coupled to one of the pulley / transition segments 146a to 146e, 152, 162a, 162b of the pulley assembly 120, such that movement of the slide plate 248 between the retracted position and the advanced position causes the coupled pulley / transition segment to move between the engagement region and the disengagement region, or vice versa. Each of the slide plates 248 is configured to move between the advanced position and the retracted position in response to an electromotive force generated on the slide plate 248 when the slide plate 248 is rotationally passed near one of the stators 224, 228. As described below, the electromotive force may be induced by a temporary magnetic field generated by the stators 224, 228. In the present embodiment, each of the slide plates 248 surrounds a portion of the back plate 254 that passes through the slide plate 248. In other embodiments, the back plate 254 may travel beside the slide plate 248, or may be omitted entirely.

[0084] Each of the slide plates 248 includes a slide base 256, a reaction plate 258, and a plurality of bumpers 260. The slide base 256 is configured to support and guide the reaction plate 258 and the bumpers 260 when the slide plate 248 moves between the advanced position and the retracted position. Thus, the slide base 256 extends between and engages the guides 244, 246 when the slide plate 248 moves. The slide base 256 includes at least one cam surface 262 for engaging a corresponding one of the followers 250 when the slide plate 248 moves between the retracted position and the advanced position. The engagement of the cam surface 262 with the follower 250 converts the generally circumferential motion of the slide plate 248 into the axial motion of the follower 250. The slide base 256 also includes a plurality of posts 264 for fastening the bumpers 260 thereto. The slide base 256 is formed of a non-magnetic, non-reactive material such as aluminum or plastic to reduce potential magnetic field interference with the electromotive force generated on the slide plate 248. However, in other embodiments, the slide base 246 may be formed of a magnetically conductive material to increase the electromagnetic force on the slide 248 .

[0085] The buffer 260 is configured to impact the support rod 234 and prevent the approximately circumferential movement of the slide plate 248 when the slide plate reaches the advanced position or the retracted position. In this way, the support rod 234 of the support structure 220 can be used as a stopper for the slide plate 248. In other embodiments, the support structure 220 may include other suitable stops located near each of the advanced position and the retracted position to prevent the slide plate from moving in a generally circumferential direction. The buffer 260 is formed of rubber or other suitable materials to mitigate the impact on the support rod 234, and can be formed as an O-ring or other suitable shape. It will be understood that in some embodiments, the buffer 260 can be omitted, and the slide plate 248 can directly impact the support rod 234 to prevent the slide plate 248 from moving in a generally circumferential direction.

[0086] The reaction plate 258 is configured to increase the electromotive force generated on the slide plate 248 by the temporary magnetic field of the adjacent first or second stator 224, 228. The reaction plate 258 is formed of a conductive but magnetically inert material (such as copper, gold or aluminum). The reaction plate 258 is fastened to the slide plate base 256 and is positioned on the outer peripheral surface of the slide plate 248. Therefore, as the actuator subassembly 222, 226 rotates around the rotation axis 132 and passes through the non-contact area of ​​the pulley assembly 120, the reaction plate 258 will approach the adjacent stator 224, 228. In other embodiments, the reaction plate 258 can form the inner peripheral surface of the slide plate 248, or another suitable surface of the slide plate 248 that will approach the adjacent stator 224, 228 during the rotation operation of the actuator subassembly 222, 226. In other embodiments, the reaction plate 258 may be omitted entirely, and the slide base 256 may be configured to generate sufficient electromotive force to move the slide 248 when exposed to the temporary magnetic field of the adjacent first or second stators 224 , 228 .

[0087] Each of the followers 250 is configured to convert the generally circumferential movement of a corresponding one of the slide plates 248 into the axial movement of a corresponding one of the pulley / transition segments of the pulley assembly 120. Thus, each of the followers 250 can engage with the cam surface 262 of a corresponding one of the slide plates 248 and can be secured to a corresponding one of the pulley / transition segments 146a to 146e, 152, 162a, 162b. Each of the followers 250 includes a protrusion 266 that can engage with the cam surface 262 of the corresponding slide plate 248. As the slide plate 248 moves between the advanced position and the retracted position, the cam surface 262 engages the protrusion 266 and causes the follower 250 to move in the retracted position ( Fig.11c ) and the extended position ( Fig.11a162a, 162b of the pulley assembly 120 by one or more connecting rods 252. Thus, as the follower 250 moves between the extended position and the retracted position, the corresponding one of the pulley / transition sections 146a to 146e, 152, 162a, 162b will move between the engagement region and the disengagement region. In other embodiments, each of the followers 250 may be directly fastened to a corresponding one of the pulley / transition sections 146a to 146e, 152, 162a, 162b, such as by an integrally formed connecting rod extending from and between the follower 250 or the corresponding section.

[0088] A plurality of connecting rods 252 fasten the follower 250 to the pulley / transition segments 146a to 146e, 152, 162a, 162b of the pulley assembly 120, such that each of the pulley / transition segments 146a to 146e, 152, 162a, 162b is coupled to one of the followers 250 and moves between an engagement region and a disengagement region as the coupled follower 250 moves between an extended position and a retracted position. Thus, each of the connecting rods 252 is fastened to one of the pulley / transition segments 146a to 146e, 152, 162a, 162b and a corresponding one of the followers 250. Each of the connecting rods 252 extends from one coupled follower 250 on the actuator side 246 of the hub 230, through the hub 230 and to the coupling segments 146a to 146e, 152, 162a, 162b on the pulley side 238 of the hub 230. In the present embodiment, a plurality of connecting rods 252 are coupled between each of the followers 250 and a corresponding one of the pulley / transition segments 146a to 146e, 152, 162a, 162b. In other embodiments, a single connecting rod 252 may be coupled between each of the followers 250 and a corresponding one of the pulley / transition segments 146a to 146e, 152, 162a, 162b. In other embodiments, the connecting rod 252 may be omitted entirely and each of the followers 250 may be directly secured to a respective one of the pulley / transition segments 146a to 146e, 152, 162a, 162b, such as by an integrally formed connecting rod extending from and between the followers 250 or respective segments.

[0089] The back plate 254 is configured to increase the electromotive force generated on the slide plate 248 by the temporary magnetic field of the stators 224, 228. The back plate 254 is formed of a magnetically conductive material (such as copper, gold or aluminum). However, in other embodiments, the back plate 254 can be formed of other suitable materials (such as low carbon steel, silicon steel, motor steel, ceramic and / or powdered metal). The back plate 254 is fastened between a corresponding one of the retaining rings 232 of the support structure 220 and the hub 230 and rotates therewith. In some embodiments, there may be a small gap between the back plate 254 and the slide plate 248 to avoid interference with the slide plate 248 during its generally circumferential movement. In other embodiments, the slide plate 248 may contact the back plate 254 to increase the electromotive force generated on the slide plate 248. In other embodiments, the back plate 254 may be omitted entirely and the slide plate 248 may be designed to generate sufficient electromotive force to move between its advanced and retracted positions when exposed to the temporary magnetic field of the first or second stators 224 , 228 without being amplified by the back plate 254 .

[0090] The first stator 224 and the second stator 228 can be energized to generate a temporary magnetic field to move the slide 248 of the first actuator subassembly 222 and the second actuator subassembly 226 between their respective advanced and retracted positions. It will be understood that the first stator 224 is configured to generate a temporary magnetic field to move the slide 248 of the first actuator assembly 222, and the second stator 228 is configured to generate a temporary magnetic field to move the slide 248 of the second actuator subassembly 226. Each of the stators 224, 228 includes a stator core 268 that extends circumferentially across at least a portion of the non-contact area of ​​the pulley assembly 120 and includes a plurality of teeth 270 extending radially therefrom. Each of the stators 224, 228 also includes a plurality of windings (not shown) surrounding the teeth 270. The windings of each of the stators 224, 228 may be selectively energized to generate a temporary magnetic field over a portion of the stators 224, 228 or over the entire span of the stators 224, 228. When the slide plate 248 travels adjacent to the stators 224, 228 and through the non-contact region of the pulley assembly 120, the windings of the stators 224, 228 may be energized to move the slide plates 248 of the actuator subassemblies 222, 226. Thus, the first stator 224 approaches a portion of the first actuator assembly 222 in the non-contact region, and the second stator 228 approaches a portion of the second actuator subassembly 226 in the non-contact region. The first stator 224 and the second stator 228 are fixed to the housing 112 of the segmented pulley transmission 110 and do not rotate with the first and second actuator subassemblies 222, 226.

[0091] Figures 11a to 11cThe sequence for moving one of the pulley segments of the second pulley 126 from the engaged region to the disengaged region during rotational operation of the pulley assembly 120 and the actuator system 122 is shown. It will be appreciated that the sequence may be reversed to move the pulley segment from the disengaged region to the engaged region. Figures 11a to 11c The pulley segment that moves in the middle is generally identified by reference numeral 146. It will be understood that the pulley segment 146 can be any one of the pulley segments 146a to 146e of the second pulley 126. Figures 11a to 11c Elements of the second actuator subassembly 226 and the second pulley 126 are hidden; for example, the first actuator subassembly 222, the first stator 224, the first pulley 124, and the axial protrusion 242 of the hub 230 are all hidden.

[0092] exist Fig.10 At the step shown in a, the pulley segment 146 is in the engagement region, the follower 250 coupled to the pulley segment 146 is in the extended position, and the slide 248 coupled to the follower 250 is in the retracted position. In order to move the pulley segment 146 to the disengagement region, when the slide 248 is close to the second stator 228 and passes through the non-contact region of the pulley assembly 120, the second stator 228 is selectively energized to generate a temporary magnetic field. As described above, the windings of the second stator 228 can be selectively energized to generate a temporary magnetic field. The temporary magnetic field generated by the second stator 228 induces a current in the slide 248 (such as in the reaction plate 258 and / or the slide base 256), and the induced current interacts with the temporary magnetic field to generate an electromotive force on the slide 248, which propels the slide 248 from the retracted position to the advanced position. It will be understood that the direction and position of the temporary magnetic field can be changed by changing which windings of the second stator 228 are energized and the direction of the current traveling through the windings.

[0093] exist Fig.11b , the electromotive force causes the slide plate 148 to move from the retracted position toward the advanced position. The slide plate 248 engages the guides 244, 246 as it moves and is guided in a generally circumferential direction by the guides 244, 246. As the slide plate 148 moves generally circumferentially from the retracted position toward the advanced position, the cam surface 262 on the slide plate 248 engages the protrusion 266 on the follower 250 and causes the follower 250 to move axially from the extended position toward the retracted position. This axial movement of the follower 250 is transmitted to the coupled pulley segment 146 through the connecting rod 252 and causes the pulley segment 146 to move from the engagement area toward the disengagement area.

[0094] exist Fig.11c, one of the buffers 260 impacts the rotationally forward one of the support rods 234 and blocks the movement of the slide plate 248 in the advanced position. Additionally or alternatively, one of the buffers 260 may impact the rotationally forward one of the connecting rods 252 to block the circumferential movement of the slide plate 248. In this way, the support rods 234 and / or the connecting rods 252 may act as a stopper to block the movement of the slide plate 148 in the advanced position. The cam surface 262 of the slide plate 248 is configured so that when the slide plate 148 is in the advanced position, the coupled follower 250 is in the retracted position and the coupled pulley segment 146 is outside the engagement region and in the disengagement region.

[0095] Although the above sequence is described with respect to the second stator 228 and for moving one of the pulley segments 146 of the second pulley 126, it will be understood that each of the transition segments 152, 162 of the transition segment groups 128, 130 is moved between the engagement region and the disengagement region by energizing the first stator 224 in a similar sequence.

[0096] Although the actuator system 122 has been shown and described herein as moving the pulley / transition segments 146a, 152, 162a, 162b of the pulley assembly 120 in the segmented pulley transmission 110, it will be understood that in other embodiments, the actuator system 122 can be used to bi-directionally move discrete rotating elements of another working system, such as a seal segment in a downhole drilling system.

[0097] Although the pulley system 120 has been shown and described herein as including two concentric pulleys, namely a first pulley 124 and a second pulley 126, it will be understood that in other embodiments, the pulley system may include more concentric pulleys when other gear ratios of the segmented pulley transmission 110 are desired.

[0098] Although the pulley system 120 has been shown and described herein as including two transition segment groups, namely the first transition segment group 128 and the second transition segment group 130, it will be appreciated that in other embodiments, the pulley assembly may include only one transition segment group interposed between immediately adjacent pulleys. For example, a single transition segment group may be interposed between immediately adjacent pulleys when only a smooth transition is desired during an upshift event or during a downshift event but not both.

[0099] While embodiments of a pulley assembly and actuator system for a segmented pulley transmission have been described, other aspects thereof have been considered in accordance with the following provisions:

[0100] Clause 1. A pulley assembly for engaging an endless member of a segmented pulley transmission, the pulley assembly comprising:

[0101] a first pulley having an outer peripheral surface for engaging the annular member;

[0102] a second pulley configured to concentrically surround the first pulley and having an outer peripheral surface for engaging the annular member, the second pulley including a set of second pulley segments, each second pulley segment being independently movable between an engagement region in which the second pulley segments are in the path of the annular member and a disengagement region in which the second pulley segments are offset from the path of the annular member; and

[0103] At least one transition segment set includes one or more transition segments defining at least one transition surface, the one or more transition segments being independently movable to the engagement region to engage and transition the annular member between the first pulley and the second pulley.

[0104] Clause 2. The pulley assembly of clause 1, wherein at least one transition segment set is interposed between the first pulley and the second pulley when located in the engagement region with the first pulley and the second pulley.

[0105] Clause 3. A pulley assembly according to clause 1 or 2, wherein at least one transition segment group includes a first transition segment group, which is configured to transition the annular member from the first pulley to the second pulley, and wherein the at least one transition surface includes a first transition surface defined by the first transition segment group.

[0106] Clause 4. The pulley assembly of Clause 3, wherein the first transition surface has a front portion that is substantially aligned with the first adjacent portion of the first pulley.

[0107] Clause 5. The pulley assembly of clause 3 or 4, wherein the first transition surface has a trailing portion that is substantially aligned with the first adjacent portion of the second pulley.

[0108] Clause 6. The pulley assembly of any of Clauses 3 to 5, wherein the first transition segment set includes only a single first transition segment.

[0109] Clause 7. A pulley assembly according to any one of clauses 1 to 6, wherein at least one transition segment group includes a second transition segment group, which is configured to transition the annular member from the second pulley to the first pulley, and wherein the at least one transition surface includes a second transition surface defined by the second transition segment group.

[0110] Clause 8. The pulley assembly of Clause 7, wherein the second transition surface has a front portion that is substantially aligned with the second adjacent portion of the second pulley.

[0111] Clause 9. The pulley assembly of clause 7 or 8, wherein the second transition surface has a trailing portion that is substantially aligned with the second adjacent portion of the first pulley.

[0112] Clause 10. The pulley assembly of any one of clauses 7 to 9, wherein the second transition segment set comprises a plurality of second transition segments.

[0113] Clause 11. The pulley assembly of any of Clauses 1 to 10, wherein at least one of the transition surfaces extends from an adjacent first pulley to an adjacent second pulley over a partial revolution about the axis of rotation.

[0114] Clause 12. The pulley assembly of any of clauses 1 to 11, wherein at least one of the transition surfaces follows a smooth, generally helical path about the axis of rotation.

[0115] Clause 13. A pulley assembly according to any one of clauses 1 to 12, further comprising an actuator system coupled to a set of second pulley segments and at least one transition segment set, wherein the actuator system is configured to independently move a set of second pulley segments and at least one transition segment set between an engagement region and a disengagement region.

[0116] Clause 14. The pulley assembly of clause 13, wherein the actuator system is configured to independently move the set of second pulley segments and the at least one set of transition segments between the engagement region and the disengagement region using electromotive force.

[0117] Clause 15. An actuator system for moving a discrete rotating element of a working system, the actuator system comprising:

[0118] a support structure rotatably fastened to the working system about a rotation axis;

[0119] At least one actuator subassembly secured to the support structure and comprising:

[0120] at least one slide movable relative to the support structure between a respective advanced position and a respective retracted position in response to an electromotive force generated on the slide by the temporary magnetic field; and

[0121] at least one follower engaged with the at least one slide plate to move between a respective extended position and a respective retracted position when the at least one slide plate moves between a respective advanced position and a respective retracted position, the follower being securable to one or more of the discrete rotating elements of the working system; and

[0122] At least one stator, fixably secured to the working system in a position proximate to at least one actuator subassembly, is selectively energizable to generate a temporary magnetic field.

[0123] Clause 16. The actuator system of clause 15, wherein at least one actuator subassembly further comprises a back plate positioned adjacent to at least one sliding plate to increase the electromotive force generated on the sliding plate by the temporary magnetic field.

[0124] Clause 17. The actuator system of clause 16, wherein the backing plate is secured to the support structure and extends in a generally circumferential direction.

[0125] Clause 18. The actuator system of clause 17, wherein the back plate passes through at least one slide plate.

[0126] Clause 19. An actuator system according to any one of clauses 15 to 18, wherein the support structure includes a pair of guide members, and when the slide plate moves between the corresponding advanced position and the corresponding retracted position, the at least one slide plate can be slidably secured between the pair of guide members to guide the at least one slide plate.

[0127] Clause 20. An actuator system according to any one of clauses 15 to 19, wherein each of the at least one skateboard comprises a skateboard base and a reaction plate secured to the skateboard base, and wherein the reaction plate is formed of a conductive but magnetically inert material to increase the electromotive force generated on the skateboard.

[0128] Clause 21. The actuator system of any one of clauses 15 to 20, wherein the support structure comprises at least one stop to prevent movement of the at least one slide plate at the respective advanced position and the respective retracted position.

[0129] Clause 22. The actuator system of clause 21, wherein at least one slide plate comprises at least one bumper for impacting a stop to arrest movement of the at least one slide plate at the respective advanced position and the respective retracted position.

[0130] Clause 23. The actuator system of any of clauses 15 to 22, wherein each of the at least one stator comprises a stator body and at least one winding that can be selectively energized to generate a temporary magnetic field.

[0131] Clause 24. An actuator system according to any one of clauses 15 to 23, wherein at least one follower includes a protrusion engageable with a cam surface of at least one slide to cause the follower to move between a corresponding extended position and a corresponding retracted position when the at least one slide moves between a corresponding advanced position and a corresponding retracted position.

[0132] Clause 25. The actuator system of any of clauses 15 to 24, wherein the discrete rotating elements of the working system are a set of second pulley segments and a segment of at least one transition segment set of a pulley assembly as defined in any of clauses 1 to 14.

[0133] Although embodiments have been described above and shown in the accompanying drawings, those skilled in the art will appreciate that changes and modifications may be made without departing from the scope defined by the appended claims and the scope of the present invention. The claims should be given the broadest interpretation consistent with the entirety of the specification.

Claims

1. A pulley assembly for engaging an annular member of a segmented pulley transmission, the pulley assembly comprising: a first pulley rotatable about a rotation axis and having an outer peripheral surface for engaging the annular member; a second pulley configured to concentrically surround the first pulley and having an outer peripheral surface for engaging the annular member, the second pulley comprising a set of second pulley segments independently movable between an engagement region and a disengagement region; as well as At least one transition segment group includes one or more transition segments, and the one or more transition segments can be independently moved between the engagement area and the disengagement area to transition the annular member between the first pulley and the second pulley, and the at least one transition segment group defines at least one transition surface for engaging and transitioning the annular member between the first pulley and the second pulley.

2. The pulley assembly according to claim 1, wherein: The at least one transition segment set is interposed between the first pulley and the second pulley when located in the engagement region with the first pulley and the second pulley.

3. The pulley assembly according to claim 1, wherein: The at least one transition segment set includes a first transition segment set configured to transition the annular member from the first pulley to the second pulley, and wherein the at least one transition surface includes a first transition surface defined by the first transition segment set.

4. The pulley assembly according to claim 2, wherein: The at least one transition segment set includes a first transition segment set configured to transition the annular member from the first pulley to the second pulley, and wherein the at least one transition surface includes a first transition surface defined by the first transition segment set.

5. The pulley assembly according to claim 3, wherein: The first transition surface has a front portion that is generally aligned with a first adjacent portion of the first pulley.

6. The pulley assembly according to claim 4, wherein: The first transition surface has a front portion that is generally aligned with a first adjacent portion of the first pulley.

7. The pulley assembly according to claim 3, wherein: The first transition surface has a trailing portion that is generally aligned with a first adjacent portion of the second pulley.

8. The pulley assembly according to claim 4, wherein: The first transition surface has a trailing portion that is generally aligned with a first adjacent portion of the second pulley.

9. The pulley assembly according to claim 5, wherein: The first transition surface has a trailing portion that is generally aligned with a first adjacent portion of the second pulley.

10. The pulley assembly according to claim 6, wherein: The first transition surface has a trailing portion that is generally aligned with a first adjacent portion of the second pulley.

11. The pulley assembly according to claim 3, wherein: The first transition segment group includes only a single first transition segment.

12. The pulley assembly according to any one of claims 1 to 11, wherein: The at least one transition segment set includes a second transition segment set configured to transition the annular member from the second pulley to the first pulley, and wherein the at least one transition surface includes a second transition surface defined by the second transition segment set.

13. The pulley assembly according to claim 12, wherein: The second transition surface has a front portion that is generally aligned with a second adjacent portion of the second pulley.

14. The pulley assembly according to claim 12, wherein: The second transition surface has a trailing portion that is generally aligned with a second adjacent portion of the first pulley.

15. The pulley assembly of claim 12, wherein: The second transition segment group includes a plurality of second transition segments.

16. The pulley assembly according to any one of claims 1 to 11, wherein: At least one of the transition surfaces extends from an adjacent first pulley to an adjacent second pulley over a partial revolution about the rotational axis.

17. The pulley assembly of claim 12, wherein: At least one of the transition surfaces extends from an adjacent first pulley to an adjacent second pulley over a partial revolution about the rotational axis.

18. The pulley assembly according to any one of claims 1 to 11, wherein: At least one of the transition surfaces follows a smooth, generally helical path about the axis of rotation.

19. The pulley assembly of claim 12, wherein: At least one of the transition surfaces follows a smooth, generally helical path about the axis of rotation.

20. The pulley assembly of claim 16, wherein: At least one of the transition surfaces follows a smooth, generally helical path about the axis of rotation.

21. The pulley assembly of any one of claims 1 to 11, further comprising an actuator system coupled to the set of second pulley segments and the at least one transition segment set, wherein: The actuator system is configured to independently move the set of second pulley segments and the at least one set of transition segments between the engagement region and the disengagement region.

22. The pulley assembly of claim 12, further comprising an actuator system coupled to the set of second pulley segments and the at least one transition segment set, wherein: The actuator system is configured to independently move the set of second pulley segments and the at least one set of transition segments between the engagement region and the disengagement region.

23. The pulley assembly of claim 16, further comprising an actuator system coupled to the set of second pulley segments and the at least one transition segment set, wherein: The actuator system is configured to independently move the set of second pulley segments and the at least one set of transition segments between the engagement region and the disengagement region.

24. The pulley assembly of claim 18, further comprising an actuator system coupled to the set of second pulley segments and the at least one transition segment set, wherein: The actuator system is configured to independently move the set of second pulley segments and the at least one set of transition segments between the engagement region and the disengagement region.

25. The pulley assembly of claim 21, wherein: The actuator system is configured to independently move the set of second pulley segments and the at least one transition segment set between the engagement region and the disengagement region using electromotive force.

26. A method for shifting an endless member on a pulley assembly during rotational operation of the pulley assembly, the method comprising: engaging the annular member with a start pulley of the pulley assembly; positioning a transition segment set of the pulley assembly in an engagement region, the transition segment set extending between the starting pulley and a destination pulley of the pulley assembly; rotating the pulley assembly to engage the annular member with the transition segment set; transitioning the annular member from an adjacent starting pulley to an adjacent destination pulley during a partial rotation of the pulley assembly about its rotational axis; positioning the destination pulley in the engagement region; rotating the pulley assembly to engage the annular member with the destination pulley; Disengaging the annular member from the starting pulley; as well as The annular member is disengaged from the transition segment set.

27. The method according to claim 26, wherein: The step of transitioning the annular member occurs over only a portion of a rotation of the pulley assembly about the axis of rotation.

28. The method according to claim 26, wherein: The transition segment set provides support to the annular member during the step of transitioning the annular member from the adjacent starting pulley to the adjacent destination pulley.

29. The method according to claim 27, wherein: The transition segment set provides support to the annular member during the step of transitioning the annular member from the adjacent starting pulley to the adjacent destination pulley.

30. The method according to any one of claims 26 to 29, wherein: The destination pulley includes a plurality of segments circumferentially surrounding the start pulley, and wherein positioning the destination pulley in the engagement region includes sequentially moving each of the segments into the engagement region while positioned in the non-contact region of the pulley assembly.

31. The method of claim 30, further comprising: The transition segment group is moved out of the engagement region after the annular member is disengaged from the transition segment group, and a different transition segment group is moved into the engagement region in preparation for a subsequent shifting event.

32. The method according to any one of claims 26 to 29, wherein: The starting pulley includes a plurality of segments circumferentially surrounding the destination pulley, and wherein the step of rotating the pulley assembly to engage the annular member with the set of transition segments includes sequentially moving each of the segments out of the engagement region while positioned in the non-contact region of the pulley assembly.

33. The method of claim 32, further comprising: The transition segment set is moved out of the engagement region after the partial rotation of the pulley assembly and before a full rotation of the pulley assembly.

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