Adjustable bevel gears arrangement for marine propulsion system

Abstract

Adjustable bevel gears arrangement disclosed herein includes two or more shafts that are not parallel but intersect at an angle, along with two or more bevel gears configured to transfer power from one shaft to another. The bevel gears are mounted on one or more bearings and are connected by an inner metal body that secures the shafts. This arrangement allows for post-assembly adjustment to optimize the distance between the bevel gear pair, maintaining a high level of efficiency. Another method involves incorporating threads in the outer metal body, which center and position the bevel gears relative to an outer shell. This feature serves as a reference for adjusting the bevel gears, eliminating the need for an inner metal body between the gears.

Description

[0001] ADJUSTABLE BEVEL GEARS ARRANGEMENT FOR MARINE PROPULSION SYSTEM

[0002] PRIORITY

[0003] The present application is related to, and claims the priority benefit of, U.S. provisional patent application serial no. 63 / 542,902, filed October 6, 2023, the contents of which are incorporated herein directly and by reference in their entirety.

[0004] BACKGROUND

[0005] Gearboxes are designed to reduce or increase the rotational speed (revolutions per minute (RPM) for example) and torque of an output shaft compared to an input shaft, and they achieve these results using gears with different sizes and configurations. Bevel gears are typically used to transfer power between two shafts that are not parallel but intersect at an angle. They are is normally used in various applications such as automotive, marine, industrial machinery, and the like. With the introduction of the electric propulsion systems in the marine industry, the efficiency of each system component affects the overall system efficiency. One of the main parts affecting efficiency are the bevel gears that transfer power from the electric motor to the propellers.

[0006] Several factors influence gearbox efficiency, including assembling errors that cause misalignment. Misalignment can lead to various issues, including friction, noise, reduced efficiency, and premature failure. Bevel gears should be axially aligned with each other, as axial misalignment is one of the worst destructive cases. Axial misalignment can result in uneven loading and increased wear on the gear’s teeth. This can lead to gear failure and a reduction in equipment performance.

[0007] Correcting the axial misalignment of bevel gears is important to ensure smooth and efficient power transmission in mechanical systems. To correct axial misalignment in bevel gears, the gap or offset between the gears along their axis need to be measured. Then, it can be corrected by adding or removing shims to the gears or removing shims from the gears. At the end, the gap is measured again to confirm the misalignment is resolved.

[0008] Furthermore, conventional marine suppliers are using high precision metal outer bodies that have the bevel gears inside to control the position of each bevel gear and to avoid misalignment between the pair of bevel gears. By that, the production of the bevel gears and the metal outer body need to be very precise as it cannot be adjusted in the assembly phase which makes the production of bevel gears components relatively expensive. Any misalignment between the bevel gears leads to a significant reduction in efficiency accompanied by a rise in heat and noise levels.

[0009] In view of the same, devices, systems, and methods for accommodating the above problems would be well received in the marketplace.

[0010] BRIEF SUMMARY

[0011] The present disclosure includes disclosure of a bevel gears arrangement that can be adjusted after the assembly to find the optimal distance between the bevel gear pair in order to maintain a high level of efficiency as well as to reduce the noise and production cost and complexity. By that, the metal outer body is not needed as the distance between the bevel gears can be adjusted using threads in the bearing and the outer shell where the bevel gears are attached to the bearing instead of an outer metal body.

[0012] The present disclosure includes disclosure of a propulsion gears arrangement, as shown and / or described herein.

[0013] The present disclosure includes disclosure of a propulsion gears arrangement, comprising two or more shafts that are not parallel but intersect at an angle, two or more bevel gears configured to transfer power from one shaft to another shaft of the two or more shafts, the two or more bevel gears attached to one or more bearings, and an inner metal body located between the two or more bevel gears and that secures the two or more shafts.

[0014] The present disclosure includes disclosure of a propulsion gears arrangement, wherein the one or more bearings are configured to reduce vibration, friction, and to support the bevel gears by having threads on the upper surface that can be adjusted to adjust the axial movement of the bevel gears.

[0015] The present disclosure includes disclosure of a propulsion gears arrangement, further comprising an outer shell that houses components of the propulsion gears arrangement.

[0016] The present disclosure includes disclosure of a propulsion gears arrangement with an outer metal body with threads for centering and positioning the bevel gear to an outer shell and serves as a reference for adjusting the bevel gears instead of using the inner box to align the bevel gears.

[0017] The present disclosure includes disclosure of a propulsion gears arrangement, wherein a precise measuring tool is used to precisely measure the distance between the bevels. The present disclosure includes disclosure of a propulsion gears arrangement, wherein a noise measuring device is used to provide feedback about the noise level after the bevel gears adjustments.

[0018] The present disclosure includes disclosure of a propulsion gears arrangement, wherein an automated system is used to measure the distance between the bevels and tune them accordingly with a noise measuring feedback to confirm the bevel gears precise arrangement.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The disclosed embodiments and other features, advantages, and disclosures contained herein, and the matter of attaining them, will become apparent and the present disclosure will be better understood by reference to the following description of the present disclosure taken in conjunction with the accompanying drawings, wherein:

[0021] Fig. 1 illustrates a cross-sectional view of propulsion gears arrangement, according to an exemplary embodiment of the present disclosure, using inner metal box to align the bevel gears.

[0022] Fig. 2 illustrates a cross-sectional view of propulsion gears arrangement, according to an exemplary embodiment of the present disclosure, using a detachable outer metal body with threads to align the bevel gears.

[0023] As such, an overview of the features, functions and / or configurations of the components depicted in the figures will now be presented. It should be appreciated that not all of the features of the components of the figures are necessarily described and some of these non-discussed features (as well as discussed features) are inherent from the figures themselves. Other non-discussed features may be inherent in component geometry and / or configuration. Furthermore, wherever feasible and convenient, like reference numerals are used in the figures and the description to refer to the same or like parts or steps. The figures are in a simplified form and not to precise scale.

[0024] DETAILED DESCRIPTION

[0025] For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended. The revolution of electrifying the automotive industry has been extended to include the marine industry. A few changes need to be made when replacing the internal combustion engine with an electric motor as the efficiency of each component can affect the overall electric propulsion system efficiency. Any misalignment between gears can affect the performance of the overall system. On the other hand, the precise production of the system mechanical components can be complex and relatively expensive. In order to achieve a high level of efficiency without a complex production process, an adjustable bevel gears arrangement can be used in the marine propulsion system.

[0026] The present disclosure includes disclosure of a propulsion gears arrangement 100 that comprises a two or more shafts 101, 102 that are not parallel but intersect at an angle, two or more bevel gears 103, 104, 105 that transfer the power from one shaft 101 to another shaft 102 and are attached to one or more bearings 107, 108, 109, and an inner metal body 110 located between the bevel gears 103, 104, 105 and that secures the shafts 101, 102. The one or more bearings 107, 108, 109 are configured to reduce vibration, friction, and to support the bevel gears 103, 104, 105. An outer shell 106 that houses the components of the propulsion gears arrangement 100 can also be used, wherein the bearing 107, 108, 109 has threads 111 in its outer body that is threaded with inner threads 112 of the outer shell 106 to adjust the distance of the bevel gears pair 103, 104, 105 in order to increase the efficiency and reduce the noise, such as shown in Fig. 1. After the components of the propulsion gears arrangement 100 are assembled, the propulsion gears arrangement 100 can be powered and observed while varying the distance between the bevel gears 103, 104, 105 by adjusting the pairs of bevel gears 103, 104, 105 by rotating the threads 111, 112 until the propulsion gears arrangement 100 has the optimum efficiency with the lowest noise levels. After that, the threads 111, 112 can be locked, and the propulsion gears arrangement 100 is ready to be used. Using this method, the complex and precise production process can be avoided. Also, the outer metal body is replaced with the inner metal body 110 as it is not used to align the bevel gears 103, 104, 105 like conventional marine bevel gears.

[0027] Also, using the propulsion gears arrangement 100 of the present disclosure without the conventional outer body around the bevel gears can significantly reduce the electrical propulsion gears thickness which increases the hydrodynamics of the propulsion drive unit.

[0028] In at least one embodiment of the present disclosure, instead of using the inner metal body 110 to align the bevel gears 103, 104 and 105, a detachable outer metal body 114 with threads 115, 116, such as shown in Fig. 2, can be used that allows subsequent disengagement of the one or more bevel gears 103, 104, 105 for disassembly and assembly into the same or different outer structure that houses components of the propulsion gears arrangement 100. That outer metal body 114, for example, is centering and positioning the bevel gear 103 to an outer shell 106, 113 using the threads 115, 116 and serves as a reference for adjusting the bevel gears 104, 105 as shown in Fig. 2.

[0029] In at least one embodiment of the present disclosure, wherein a precise measuring tool 150, shown in block component diagram form in Fig. 2, is used to precisely measure the distance between the bevels gears 103, 104, 105.

[0030] In at least one embodiment of the present disclosure, wherein a noise measuring device 155, shown in block component diagram form in Fig. 2, is used to provide feedback about the noise level after the bevel gears 103, 104, 105 adjustments.

[0031] In at least one embodiment of the present disclosure, wherein an automated system 160, shown in block component diagram form in Fig. 2, is used to measure the distance between the bevels gears 103, 104, 105 and tune them accordingly with a noise measuring feedback to confirm the bevel gears precise arrangement.

[0032] While various embodiments of devices and systems and methods for using the same have been described in considerable detail herein, the embodiments are merely offered as non-limiting examples of the disclosure described herein. It will therefore be understood that various changes and modifications may be made, and equivalents may be substituted for elements thereof, without departing from the scope of the present disclosure. The present disclosure is not intended to be exhaustive or limiting with respect to the content thereof.

[0033] Further, in describing representative embodiments, the present disclosure may have presented a method and / or a process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth therein, the method or process should not be limited to the particular sequence of steps described, as other sequences of steps may be possible. Therefore, the particular order of the steps disclosed herein should not be construed as limitations of the present disclosure. In addition, disclosure directed to a method and / or process should not be limited to the performance of their steps in the order written. Such sequences may be varied and still remain within the scope of the present disclosure.

Claims

CLAIMS1. A propulsion gears arrangement, comprising: two or more shafts that are not parallel but intersect at an angle; two or more bevel gears configured to transfer power from one shaft to another shaft of the two or more shafts, the two or more bevel gears attached to one or more bearings; and an inner metal body located between the two or more bevel gears and that secures the two or more shafts.

2. The propulsion gears arrangement of claim 1, wherein the one or more bearings supporting the two or more bevel gears are configured to reduce vibration and friction by having threads on an upper surface that can be adjusted to adjust an axial movement of the two or more bevel gears.

3. The propulsion gears arrangement of claim 1, further comprising: an outer shell that houses components of the propulsion gears arrangement.

4. The propulsion gears arrangement of claim 1, wherein a precise measuring tool is used to precisely measure a distance between the two or more bevel gears.

5. The propulsion gears arrangement of claim 1, wherein a noise measuring device is used to provide feedback about a noise level after adjustment of the two or more bevel gears.

6. The propulsion gears arrangement of claim 1, wherein an automated system is used to measure a distance between two or more bevel gears and tune them accordingly with a noise measuring feedback to confirm a precise arrangement of the two or more bevel gears.

7. A propulsion gears arrangement, comprising: two or more shafts that are not parallel but intersect at an angle; two or more bevel gears configured to transfer power from one shaft to another shaft of the two or more shafts, the two or more bevel gears attached to one or more bearings; and a detachable outer metal body with threads that allows subsequent disengagement of one or more of the two or more bevel gears for disassembly and assembly into a same or different outer structure that houses components of the propulsion gears arrangement wherein the outer metal body is configured for centering and positioning the one or more of the bevel gears to an outer shell and serves as a reference for adjusting the other of the two or more bevel gears.

8. The propulsion gears arrangement of claim 7, wherein a precise measuring tool is used to precisely measure a distance between the two or more bevel gears.

9. The propulsion gears arrangement of claim 7, wherein a noise measuring device is used to provide feedback about a noise level after adjustment of the two or more bevel gears.

10. The propulsion gears arrangement of claim 7, wherein an automated system is used to measure a distance between two or more bevel gears and tune them accordingly with a noise measuring feedback to confirm a precise arrangement of the two or more bevel gears.

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