Hydraulic variable ratio gearbox with an innovative mechanism for torque and speed adjustment

Abstract

The Variable Hydraulic variable ratio gear box uses a hydraulic pump and motor to transmit power without mechanical gears. The pump converts constant input torque into pressurized hydraulic fluid, with adjustable flow and pressure to control power delivery. This fluid powers the hydraulic motor, which converts it back into mechanical output torque. By varying the volumetric capacities of both pump and motor, the system continuously adjusts the transmission ratio. Decreasing the pump's volume while increasing the motor's results in higher output torque at lower speed, while the reverse yields higher speed with lower torque. Braking is hydraulically applied directly to the output shaft, eliminating mechanical clutches and enhancing efficiency and control during operation.

Description

Hydraulic Variable Ratio Gearbox with an Innovative Mechanism for Torque and Speed Adjustment

[0001] This invention pertains to the field of mechanical engineering, specifically to variable ratio gearboxes. This gearbox introduces an innovative method for changing the ratio hydraulically, eliminating the need for a torque converter while enabling hydraulic braking. It is applicable in industries such as transportation, heavy machinery, and industrial systems that require precise control of torque and rotational speed.

[0002] In many applications such as transportation and rotational systems, it is essential to use mechanisms that can adjust rotational speed and torque. This has led to the widespread use of gearboxes in power transmission systems. Gearboxes are generally divided into two main categories: manual and automatic. Manual gearboxes rely on older designs, where torque and speed adjustment are achieved by manually changing gears. On the other hand, automatic gearboxes have advanced systems that enable automatic adjustments in power ratios. Various gearbox types, such as planetary, CVT, dual-clutch, and sequential gearboxes, are utilized in automobiles and industries, but each comes with its own limitations.

[0003] For instance, manual and automatic gearboxes typically use step-based mechanisms for gear shifting, resulting in limitations such as slow shifting, high pressure, and short lifespans. Even modern gearboxes like dual-clutch and sequential systems, despite their higher efficiency, suffer from issues such as stepped shifting and weaknesses in handling high torque. CVT gearboxes, while offering smooth and continuous gear shifting, face limitations like low torque tolerance and short lifespans in demanding applications. Additionally, all current gearboxes require a clutch plate or torque converter to disconnect or connect the power input, increasing system complexity.

[0004] This invention aims to address these challenges through a novel design that eliminates the need for a torque converter or clutch, increases torque tolerance, and integrates hydraulic braking capabilities. It not only resolves existing drawbacks but also enhances system longevity and optimizes overall power transmission efficiency.

[0005] This invention introduces a hydraulic variable ratio gearbox with a novel mechanism for torque and rotational speed adjustment. Unlike existing gearboxes that require torque converters or clutch plates, this innovative design eliminates these components and offers a simpler, more efficient system with a longer lifespan. The hydraulic mechanism developed in this invention enables seamless torque and speed adjustment while incorporating hydraulic braking capabilities, enhancing overall system productivity. Furthermore, the gearbox provides high torque tolerance, extended operational life, and resolves existing limitations such as stepped gear shifting and pressure handling. Its applications span various industries, including transportation, heavy machinery, and industrial systems, offering precise control of torque and rotational speed and revolutionizing power transmission systems.

[0006] One of the fundamental problems with existing power transmission systems is the complexity and low reliability of their mechanisms. Common manual and automatic gearboxes, due to their outdated designs, suffer from short lifespans, frequent maintenance requirements, and high costs. Furthermore, the inclusion of torque converters and clutch plates in many systems adds complexity, limits torque tolerance, and prevents seamless gear shifting.

[0007] Additional issues include low energy efficiency, the inability to handle high torque in CVT systems, and delays in the operation of stepped gearboxes. These challenges reduce the applicability of such gearboxes in heavy industries and systems requiring high torque and precision.

[0008] Therefore, there is a need for a new power transmission system with a simpler mechanism, longer lifespan, and advanced capabilities that can address these issues by eliminating torque converters, providing smooth gear shifting, and tolerating high torque.

[0009] In CVT gearboxes, two major issues often arise: low torque tolerance and short lifespan of current designs (belt-based or chain-based systems). The hydraulic variable ratio gearbox is being introduced for the first time in the world, designed based on hydraulic engineering principles. Due to its hydraulic structure, the gearbox is capable of handling significantly higher torque levels. Additionally, given the scientifically and experimentally proven long lifespan of hydraulic pumps and hydraulic motors, this gearbox will also have a long service life.

[0010] Thanks to its advanced engineering design, this gearbox experiences minimal harmful stress on its components, reduces energy waste to the bare minimum, and enhances efficiency compared to existing systems. It also provides other advantages, such as hydraulic braking and the elimination of torque converters, which further increase its performance and productivity.

[0011] The hydraulic variable ratio gearbox consists of a 3-speed variable displacement hydraulic pump as the hydraulic sender and a 3-speed variable displacement hydraulic motor as the hydraulic receiver. It should be noted that both the hydraulic pump and the hydraulic motor used in this gearbox are original designs created by the inventor.

[0012] By reducing the hydraulic displacement per revolution of the hydraulic pump while simultaneously increasing the hydraulic displacement per revolution of the hydraulic motor, the output shaft’s rotational speed significantly decreases, and torque increases. Conversely, by increasing the hydraulic displacement per revolution of the hydraulic pump and simultaneously reducing the hydraulic displacement per revolution of the hydraulic motor, the output shaft’s rotational speed significantly increases, and torque decreases.

[0013] To achieve this, the method involves the internal engagement and disengagement of hydraulic gears with the gearbox cover. For example, hydraulic gears (7) engage within the cover (3) using seal bushings (32), while hydraulic gears (8, 9) engage inside the cover (5) using seal bushings (33, 34). Similarly, hydraulic gear (507) engages within bushing (532), and hydraulic gears (508, 509) engage within bushings (533, 534). This innovative method involves increasing or decreasing the area of gear engagement, a solution that has not yet been applied to any other hydraulic pump or motor.

[0014] Our design consolidates a system where a 3-speed variable displacement hydraulic pump serves as the hydraulic sender, and a 3-speed variable rotation hydraulic motor acts as the hydraulic receiver. This system allows the input torque to be adjusted according to the user’s needs, within a broader and more optimized range of power and performance compared to any existing gearbox. Both the pump and motor in this system are original technologies invented and designed by the creator.

[0015] Diagram (200, 201, 202) illustrates all parts used in the hydraulic variable ratio gearbox and their placement within it.

[0016] The gearbox comprises the following components:

[0017] 1_Housing (44, 544, 545)

[0018] 2_Covers (1, 3, 4), (501, 503, 504)

[0019] 3_Hydraulic gears (7, 8, 9), (507, 508, 509)

[0020] 4_Hollow shaft (10, 11)

[0021] 5_Solid shaft (12), (512)

[0022] 6_Retaining nuts (13, 14, 15, 16, 17, 18), (513, 514)

[0023] 7_Bushing bearings (23, 25), (523, 525)

[0024] 8_Screw bushings (26, 27)

[0025] 9_Drive gears (28, 29)

[0026] 10_Worm drive gears (30, 31)

[0027] 11_Seal bushings (32, 33, 34), (532, 533, 534)

[0028] 12_Cylindrical pistons (35, 36)

[0029] 13_Rail shafts (37, 38)

[0030] 14_Gear bearings (39, 40), (539, 540)

[0031] 15_Hydrophobic packing (41, 42), (541)

[0032] 16_Adjustment bolts (45, 46)

[0033] 17_Piston bushings (47, 48, 49, 50)

[0034] 18_Hydraulic gear locking pins (51), (551)

[0035] 19_Stationary packing bushes (54), (554)

[0036] 20_Worm gear shaft (55)

[0037] 21_Allen screws (53)

[0038] 22_Fixing screws (52)

[0039] 23_Cover O-rings

[0040] 24_Bearing washers (56, 57)

[0041] The seal bushing (33), (533) is placed in locations (2-4), (3-504) and the seal bushing (34), (534) is placed in locations (3-4), (2-504) with a clearance of 0.01 mm. The bearing bushing (25), (525) is placed and secured in locations (1-4), (1-504). The cover (4), (504) is placed into location (2-44), (2-544) inside the housing (44), (544), and each of them is fastened with 14 Allen screws (53).

[0042] It is important to note that the housing wall in location (2-44), (2-544) and the surface of the gear (7), (507) prevent the seal bushings (33), (533) and (34), (534) from moving out of place. The solid shaft (12), (512) is positioned inside the bearing bushing (25), (525) with a clearance of 0.01 mm, and its end is secured with the stabilizer nut (13), (513) and then tightened with the stabilizer screw (52). Hydrophobic O-rings are positioned on the housing (44), (544). Housing parts (44) and (544) are connected via the intermediary housing (545), which is secured with 16 Allen screws (53).

[0043] Gear (8), (508) is positioned in location (2-4), (3-504) inside the seal bushing (35), (535), and gear (9), (509) is positioned in location (3-4), (2-504) inside the seal bushing (34), (534) with a clearance of 0.01 mm. It is important to note that the reciprocal movement of gears (8, 9), (508, 509) inside the seal bushings (34, 33), (534, 533) occurs with a clearance of 0.01 mm.

[0044] The cylindrical piston (35) is positioned in location (4-4), (4-504), and the cylindrical piston (36) is positioned in location (5-4), (5-504) with a clearance of 0.01 mm. It is important to mention that the reciprocal movement of cylindrical pistons (36, 35) occurs inside locations (4-4, 5-4), (504-4, 505-4).

[0045] The hollow shaft (10) is placed inside the gear bearing (39), (539), and the hollow shaft (11) is placed inside the gear bearing (40), (540) with a clearance of 0.01 mm. Bearing washer (56) is placed between gear (8), (508) on both sides with a clearance of 0.01 mm, and bearing washer (57) is placed between gear (9), (509) on both sides with a clearance of 0.01 mm.

[0046] It is important to mention that the rotational motion of gears (8, 9), (508, 509) mounted on gear bearings (39, 40), (539, 540) occurs with a clearance of 0.01 mm. Seal bushing (32), (532) is positioned in location (1-3), (1-503) with a clearance of 0.01 mm. The movable cover (3), (503) is fitted into its position (3-44), (3-544) with a clearance of 0.01 mm from the housing wall.

[0047] One side of hollow shaft (10) is placed in location (2-3), and the other side of hollow shaft (10) is placed in location (3-503), secured with stabilizer nuts (15, 17). Similarly, one side of hollow shaft (11) is placed in location (3-3), and the other side in location (2-503), secured with stabilizer nuts (16, 18), and tightened using screws (52).

[0048] It is important to note that the reciprocal movement of gear (7), (507) inside the seal bushing (32), (532) occurs with a clearance of 0.01 mm. Additionally, the surface of gears (9, 8), (509, 508) and the surface of cylindrical pistons (35, 36) prevent the seal bushings (32), (532) from moving out of their positions.

[0049] The cylindrical piston bush (47) is positioned in location (1-35), the cylindrical piston bush (48) is positioned in location (2-35), the cylindrical piston bush (49) is positioned in location (1-36), and the cylindrical piston bush (50) is positioned in location (2-36), all of which are secured tightly.

[0050] The upper surface of cylindrical piston (35) is positioned in location (4-3) and the surface of cylindrical piston (36) is positioned in location (5-3), with each being secured by 4 Allen screws (53). The lower surface of cylindrical piston (36) is secured in location (4-503), while the other surface is secured in location (503-5) with 4 Allen screws each.

[0051] Gear (7), (507) is mounted on the solid shaft (12), (512) in location (1-3), (1-503) and passes through seal bushing (32), (532) with a clearance of 0.01 mm. It is secured on the solid shaft (12), (512) by the stabilizer nut (14), (514), tightened with stabilizer screws (52).

[0052] The clearance between the fixed bush (54), (554) and stabilizer nut (14), (514) is 0.01 mm. The clearance between hydraulic gear (7), (507) and housing (4), (504) is 0.01 mm. The stabilizer nut (14), (514) is positioned between gear (7), (507) and fixed bush (54), (554), preventing the solid shaft (12), (512) from coming out of place. The gear lock (51), (551) stabilizes the solid shaft (12), (512) with gear (7), (507).

[0053] The rail shaft (37) passes through the piston bushes (47, 48) with a clearance of 0.01 mm, and one end is tightly secured in location (4-501) and the other in location (4-1). Similarly, the rail shaft (38) passes through piston bushes (49, 50) with a clearance of 0.01 mm, and one end is secured in location (5-501) and the other in location (5-1).

[0054] It is important to mention that the reciprocal motion and rotational movement of the assembly occur on shafts (37, 38). Adjustment screws (45, 46) are threaded into the hollow shafts (10, 11) and pass through. On one side of adjustment screw (45), the threaded bearing bushing (26) is secured, while on the other side the drive gear (28) is mounted and tightened with stabilizer screws (52). Similarly, adjustment screw (46) secures the threaded bearing bushing (27) on one side and the drive gear (29) on the other, tightened with stabilizer screws (52).

[0055] It is important to note that adjustment screws (45, 46), through the rotational motion of drive gears (28, 29), perform clockwise and counterclockwise rotation and, through this motion, the threads of hollow shafts (10, 11) are opened and closed, enabling the simultaneous reciprocal and rotational movement of the assembly on rail shafts (37, 38).

[0056] The threaded bearing bushings (26) and (27) are positioned respectively in cover locations (2-501) and (3-501) with a clearance of 0.01 mm. On the other side, the drive gear (28) is located at (2-1), and gear (29) is located at (3-1) on cover (1) with a clearance of 0.01 mm.

[0057] Packing (41), (541) is positioned in its place within the fixed bush (54), (554) and secured with 4 Allen screws (53) at locations (1-1), (501-1). The bearing bushing (23), (523) is tightly secured at locations (1-1), (1-501). Cover (1), (501) is secured at location (1-44), (1-544) with O-ring seals and tightened using Allen screws (53).

[0058] The solid shaft (12), (512) passes through bearing bushings (23), (523) and fixed bushings (54), (554) with a clearance of 0.01 mm. By applying torque to the shaft (12) through a driving motor mounted on bearing bushings (23) and (25), the hydraulic gear (7) and seal bushing (32), along with the stabilizer nuts (13, 14) and stabilizer screws (52), are set into motion via the locking pin (51).

[0059] Upon rotation of gear (7), the force applied to gear (8), which is mounted on gear bearing (39) along with seal bushing (33), and gear (9), along with seal bushing (34), mounted on gear bearing (40) as idle gears, begins rotating

[0060] With the simultaneous rotation of gears (7), (8), (9), hydraulic oil enters the suction chamber (70) through the main inlet and then is directed into the suction section of the main chamber (1-80) via the inlets (1, 2) on the cover (3). With the rotation of the hydraulic gears (7), (8), (9), the hydraulic oil is transferred from the suction section of the main chamber (1-80) to the discharge section of the main chamber (2-80). It is then pumped out through the outlets (1, 2) on the cover (4) toward the pressure chamber (90).

[0061] Next, as it passes through the inlets (1, 2) of cover (504), the pressurized hydraulic oil enters section (1-580). It then flows between the teeth of hydraulic gears (507, 508, 509), causing the rotation of these gears inside the seal bushings (532, 533, 534). During this process, the fluid’s pressure is converted into torque. The fluid then moves from section (1-580) to section (2-580), passing through the outlets (1, 2) located on cover (503), and exits through the main outlet.

[0062] As a result of this operation, the torque produced by hydraulic gears (508, 509), mounted on the gear bearings (39, 40), is transmitted to the solid shaft (512) through the hydraulic gear (7) and the gear lock (551). This causes the solid shaft (12), along with the stabilizer nuts (513, 514) and stabilizer screws (52), mounted on the bearing bushings (523, 525), to rotate.

[0063] It should be noted that the seal bushing (32, 532) is enclosed by the surfaces of gears (8, 508) and (9, 509), as well as the surfaces of cylindrical pistons (35, 36), ensuring that it remains in place. Similarly, the seal bushings (33, 533) and (34, 534) are confined by the housing wall (1-544, 1-44) and the surface of gear (7, 507), preventing them from moving out of place.

[0064] It is important to mention that the seal bushings (32, 33, 34) rotate simultaneously with gears (7, 8, 9), and the seal bushings (532, 533, 534) rotate simultaneously around the gears (507, 508, 509). This allows the reciprocal motion of the hydraulic gears and prevents the hydraulic fluid from escaping the hydraulic gears’ sides into the suction and discharge chambers. Additionally, this mechanism stops the hydraulic fluid from moving between the suction and discharge chambers and the main chamber. This innovative mechanism has not been used in any devices, hydraulic pumps, or hydraulic motors to date.

[0065] By applying force in both clockwise and counterclockwise directions to the worm gear shaft (55), along with the rotation of the drive gears (30, 31) and stabilizer screws (52), and subsequently turning the drive gears (29, 28) and stabilizer screws (52), the adjustment screws (45, 46) rotate. This operation applies opening or closing forces to the threads inside the hollow shafts (10, 11). As a result, the reciprocating motion of the drive assembly and rotational assembly occurs simultaneously on the rail shafts (37, 38) with the engagement of the cylindrical piston bushes (47, 48) and (49, 50).

[0066] In this mechanism, gears (7, 8, 9) are positioned inside the seal bushings (32, 33, 34) with a clearance of 0.01 mm, and gears (507, 508, 509) are positioned inside the seal bushings (532, 533, 534) with a clearance of 0.01 mm. Similarly, the cylindrical pistons (35, 36) move inside locations (4-4), (5-4) and (4-504), (5-504) with a clearance of 0.01 mm and are responsible for stabilizing the main chambers.

[0067] As a result of this reciprocal motion:

[0068] When the volume of the main chamber (80) and the engagement surface (101, 102) of hydraulic gear (7) with idler gears (8), (9) decreases, the volume of the main chamber (580) and the engagement surface (601, 602) of hydraulic gears (507) with idler gears (508), (509) increases. Consequently, the speed of the solid shaft (512) significantly decreases, but the torque significantly increases.

[0069] Conversely, when the volume of the main chamber (80) and the engagement surface (101, 102) of hydraulic gear (7) with idler gears (8), (9) increases, the volume of the main chamber (580) and the engagement surface (601, 602) of hydraulic gears (507) with idler gears (508), (509) decreases. Consequently, the speed of the solid shaft (512) significantly increases, but the torque significantly decreases.

[0070] The mechanism and components used in this gearbox are unprecedented and have not been implemented in any device to date.

[0071] Gearbox Fixed Components:

[0072] 1_Covers (1, 4, 501, 504)

[0073] 2_Bearing bushings (23, 25, 523, 525)

[0074] 3_Rail shafts (37, 38)

[0075] 4_Allen screws (53)

[0076] 5_Fixed bushes (554, 54)

[0077] 6_Cover O-rings

[0078] 7_Packings (41, 42)

[0079] 8_Housings (44, 544, 545)

[0080] Gearbox Fixed Rotational Components:

[0081] 1_Solid shaft (12, 512)

[0082] 2_Stabilizer nuts (513, 514, 13, 14)

[0083] 3_Hydraulic locks (551, 51)

[0084] 4_Hydraulic gear (7, 507)

[0085] 5_Hydraulic gear locks (51, 551)

[0086] 6_Drive gears (28, 29, 30, 31)

[0087] 7_Adjustment screws (45, 46)

[0088] 8_Seal bushings (33, 34, 533, 534)

[0089] 9_Screw bearing bushings (26, 27)

[0090] Gearbox Movable Components:

[0091] 1_Stabilizer nuts (17, 18, 15, 16)

[0092] 2_Covers (3, 503)

[0093] 3_Cylindrical pistons (35, 36)

[0094] 4_Piston bushes (47, 48, 49, 50)

[0095] 5_Hollow shafts (10, 11)

[0096] 6_Allen screws (53)

[0097] Gearbox Movable Rotational Components:

[0098] 1_Hydraulic gears (8, 9, 508, 509)

[0099] 2_Gear bearings (539, 540, 39, 40)

[0100] 3_Seal bushings (532, 32)

[0101] 4_Bearing washers (56, 57).

[0102] The present invention offers significant advantages that distinguish it from conventional systems. The hydraulic variable ratio gearbox in this invention, due to its innovative mechanism for torque and speed adjustment, provides improved efficiency and precision compared to existing models. This design eliminates the need for a torque converter, leading to reduced system weight and production costs while optimizing energy consumption. Furthermore, the gearbox is engineered to withstand high torque under demanding working conditions, ensuring reliability and long-term performance. Additionally, the integrated hydraulic braking system enhances safety and reduces potential failures. These features make the invention an excellent choice for industries such as transportation, heavy machinery, and industrial systems.

[0103] 1- : A 3D perspective drawing without the casing, illustrating the placement of components.

[0104] 2- : A longitudinal cross-sectional drawing of the gearbox showing the position of the main input (110), the main output (111), the inlets or outlets for the clutch or other purposes (106), the gear engagement surfaces (101, 102, 601, 602), and the locations on the shell (1-44), (3-44), (4-44), (544-1), (544-3), (544-4).

[0105] 3- : Depicts the mechanism of reciprocating motion.

[0106] 4- : Shows the longitudinal cross section of the gearbox and the chambers (70, 80, 90).

[0107] 5- : Shows the transverse cross-section of the gearbox and the mechanism of the driving gears (28, 29), the worm gears (30, 31), and the shaft of the worm gears (55).

[0108] 6- Figures 6, 7, 8: Show transverse sections and external views of the gearbox.

[0109] 7- : Shows front and rear views of the gearbox.

[0110] 8- : Depicts the casing (44, 544), the attachment points for Allen screws (53), and the placement of hydrophobic O-rings.

[0111] 9- : Depicts the casing (545) and the attachment points for Allen screws (53).

[0112] 10- : Shows the cover (1, 501), bearing bush (23, 523), and the placement of components.

[0113] 11- : Depicts the cover (3, 503) and shows the placement of cylindrical pistons (35, 36), sealing bush (32), and the location numbers of the components.

[0114] 12- : Shows the cover (4, 504), the placement of water seals (33, 34, 533, 534), bearing bushes (25, 525), and the location numbers of the components.

[0115] 13- : Depicts the hydraulic idler gears (9, 8, 508, 509) and the bearing location for the gears (39, 40, 539, 540).

[0116] 14- : Shows the drawing of bearing washers (56, 57).

[0117] 15- : Shows the drawing of sealing bushes (32, 33, 34, 532, 533, 534) and the additional hydraulic escape grooves (for trapped fluid during a fraction of the rotational cycle between hydraulic gears).

[0118] 16- : Shows the drawing of adjustment screws (45, 46).

[0119] 17- : Shows the drawing of rail shafts (37, 38).

[0120] 18- : Shows the drawing of tubular shafts (10, 11).

[0121] 19- : Depicts the drawing of cylindrical pistons (35, 36) and the piston bushes (47, 48, 49, 50), along with the placement of components.

[0122] 20- : Shows the drawing of driving gears (28, 29) and the locations of stabilizing screws.

[0123] 21- : Depicts the drawing of the worm gear shaft (55).

[0124] 22- : Shows the drawing of the solid shaft (12, 512) and the location of keys (52, 552).

[0125] 23- : Depicts the drawing of gear bearings (39, 40, 539, 540).

[0126] 24- : Shows the drawing of the main hydraulic gear (7, 507) and the location of the hydraulic gear key (51, 551).

[0127] 25- : Depicts the drawing of the gear key (51, 551).

[0128] 26- : Shows the drawing of the fixed packing bush (54, 554).

[0129] 27- : Depicts the drawing of the worm driving gears (30, 31).

[0130] 28- : Shows the drawing of the Allen screw (53).

[0131] 29- : Depicts the drawing of the screw bearing bushes (26, 27) and the placement of stabilizing screws.

[0132] 30- : Shows the drawing of the stabilizing nuts (15, 16, 17, 18) and the placement of stabilizing screws.

[0133] 31- : Depicts the drawing of stabilizing screws (52).

[0134] 32- : Shows the drawing of the main shaft packing (41, 541).

[0135] 33- : Shows the drawing of the worm gear shaft packing (35).

[0136] 34- : Shows the drawing of the stabilizing nuts for the solid shaft (13, 14, 513, 514) and the stabilizing screws, along with their oil lines.

[0137] 35- : Depicts the drawing of bearing bushes (23, 25, 523, 525).

[0138] 36- : Shows the drawing of the cylindrical piston bushes (47, 48, 49, 50).

[0139] This invention presents a hydraulic variable ratio gearbox designed to provide advanced torque and speed adjustments with high efficiency, reliability, and compatibility for industrial applications. Utilizing innovative technology, this gearbox enables hydraulic adjustment of the transmission ratio and introduces a new method for controlling speed and torque.”

[0140] 1. General Mechanism of Operation

[0141] This gearbox is designed to facilitate precise changes in power transmission without the need for a torque converter. Additionally, the inclusion of an internal hydraulic braking system enhances safety and reduces potential failures during use. This mechanism increases efficiency, reduces system weight, and lowers energy consumption and overall costs.

[0142] 2. Practical Applications

[0143] This gearbox is highly versatile and can be used in various industries, including transportation, heavy machinery, and industrial systems. Some practical applications include:

[0144] Transportation Industry: Utilized in trucks, buses, and other heavy vehicles requiring precise management and adjustment of speed and torque.

[0145] Heavy Machinery: Applicable for cranes, bulldozers, and machines requiring high torque and reliable performance under strenuous conditions.

[0146] Industrial Systems: Ideal for production and industrial environments that demand accurate force and speed control.

[0147] For instance, in a practical implementation, this gearbox is employed in heavy-duty trucks. Its ability to withstand high torque ensures reliable operation under challenging conditions and heavy loads. Moreover, the internal braking system of this gearbox enhances vehicle safety on steep slopes and hazardous roads, reducing reliance on traditional braking systems.

[0148] 3. Advantages of the Invention

[0149] The hydraulic variable ratio gearbox offers multiple advantages that distinguish it from existing systems:

[0150] High torque tolerance: Suitable for operation under heavy loads and demanding conditions.

[0151] Integrated braking system: Enhances safety and minimizes potential failures in various operational environments.

[0152] Elimination of the torque converter: Reduces the weight and cost of the system while improving overall efficiency.

[0153] Economic and efficient design: Optimized system design reduces energy consumption and operational costs.

[0154] Flexibility in applications: Adaptable for use across various industries with diverse requirements..Examples

[0155] To demonstrate the practical capabilities of this invention, several specific applications of the hydraulic variable ratio gearbox are presented. These examples evaluate the performance of the invention in real-world conditions:

[0156] 1. Application in Heavy-Duty Trucks

[0157] In one implementation, this gearbox was utilized in heavy-duty transport trucks. These trucks often operate on steep roads or under heavy-load conditions and require high torque and precise control.

[0158] Operating Conditions:

[0159] Load carried: 30 tons.

[0160] Incline angle: 8%.

[0161] Average speed on the incline: 50 km / h.

[0162] Results:

[0163] The gearbox successfully adjusted the output torque without requiring a torque converter.

[0164] The hydraulic braking system reduced the stress on the truck’s conventional brakes during descent.

[0165] Energy efficiency improved by 15%, as the overall system weight and energy loss were reduced.

[0166] This example demonstrated that the hydraulic gearbox is effective in managing heavy loads and reducing wear on the truck’s braking systems.

[0167] 2. Application in Industrial Machinery

[0168] In another example, the gearbox was implemented in an industrial manufacturing system requiring precise control of speed and torque. This system involved a device used for cutting and shaping metal parts.

[0169] Operating Conditions:

[0170] Cutting force: 250 N.

[0171] Speed control precision: ±0.5 RPM.

[0172] Operating time per cycle: 3 minutes.

[0173] Results:

[0174] The gearbox provided precise cutting force and reduced torque fluctuations to less than 3%.

[0175] The manufactured parts displayed higher quality, and the accuracy of the production process improved.

[0176] Replacing traditional systems with this gearbox reduced the machine’s noise levels by 20%.

[0177] This example demonstrated that the gearbox is suitable for application in sensitive and precise industrial devices.

[0178] 3. Testing in Extreme Environmental Conditions

[0179] To evaluate the gearbox’s performance under harsh conditions, a test was conducted in a stone quarry. The machinery used in this test included heavy loaders operating in environments with high heat and excessive dust.

[0180] Operating Conditions:

[0181] Ambient temperature: 45°C.

[0182] Dust levels: Higher than the normal standard threshold.

[0183] Duration of operation: 12 continuous hours.

[0184] Results:

[0185] The gearbox maintained stable performance in high temperatures, and no faults in the hydraulic system were observed.

[0186] The integrated braking system effectively prevented overheating of the components.

[0187] After the test, the need for maintenance and part replacement was minimized.

[0188] This test demonstrated that the gearbox performs reliably under extremely demanding conditions and increases the operational lifespan of the system.

[0189] Final Review

[0190] These examples illustrate that the hydraulic variable ratio gearbox presented in this invention exhibits dependable performance across various applications

[0191] This invention has extensive industrial applicability and offers significant advantages. The hydraulic variable ratio gearbox with an innovative mechanism for torque and speed adjustment is designed to cater to various industries that demand precise torque and speed control.

[0192] The industrial applications of this invention include the following areas:

[0193] Transportation Industry:

[0194] Passenger Vehicles: Applicable in passenger cars to enhance power transmission performance, reduce fuel consumption, and increase the durability of the transmission system.

[0195] Trucks and Buses: Applicable in heavy-duty trucks and buses to optimize energy consumption and improve load management in tough conditions.

[0196] Agricultural Machinery: Suitable for tractors and agricultural equipment requiring high torque and precise control.

[0197] Heavy Machinery Industry:

[0198] Applicable in loaders, bulldozers, and mining equipment, which demand high torque and resilience in extreme environmental conditions.

[0199] Manufacturing and Factory Industries:

[0200] Suitable for machines producing metal parts and industrial equipment requiring precise speed control and reduced torque fluctuations.

[0201] Sensitive Industrial Systems:

[0202] Applicable in machinery that requires high precision in speed and torque, such as medical, laboratory, or precision automated processes.

[0203] Energy Production Systems:

[0204] Useful in mechanical power generation systems, such as turbines, requiring efficient and high-performance power transmission.

[0205] This invention not only reduces energy consumption and enhances efficiency but also ensures reliable operation in challenging industrial conditions

[0206] 1_Housing (44, 544, 545)

[0207] 2_Covers (1, 3, 4), (501, 503, 504)

[0208] 3_Hydraulic gears (7, 8, 9), (507, 508, 509)

[0209] 4_Hollow shaft (10, 11)

[0210] 5_Solid shaft (12), (512)

[0211] 6_Retaining nuts (13, 14, 15, 16, 17, 18), (513, 514)

[0212] 7_Bushing bearings (23, 25), (523, 525)

[0213] 8_Screw bushings (26, 27)

[0214] 9_Drive gears (28, 29)

[0215] 10_Worm drive gears (30, 31)

[0216] 11_Seal bushings (32, 33, 34), (532, 533, 534)

[0217] 12_Cylindrical pistons (35, 36)

[0218] 13_Rail shafts (37, 38)

[0219] 14_Gear bearings (39, 40), (539, 540)

[0220] 15_Hydrophobic packing (41, 42), (541)

[0221] 16_Adjustment bolts (45, 46)

[0222] 17_Piston bushings (47, 48, 49, 50)

[0223] 18_Hydraulic gear locking pins (51), (551)

[0224] 19_Stationary packing bushes (54), (554)

[0225] 20_Worm gear shaft (55)

[0226] 21_Allen screws (53)

[0227] 22_Fixing screws (52)

[0228] 23_Cover O-rings

[0229] 24_Bearing washers (56, 57)

[0230] 25_Main Input (110)

[0231] 26_Main Output (111)

[0232] 27_Input / Output for Clutch or Other Purposes (106)

[0233] 28_Chambers (70, 80, 90).

[0234] US8360917B2

[0235] Continuously Variable Transmission

[0236] This patent describes a shifting mechanism for a CVT (Continuously Variable Transmission) designed to enhance gear ratio transitions and reduce system slippage.

[0237] Link: https: / patents.google.com / patent / US8360917B2 / en

[0238] US4589303A

[0239] Continuously Variable Transmission with Synchronous Shift

[0240] This patent introduces a synchronized design for smooth and continuous transitions between gear ratios, improving efficiency and reducing interruptions in power delivery.

[0241] Link: https: / patents.google.com / patent / US4589303A / en

[0242] US20030084530A1

[0243] Continuously Variable Transmission Using Traction Drive Elements

[0244] This patent focuses on a CVT mechanism using traction drive elements to regulate gear ratios and improve the efficiency of power transmission.

[0245] Link: https: / patents.google.com / patent / US20030084530A1 / en

[0246] US6599221B1

[0247] Control System for a Continuously Variable Transmission

[0248] This patent presents an advanced control system that optimizes the interaction between the engine and the CVT, enhancing its performance and adaptability.

[0249] Link: https: / patents.google.com / patent / US6599221B1 / en

[0250] CN204796953U

[0251] Continuously Variable Transmission Assembly for Vehicle

[0252] This patent focuses on the design and assembly of a CVT for vehicle applications, aiming to reduce performance fluctuations and increase efficiency.

[0253] Link: https: / patentscope.wipo.int / search / en / detail.jsf?docId=CN204796953&_cid=P11-M8NKOT-88487-1

[0254] The Ability of the Continuously Variable Transmission to Control the Engine at Maximum Power: Literature Review

[0255] This paper evaluates the current state of CVT technology and examines various aspects of engine control at maximum power. It highlights the flexibility of CVTs in maintaining a constant angular velocity over a range of output speeds and delves into recent advancements in drivetrain control.

[0256] Link to the article: https: / www.researchgate.net / publication / 355055950_THE_ABILITY_OF_THE_CONTINUOUSLY_VARIABLE_TRANSMISSION_TO_CONTROL_THE_ENGINE_AT_MAXIMUM_POWER_LITERATURE_REVIEW

[0257] Trends in Continuously Variable Transmission System: A Literature Review

[0258] This article reviews trends in CVT systems, focusing on their ability to provide continually variable gear ratios. It highlights the benefits of improved fuel efficiency, better performance, and CVT innovations in hybrid and electric vehicle applications.

[0259] Link to the article: https: / www.researchgate.net / publication / 372689937_Trends_in_Continuously_Variable_Transmission_System_A_Literature_Review

Claims

A continuously variable hydraulic gearbox is claimed, which can smoothly and uniformly change the ratio of torque and rotational speed of the input shaft according to the user’s needs. The innovation of this device lies in its hydraulic mechanism compared to older generations of similar devices. Its advantages include long lifespan, high torque capacity, a hydraulic braking system, and the removal of a torque converter. The gearbox consists of the following components: 3 housings (44, 544, 545), 6 covers (1, 3, 4, 501, 503, 504), 6 hydraulic gears (7, 8, 9, 507, 508, 509), 2 hollow shafts (10, 11), 2 solid shafts (12, 512), 8 stabilizing nuts (13, 14, 15, 16, 17, 18, 513, 514), 4 bearing bushes (23, 25, 523, 525), 2 threaded bearing bushes (26, 27), 2 driving gears (28, 29), 2 worm driving gears (30, 31), 6 sealing bushes (32, 33, 34, 532, 533, 534), 2 cylindrical pistons (35, 36), 2 rail shafts (37, 38), 4 gear bearings (39, 40, 539, 540), 3 hydrophobic packings (41, 42, 541), 2 adjusting screws (45, 46), 4 piston bushes (47, 48, 49, 50), 2 hydraulic gear locks (51, 551), 2 packing stabilizing bushes (54, 554), 1 worm gear shaft (55), 108 Allen screws (53), 14 stabilizing screws (52), 4 cover O-rings, 2 bearing washers (56, 57).According to Claim 1, the following components form the fixed assembly of the device:Covers (1, 4, 501, 504), Bearing bushes (23, 25, 523, 525), Rail shafts (37, 38), Packings (41, 42), Allen screws (53), Stabilizing bushes (54, 554), Cover O-rings, Housings (44, 544, 545)According to Claim 1, the following components form the rotary assembly of the device:Solid shafts (12, 512), Stabilizing nuts (13, 14, 513, 514), Hydraulic locks (51, 551), Hydraulic gears (7, 507), Hydraulic gear locks (51, 551), Driving gears (28, 29, 30, 31), Adjusting screws (45, 46), Sealing bushes (33, 34, 533, 534), Threaded bearing bushes (26, 27), Worm gear shaft (55)According to Claim 1, the following components form the driving assembly:Stabilizing nuts (17, 18, 15, 16, 516, 517, 518, 519), Covers (3, 5, 503, 505), Cylindrical pistons (35, 36), Piston bushes (47, 48, 49, 50), Hollow shafts (10, 11), Allen screws (53)According to Claim 1, the following components form the rotary driving subassembly:Hydraulic gears (8, 9, 508, 509), Gear bearings (39, 40, 539, 540), Sealing bushes (32, 532), Bearing washers (56, 57)According to Claims 2, 3, 4, and 5, by the clockwise and counterclockwise rotation of the worm gear shaft (55), the driving and rotary driving assemblies perform a reciprocating motion on rail shafts (37, 38).According to Claim 1, the hydraulic variable ratio gearbox comprises a variable displacement hydraulic pump as the sender, which converts constant input torque into hydraulic fluid with adjustable flow rate and pressure, and a variable displacement hydraulic motor as the receiver, which converts the incoming fluid into adjustable output torque and speed.According to Claim 7, the method for reducing or increasing the torque and rotational speed of the input shaft (12) on the output shaft (512) is innovative and unparalleled. It utilizes a variable displacement hydraulic pump as the hydraulic sender and a variable displacement hydraulic motor as the hydraulic receiver, a design that has not yet been implemented in any existing system.According to Claim 1, this innovative mechanism provides the ability to continuously and controllably change the force transmission ratio without requiring a torque converter or clutch plates.According to Claim 1, the hydraulic variable ratio gearbox is equipped with an integrated hydraulic braking system that utilizes a mechanism for adjusting or limiting fluid displacement volume, thereby enabling braking force to be applied to the output shaft. This system is designed not only to reduce speed but also to ensure high safety and prevent mechanical failures caused by excessive pressure.According to Claim 1, this hydraulic variable ratio gearbox, with its innovative design for torque and speed adjustment, is widely applied in transportation industries, heavy industrial machinery, agricultural machinery, power generation systems, and sensitive industrial systems. It offers significant advantages, including reduced energy consumption, increased efficiency, and reliable performance in harsh environmental conditions.According to Claim 6, the gearbox consists of two sections: a hydraulic transmitter and a hydraulic receiver (Figure 2). By reducing the transmission volume of the hydraulic transmitter and increasing the receiving volume of the hydraulic receiver, the input speed of the solid shaft (12) decreases in the solid output shaft (512), resulting in higher torque. Similarly, by increasing the transmission volume of the hydraulic transmitter and decreasing the receiving volume of the hydraulic receiver, the speed of the solid output shaft (512) increases with lower torque.According to Claims 1 and 2, the design of the hydraulic displacement reduction and increase by the hydraulic transmitter and receiver, as well as the reduction and increase in the engagement area of the hydraulic gears using sealing bushes (32, 33, 34, 532, 533, 534) located around the hydraulic gears (7, 8, 9, 507, 508, 509), prevents hydraulic oil leakage between the chambers.According to Claims 1, 3, 6, 7, and 8, the external and technical design of the gearbox and the configurations on the covers (1, 3, 4) and (501, 503, 504) are the result of the inventor’s design and are not based on any example.

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