Gearless Speed Reducer Using Tilted Ball Bearing Races
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Solution Overview
Problem
Traditional gear-based speed reducers face challenges in achieving precise tolerances and are difficult to manufacture with minimal parts, leading to inaccuracies in applications requiring precise positioning, such as jewelry making and circuit board operations.
Innovation Solution
A gearless speed reducer system using an input and output shaft with external and internal races and loosely disposed ball bearings, where the shafts are tilted to form a pocket for the balls, ensuring they stay in place and rotate without slipping, with the speed ratio determined by the diameter difference between the races.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional gear-based speed reducers are used, then speed reduction or increase is achieved, but manufacturing precision and positioning accuracy deteriorate due to play between gears
Solution Approach 1:
The patent removes the gears entirely from the speed reduction system, extracting the problematic gear-based power transmission mechanism and replacing it with a direct ball bearing-based system that eliminates gear play and associated positioning inaccuracies
Solution Approach 2:
The patent substitutes the traditional mechanical gear system with a ball bearing-based mechanical system, where balls are contained within a pocket formed by tilted races, replacing the gear meshing mechanism with a rolling contact mechanism that eliminates backslash and improves positioning precision
2Ease of manufacture
If gear-based speed reducers are used, then speed ratio is achieved, but device complexity increases due to multiple parts and difficult manufacturing
Solution Approach 1:
The patent merges multiple traditional gear components into a single integrated structure where the input shaft, output shaft, and ball containment mechanism form a unified assembly, reducing the total number of discrete parts and simplifying manufacturing
Solution Approach 2:
The patent segments the speed reduction function into distinct operational components (input shaft, output shaft, ball bearings, tilted races) that can be manufactured separately and assembled, allowing for easier manufacturing of individual components while maintaining overall system simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves precise rotational motion transmission with minimal play, reducing wear and maintenance, and is simpler to construct, making it suitable for applications requiring accurate positioning while offering cost savings.
Implementation Method 1
Two ball bearings are loosely disposed between the races. After the ball bearings have been inserted, the shafts are tilted relative to each other to form a pocket for the balls so that the balls are held in place
Implementation Method 2
the shafts are tilted relative to each other to form a pocket for the balls so that the balls are held in place, and cannot slide around within the races
Data Source
AI summary
A gearless speed reducer or increaser consists of an input shaft, an output shaft, and a motor connected to the input shaft. There is an external race connected to one of the shafts, and an internal race attached to the other shaft. Two ball bearings are disposed between the races. After the ball bearings have been inserted, the shafts are tilted relative to each other so that the balls become fixed in pockets created between the races and cannot slide within the races. Rotating one of the shafts thus rotates the other shaft, since the balls do not slip but only rotate between the races. The system acts as a speed reducer or increaser due to the different diameters of the inner and outer races. The system can be uncoupled by pivoting the shafts back into alignment so that the balls can slide freely within the races.