Hybrid Magnetic Epicyclic Gear for Quiet High-Ratio Reduction
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Solution Overview
Problem
Existing epicyclic reducers for winding and unwinding fabrics, screens, and rolling shutters face limitations in robustness and acoustic performance due to the significant difference in rotational speed between input and output shafts, which restricts the number of teeth on gears and affects mechanical strength and noise levels.
Innovation Solution
The design incorporates a substantially longitudinal actuator with an epicyclic reduction gear featuring a combination of magnetic and mechanical drive portions, where the magnetic drive portion allows for a higher rotational speed ratio than purely mechanical systems, and the mechanical drive portion is axially and radially offset, with a magneto-mechanical transmission mechanism to prevent synchronization loss and reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a significant difference in rotational speed between input and output shafts is achieved using traditional mechanical gears, then the reduction ratio is obtained, but the number of teeth on gears is limited which reduces robustness and increases noise
Solution Approach 1:
The patent replaces the traditional mechanical gear transmission with a magnetic field-based transmission system. The first planetary gear uses magnetic interaction between magnets on the planet gears and the sun gear to transmit torque, eliminating the need for mechanical tooth meshing. This allows for a higher rotational speed ratio without being constrained by the minimum number of teeth required for mechanical gear engagement, thereby improving robustness while achieving the desired speed reduction.
2Speed
If a significant difference in rotational speed between input and output shafts is achieved using traditional mechanical gears, then the reduction ratio is obtained, but noise levels increase due to mechanical constraints
Solution Approach 1:
The patent replaces the traditional mechanical gear transmission with a magnetic field-based transmission system. The first planetary gear uses magnetic interaction between magnets on the planet gears and the sun gear to transmit torque, eliminating the need for mechanical tooth meshing. This allows for a higher rotational speed ratio without being constrained by the minimum number of teeth required for mechanical gear engagement, thereby improving robustness while achieving the desired speed reduction.
3Speed
If purely magnetic drive is used in planetary gear, then higher reduction ratios are achieved, but torque transmission capacity may be limited
Solution Approach 1:
The patent combines two different transmission mechanisms in a single planetary gear system. The first planetary gear uses magnetic field interaction for torque transmission, while the second planetary gear uses traditional mechanical tooth meshing. This hybrid configuration allows the magnetic transmission stage to achieve high reduction ratios without mechanical constraints, while the mechanical transmission stage provides robust torque transmission capacity, thereby overcoming the limitations of using either system alone.
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
This configuration enhances the robustness and reduces noise by allowing higher reduction ratios with fewer stages, minimizing contact and friction, and enabling greater torque transmission with reduced wear and noise compared to purely mechanical systems.
Implementation Method 1
a magnetic drive portion arranged to cooperate with a complementary magnetic part of the first planetary gear train by a magnetic interaction effect between at least one magnetic pole of the magnetic drive portion and at least one magnetic pole of the complementary magnetic drive portion
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
An epicyclic reducer (4) comprising at least two epicyclic gear trains (5, 9), each epicyclic gear train (5, 9) comprising an input shaft (11, 15) and an output shaft (13, 17), the output shaft (13) of the first epicyclic gear train (5) being coupled to the input shaft (15) of the second epicyclic gear train (9). The first epicyclic gear train (5) comprises a first planet gear (25) including a magnetic drive portion arranged to cooperate with a complementary magnetic portion of the first epicyclic gear train (5) by magnetic interaction. The first planet gear (25) includes a mechanical drive portion arranged to cooperate mechanically with a complementary mechanical drive portion of the first epicyclic gear train (5). The magnetic drive portion and the mechanical drive portion are rotationally fixed about an axis of revolution (29) of the first planet gear (25).