Nonlinear Gear Transmission for Continuous Torque Shifting
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Solution Overview
Problem
Existing gear transmission systems interrupt torque when switching gears, requiring braking and re-acceleration of inert masses, which is inefficient and disruptive.
Innovation Solution
A gear transmission unit with a driven gear comprising multiple sections and radially protruding teeth, where the drive gear shifts axially along the driven gear's surface, following a non-linear path through channels, allowing continuous torque transmission during gear switching by using motors for controlled horizontal and vertical movement to maintain contact pressure and ensure smooth gear transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gear switching is used, then gear ratio changes are achieved, but torque transmission is interrupted requiring braking and re-acceleration
Solution Approach 1:
The driven gear is segmented into multiple sections with different wheel diameters along its axial length. Each section corresponds to a different gear ratio. The drive gear can engage with different sections by axial displacement, enabling gear switching without interrupting torque transmission to the load.
Solution Approach 2:
The gear switching mechanism transitions from radial tooth engagement to axial displacement of the drive gear along the driven gear's surface. The non-linear path channels guide the drive teeth through a three-dimensional trajectory that maintains continuous contact while changing the effective gear ratio.
2Adaptability or versatility
If a truncated cone gear is used for switching, then gear ratio changes are enabled, but the structure becomes more complex
Solution Approach 1:
Instead of a single truncated cone gear, the driven gear is divided into discrete sections with different diameters. This segmentation allows for simpler manufacturing of each section while achieving the same variable ratio capability through axial positioning of the drive gear.
Solution Approach 2:
The driven gear features a curved surface with non-linear path channels that guide the drive teeth during switching. This curved geometry enables smooth transition between gear sections while maintaining continuous tooth engagement, replacing the need for complex truncated cone mechanisms.
3Ease of operation
If gear switching interrupts torque, then switching can be performed, but load coupling must be broken and re-established
Solution Approach 1:
The drive teeth follow continuous non-linear path channels on the driven gear surface during switching. This ensures that torque transmission to the load is maintained throughout the entire switching process, eliminating the need to break and re-establish load coupling while enabling smooth gear ratio changes.
Data Source
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AI summary
To improve a gear transmission for switching between gears without interrupting a torque, it is suggested that channels between neighboring driven teeth of a driven gear extend none-linearly along an outer surface of the driven gear from a first section to a second section of the driven gear.