Compact Planetary Gearbox for High Torque Conversion
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Solution Overview
Problem
Conventional gearboxes are bulky and not easily adaptable to various applications, particularly in confined spaces where high torque conversion is required, such as in large and heavy barrier systems, due to their size and lack of interchangeability.
Innovation Solution
A compact gearbox design utilizing multiple gear sets and planetary gears with a carrier system that allows for adjustable torque and speed conversion, including a first gear set engaging a motor output, a second gear set, a third gear set with external and internal teeth, and an annulus gear, along with a carrier with fasteners that secure the system, enabling efficient torque and speed adjustment in a small space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gearboxes are designed to be durable, then reliability is improved, but the gearbox becomes bulky and occupies more space
Solution Approach 1:
The patent implements a nested planetary gear configuration where multiple gear sets (first, second, third planetary gear sets) are arranged concentrically around a central input shaft. The sun gears, planet gears, and ring gears are nested within each other, with the third planetary gear set positioned inside the second, which is inside the first. This nesting allows high torque conversion in a compact radial arrangement, achieving high reduction ratios without increasing overall gearbox volume proportionally.
Solution Approach 2:
The patent transitions from conventional parallel or sequential gear arrangements to a three-dimensional planetary configuration. Multiple gear sets operate simultaneously in different radial positions around the input shaft, utilizing the third dimension (radial space) to achieve high reduction ratios. The carrier assemblies are stacked axially while planet gears engage in radial directions, creating a compact 3D structure that delivers high torque conversion without proportional increases in external dimensions.
2Reliability
If conventional gearboxes are designed for specific applications, then reliability for that application is improved, but adaptability to other applications is reduced
Solution Approach 1:
The gearbox is divided into modular components: input shaft assembly, multiple carrier assemblies (first, second, third carriers), planet gear sets, and output mechanisms. Each carrier assembly can be independently configured with different gear ratios by changing the number of teeth on sun gears, planet gears, or ring gears. This segmentation allows the same basic housing and input shaft to support multiple gear ratio configurations for different applications.
Solution Approach 2:
The planetary gear mechanism serves multiple functions within a single configuration: it provides torque multiplication, speed reduction, and self-locking capabilities simultaneously. The same gear sets can be reconfigured to achieve different reduction ratios by changing which gears are fixed, which rotate, and their relative tooth counts. This multi-functionality allows a single gearbox design to serve multiple barrier gate applications with different torque and speed requirements.
3Volume of moving object
If high torque conversion is achieved in confined spaces, then space utilization is improved, but device complexity increases
Solution Approach 1:
Multiple gear functions are merged into a single planetary stage configuration. The first, second, and third planetary gear sets operate simultaneously within the same housing, with their carrier assemblies connected through the planet gear mechanisms. This merging eliminates the need for multiple separate gear stages that would require sequential arrangements, thereby achieving high reduction ratios in a compact single-stage configuration.
Solution Approach 2:
The nested arrangement of three planetary gear sets allows them to occupy overlapping radial and axial spaces. The third planetary gear set is positioned inside the second, which is inside the first, creating a nested doll-like structure. This nesting maximizes space utilization by allowing gear teeth to engage in concentric patterns, achieving high torque conversion without proportionally increasing the gearbox external dimensions.
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 design provides robust, efficient torque conversion with reduced power loss, allowing for high torque delivery in a compact and lightweight form, with interchangeable components for versatile applications, and is fully back drivable at high reduction ratios.
Implementation Method 1
The first gear set or first stage gears have external gear teeth configured to engage a motor output and receive a rotational input therefrom. The first stage gears also engage and rotate the second gear set or second stage gears.
Implementation Method 2
a first gear set, a second gear set, a third gear set, and a fourth gear or annulus gear
Implementation Method 3
three engaging planetary gears, three pinion planetary gears, three walking planetary gears, and a ring gear
Data Source
AI summary
A method and apparatus converts the speed and torque of a motor output and couples the adjusted output to a device or structure, such as a movable barrier. In one example, a conversion apparatus includes a first gear set, a second gear set, a third gear set, and a fourth gear or ring gear. The first gear set may engage a motor output and receive rotational input therefrom. The rotational input is transferred from the first to the second gear set and then to the third gear set, which may engage a ring gear. In one configuration, a carrier is disposed about the gear sets. Carrier fasteners may extend through openings in the third gear set and, as the third gear set travels around the ring gear, the carrier fasteners may revolve around a central axis and rotate a carrier output shaft.