Planetary Variator Shaft Design for High-Horsepower Transmission
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Solution Overview
Problem
Current power transmission systems in work vehicles, such as those in agriculture and construction, face inefficiencies when handling high horsepower outputs, as they often require redesigning driveline components to manage excessive power, which is costly and time-consuming.
Innovation Solution
The implementation of an improved variator system that receives input power from multiple sources, including traditional engines and continuously variable power sources, utilizing a planetary gear assembly with a sun gear, planet gears, and a ring gear, along with a lubrication pin for pressurized lubrication and a ring gear retention key for alignment, to provide variable speed power paths and enhance power transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If driveline components are redesigned to manage excessive high horsepower outputs, then power transmission capability is improved, but manufacturing cost and development time increase
Solution Approach 1:
The patent employs a continuously variable transmission (CVT) mechanism that dynamically adjusts gear ratios to match varying power demands. The variator system allows the driveline to adapt to different horsepower outputs without requiring complete redesign, as the variable speed mechanism can optimize power transmission across a range of operating conditions, thereby maintaining power capability while avoiding high manufacturing costs associated with fixed-gear redesigns.
Solution Approach 2:
The patent utilizes variable gear ratios and adjustable transmission parameters to manage power transmission. By changing the speed ratio continuously rather than through fixed discrete gears, the system can handle varying horsepower levels without requiring physically larger or more robust components, thus maintaining power capability while reducing manufacturing complexity and cost.
2Power
If driveline components are redesigned to manage excessive high horsepower outputs, then power transmission capability is improved, but development time increases
Solution Approach 1:
The patent designs a universal variator system that can handle multiple power levels and different operating conditions with a single configuration. This multi-functional transmission system eliminates the need for separate redesign cycles for different horsepower applications, as the same variable speed mechanism can be adapted to various power outputs through control system adjustments rather than physical redesign, thereby reducing development time while maintaining power capability.
Solution Approach 2:
The dynamically adjustable nature of the CVT allows the system to be reconfigured for different power requirements through software or control mechanism adjustments rather than hardware redesign. This dynamic adaptability significantly reduces development time when accommodating different horsepower outputs, as the same physical components can be optimized for various power levels through parameter changes alone.
3Device complexity
If traditional power transmission systems are used, then system simplicity is maintained, but efficiency in handling high horsepower outputs deteriorates
Solution Approach 1:
The patent introduces a variable speed transmission mechanism that dynamically optimizes power transmission efficiency across different operating conditions. While this adds some complexity to the traditional driveline, the dynamic adjustment capability allows the system to maintain high efficiency across a wide range of horsepower outputs and speeds, far exceeding the fixed-efficiency limitations of traditional transmission systems. The added complexity is justified by the significant efficiency improvements, particularly in handling variable high horsepower demands.
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 solution allows for efficient power delivery to the transmission, enabling vehicles to handle high horsepower outputs without the need for extensive driveline component redesign, improving traction and reducing costs by providing multiple variable speed power paths and enhanced lubrication.
Implementation Method 1
a lubrication pin comprises a channel that provides pressurized lubrication from an inner portion of a variator to the planet gears
Implementation Method 2
double reverse tapered spline between the sun drive gear and sun gear to provide forward thrust on the sun gear, to unload a thrust washer
Data Source
AI summary
One or more techniques and/or systems are disclosed for a transmission variator. The variator receives input power from at least two power sources and provides variable speed output power paths for the transmission. A variator clutch assembly transfers input power to a variator shaft, which drives a planetary gear assembly, including a sun drive gear, planetary gears, and one or more ring gears. The ring gear(s) provide output power to a high output and low output gear assembly. A double reverse tapered spline between the sun drive gear and sun gear to provide forward thrust on the sun gear. A lubrication pin in the planetary gears can provide pressurized lubrication to the planetary gear assembly. A ring gear retention key can be disposed in a spur gear of the high output gear assembly, and ride in a groove in the underside of the ring gear to provide for alignment.