Synchronic Drive Core With Rolling Contact for High Gear Ratios
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Solution Overview
Problem
Conventional drive systems are limited by the use of traditional components like gears and pulleys, leading to issues such as backlash, fatigue, low torsional stiffness, and inefficiency due to high friction, and are unable to achieve high gear ratios in a single stage.
Innovation Solution
A synchronic drive system employing a rotatable input and output disc with a drive core comprising power discs that rotate about pivot axes perpendicular to the disc planes, using engaging features like spherical elements in grooves to transmit rotational force, allowing for increased load capability and higher gear ratios without the drawbacks of traditional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional gear systems are used, then mechanical advantage is provided, but backlash and fatigue occur
Solution Approach 1:
The patent replaces traditional toothed gear mechanics with a continuous contact surface system. The driving gear engages the driven gear through smooth surfaces rather than discrete teeth, eliminating backlash while maintaining mechanical advantage through the gear ratio geometry.
Solution Approach 2:
The patent employs curved or spherical contact surfaces between gear elements instead of flat or angular tooth profiles. This curvature allows for continuous rolling contact that reduces stress concentrations and prevents fatigue while eliminating the gaps that cause backlash.
2Force
If toothed gears are used, then rotational torque is increased, but friction and inefficiency occur
Solution Approach 1:
The patent substitutes sliding friction between gear teeth with rolling contact between curved surfaces. This substitution dramatically reduces frictional losses while transmitting the same rotational torque, improving overall system efficiency.
3Speed
If conventional gear drives are used, then rotational speed is increased, but torsional stiffness is insufficient
Solution Approach 1:
The curved contact surfaces provide continuous engagement that resists torsional deformation more effectively than discrete gear teeth. The distributed contact area along the curved surface increases torsional stiffness while allowing high rotational speeds.
4Speed
If planetary gears are used, then gear ratio is achieved, but only up to 10:1 in a single stage
Solution Approach 1:
The patent extends the gear engagement into additional spatial dimensions through the use of three-dimensional curved surfaces and multiple contact points. This allows a single stage to achieve gear ratios that would traditionally require multiple stacked stages, reducing overall system complexity.
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 synchronic drive system enhances load capability, reduces fatigue and friction, and enables higher gear ratios in a single stage, improving efficiency and reducing noise compared to conventional drive systems.
Implementation Method 1
spherical elements in grooves to transmit rotational force
Data Source
AI summary
A drive system comprising a rotatable input disc that receives an input rotational force and rotates about a longitudinal axis, where the input disc comprises driving features formed on its interior face. The drive system also comprises a rotatable output disc that rotates about the longitudinal axis and comprises driving features formed on its interior face, where the output disc provides an output rotational force. The drive system comprises a drive core between the interior face of the input disc and the interior face of the output disc to translate the input rotational force to the output rotational force. As the input disc is rotated by the input rotational force, engaging feature(s) of power disc(s) in the drive core engages the driving features of the input disc causing rotation of each power disc. As the power disc(s) is rotated, the engaging feature(s) of each power disc(s) engages the driving features of the output disc causing rotation of the output disc.