Toroidal CVT Trunnion Beam Integration for Assembly Efficiency
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Solution Overview
Problem
The toroidal continuously variable transmission (CVT) faces challenges in efficiently forming assembly units comprising power rollers, trunnions, and beams, which affects manufacturing efficiency.
Innovation Solution
The configuration includes a power roller tiltably disposed between input and output discs, with a trunnion and beam structure where the beam extends opposite to the base, featuring contact and restricting portions to securely position and reinforce the trunnion, allowing for quick and proper mounting while preventing side wall displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a beam is mounted on the pair of side walls of the trunnion for reinforcement, then the structural strength is improved, but the assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The beam and trunnion are integrated into a single forged body, combining two separate components into one unified structure. This eliminates the need for separate assembly operations while maintaining the reinforcing function of the beam, thereby reducing assembly complexity without compromising structural strength.
Solution Approach 2:
The integrated beam-trunnion structure serves multiple functions simultaneously: the beam provides structural reinforcement while the unified design simplifies manufacturing and assembly processes. This multi-functional design addresses both strength requirements and manufacturing efficiency in a single component configuration.
2Productivity
If multiple assembly units are disposed in one cavity, then the productivity is improved, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
By merging the beam and trunnion into one forged body, the number of separate components requiring precise positioning and assembly is reduced. This integration maintains manufacturing precision while enabling efficient production of multiple assembly units within a single cavity, as fewer parts need to be precisely aligned during assembly.
3Reliability
If the beam is mounted on the side walls to restrict movement, then the reliability is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The integration of the beam and trunnion into a single forged body eliminates separate mounting operations and ensures inherent structural stability. The reinforcing structure is built-in during the forging process itself, improving reliability while significantly easing manufacturing compared to assembling separate components.
Data Source
AI summary
A toroidal continuously variable transmission comprises an input disc and an output disc which are disposed to face each other; a power roller which is tiltably disposed between the input disc and the output disc and transmits a rotational driving force of the input disc to the output disc in a transmission ratio corresponding to a tilt motion angle of the power roller; a trunnion including a base on which the power roller is rotatably mounted, and a pair of side walls provided on both sides of the power roller in an axial direction of a tilt motion shaft of the power roller in such a manner that the pair of side walls extend upward from the base and face a peripheral surface of the power roller, and a beam mounted on the pair of side walls, the beam extending in the axial direction of the tilt motion shaft, on a side opposite to the base when viewed from a position of the power roller, wherein the beam includes a pair of contact portions, each of the contact portions being configured to contact an end surface of a tip end side of each of the pair of side walls, and a pair of restricting portions configured to contact side surfaces of the pair of side walls, respectively, the side surfaces facing each other, to restrict a movement of the pair of side walls in a direction in which the pair of side walls approach each other.