Toroidal Gearbox Geometry for Compact High-Torque Slewing
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Solution Overview
Problem
Slewing drives face challenges in achieving high torque-to-mass and torque-to-volume ratios, particularly in compact actuators, where traditional gearing systems struggle to efficiently generate and control the motion of heavy payloads with high positioning accuracy.
Innovation Solution
A toroidal gearbox design incorporating a cylindrical gear and a toroidal spiral face drive, along with dual function gears that combine worm and cylindrical gear teeth, allows for high torque transmission while maintaining a compact form factor, enabling efficient torque conversion and positioning through a gearbox with a toroidal motor and specialized bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cylindrical or worm gearing is used in slewing drives, then the structure is simple and easy to manufacture, but the torque-to-mass and torque-to-volume ratios are low
Solution Approach 1:
The patent applies toroidal curvature to the gear faces, replacing traditional cylindrical or worm gear geometries with toroidal spiral face drives. This curvature enables more efficient load distribution across the gear contact surfaces, increasing torque capacity while reducing the overall size and mass of the gearbox, thereby improving torque-to-mass and torque-to-volume ratios
2Ease of manufacture
If traditional cylindrical or worm gearing is used in slewing drives, then the structure is simple and easy to manufacture, but the positioning accuracy is insufficient
Solution Approach 1:
The toroidal spiral face drive geometry provides more favorable contact conditions with improved load distribution and reduced stress concentrations. This enhances manufacturing precision requirements while delivering superior positioning accuracy through better gear mesh stability and reduced backlash
Solution Approach 2:
The patent modifies the fundamental geometric parameters of the gear system by implementing toroidal spiral faces with specific lead angles and curvature radii. These parameter changes optimize the contact pattern and load distribution, enabling high positioning accuracy while maintaining manufacturability through standardized toroidal gear generation processes
3Force
If compact actuators are designed to generate high torque, then the torque output is sufficient, but the torque-to-mass and torque-to-volume ratios are difficult to achieve
Solution Approach 1:
The toroidal spiral face drive geometry creates more favorable contact conditions with improved load distribution across the gear surfaces. This enables compact actuator design that achieves high torque output in a reduced volume, significantly improving torque-to-volume ratios while maintaining sufficient torque capacity
Solution Approach 2:
The patent employs a dual-function gear that performs multiple functions within a single component, effectively nesting functional capabilities. This reduces the overall number of parts and allows for more compact actuator design while maintaining high torque output, thereby improving torque-to-volume ratios
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 toroidal gearbox design achieves high torque-to-mass and torque-to-volume ratios, enhancing the positioning accuracy and load handling capacity, and simplifies integration with other systems by providing a compact, efficient solution for slewing applications.
Implementation Method 1
The toroidal spiral face drive drives the cylindrical gear. Worm drive 16 can have one or many 'starts,' which are individual tracks in the screw. For example, if there are three starts on screw drive 18, it will advance output gear 15 by three teeth 19, each time worm drive 16 completes a revolution.
Data Source
AI summary
A high transmission ratio gearbox of ring shape for easy integration inside mechanisms with limited space and robotic rotating joints for moving robotic arms. The toroidal gearbox includes at least one dual function gear, a toroidal spiral face drive to mesh with the at least one dual function gear and a cylindrical gear to mesh with the at least one dual function gear.