Two-Roller Variator Transmission with Lever-Controlled Force Equalization
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Solution Overview
Problem
Existing variator transmissions are costly and complex, making them unsuitable for low-power, low-torque applications due to the need for multiple rollers and hydraulic control systems.
Innovation Solution
A simplified variator transmission design using two rollers with lever-controlled contact and radial movement of the pivotal axis to equalize forces, reducing complexity and cost, while maintaining stability through resiliently deformable end load means and a mixing epicyclic gear train.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three rollers are used in each toroidal cavity to provide stable power transmission, then reliability is improved, but device complexity increases due to the need for multiple double-acting control pistons and computer-controlled hydraulic pressures
Solution Approach 1:
The invention extracts and removes the complex hydraulic control system (double-acting pistons and computer control) from each roller, replacing it with a simple mechanical lever mechanism. This eliminates the need for sophisticated control systems while maintaining reliable power transmission through the two-roller design
Solution Approach 2:
The lever mechanism automatically self-adjusts to equalize forces on the rollers through its geometric configuration and the radial movement of the pivotal axis, eliminating the need for external control systems. The system serves itself by using the inherent mechanics of the lever to maintain balanced roller contact
2Power
If multiple rollers and hydraulic control systems are used to handle high power and torque, then power transmission capability is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive hydraulic components and control systems with simple, inexpensive mechanical elements like levers and pivot pins. These simple components are easier and cheaper to manufacture while still providing adequate performance for the intended application range
Solution Approach 2:
The invention combines the functions of multiple complex hydraulic control systems into a single simple mechanical lever mechanism. This merging reduces the total number of components and simplifies manufacturing while maintaining the necessary power transmission capability
3Device complexity
If two rollers are used instead of three to reduce complexity, then device complexity is reduced, but stability deteriorates due to increased bending of variator components
Solution Approach 1:
The invention introduces dynamic adjustment through the lever mechanism, where the pivotal axis can move radially to equalize forces on the two rollers. This dynamic force equalization compensates for the reduced roller count and prevents excessive bending of components by optimizing the load distribution in real-time
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 solution provides a cost-effective and stable transmission suitable for low-power applications by simplifying the design and control mechanism, ensuring balanced roller contact and minimizing wear, while allowing for variable gear ratios.
Implementation Method 1
end load means to urge the rollers into contact with the input and output discs to transmit drive
Data Source
AI summary
A variator transmission comprises an input shaft (18), an input disc (10) mounted on the input shaft for rotation therewith and an output disc (12) facing the input disc and arranged to rotate coaxially therewith, the input and output discs defining between them a toroidal cavity. Two rollers (14, 16) are located in the toroidal cavity and first and second roller carriage means are provided upon which the first and second rollers respectively are rotatably mounted and end load means (34, 36) urge the rollers into contact with the input and output discs to transmit drive. The two roller carriage means are mounted on opposite sides of the pivotal axis of a lever (50) and the pivotal axis of the lever (50) is movable in the radial direction with respect to the rotational axis of the input and output discs.