Continuously variable planetary gear set

• US 7,198,583 B2
• Filed: 02/03/2005
• Issued: 04/03/2007
• Est. Priority Date: 08/11/2003
• Status: Active Grant

• Current Assignee: Fallbrook Intellectual Property Company LLC (Fallbrook Technologies Incorporated)
• Original Assignee: Fallbrook Technologies Incorporated
• Inventors: Allen, David J., Smithson, Robert A., Miller, Donald C., Birchak, Jeffrey A.
• Primary Examiner(s): ESTREMSKY, SHERRY LYNN
• Application Number:
  US11/051,093
• Publication Number:
  US 20050137052A1
• Time in Patent Office: 789 Days
• Field of Search: 475/215, 475/189, 475/196, 476/41.R, 476/40, 476/6, 476/8, 476/36, 476/38
• US Class Current: 475/189
• CPC Class Codes: B62D 5/0409 Electric motor acting on the steering column
• CPC Class Codes: B62D 5/0475 Controlling other elements
• CPC Class Codes: B62M 9/08 involving eccentrically- mounted or elliptically-shaped driving or driven wheel; with expansible driving or driven wheel
• CPC Class Codes: F16H 15/28 with external friction surface
• CPC Class Codes: F16H 15/52 in which a member of uniform effective diameter mounted on a shaft may co-operate with different parts of another member
• CPC Class Codes: F16H 37/084 at least one power path being a continuously variable transmission, i.e. CVT
• CPC Class Codes: F16H 61/6649 characterised by the means for controlling the torque transmitting capability of the gearing
• CPC Class Codes: Y10S 903/918 Continuously variable
• CPC Class Codes: Y10S 903/945 Characterized by control of gearing, e.g. control of transmission ratio
• CPC Class Codes: Y10S 903/951 Assembly or relative location of components
• CPC Class Codes: Y10T 74/19251 Control mechanism
• CPC Class Codes: Y10T 74/19555 Varying speed ratio
• CPC Class Codes: Y10T 74/1956 Adjustable

Abstract

A continuously variable planetary gear set is described having a generally tubular idler, a plurality of balls distributed radially about the idler, each ball having a tiltable axis about which it rotates, a rotatable input disc positioned adjacent to the balls and in contact with each of the balls, a rotatable output disc positioned adjacent to the balls opposite the input disc and in contact with each of the balls such that each of the balls makes three-point contact with the input disc, the output disc and the idler, and a rotatable cage adapted to maintain the axial and radial position of each of the balls, wherein the axes of the balls are oriented by the axial position of the idler.

Claims

1. A power transfer assembly comprising:

a plurality of balls distributed radially about a longitudinal axis of the power transfer assembly, each ball having a tiltable axis about which it rotates;

an input disc in contact with the balls, the input disc operationally coupled to a cam flange;

an output disc in contact with the balls;

an idler coaxial and rotatable about the longitudinal axis and in contact with the balls;

a plurality of cam rollers contacting the input disc and the cam flange;

a roller cage holding the cam rollers, wherein the cam rollers are adapted to press the input disc axially along the longitudinal axis;

a ball cage adapted to maintain a radial and axial orientation of the balls about the idler, the ball cage adapted to rotate about the longitudinal axis; and

a motor operationally coupled to the ball cage.

2. The assembly of claim 1, further comprising a cover that cooperates with the roller cage to define a passage for supplying a lubricant to the rollers.

3. The assembly of claim 2, wherein the roller cage comprises grooves, in the axial direction along the longitudinal axis, that correspond to the cam rollers.

4. The assembly of claim 3, wherein the roller cage comprises holes radially formed through the roller cage.

5. The assembly of claim 2, wherein the cover comprises recesses that correspond to the cam rollers.

6. The assembly of claim 1, wherein the ball cage comprises:

a disc-shaped input stator positioned between the balls and the input disc;

a disc-shaped output stator positioned between the balls and the output disc; and

a plurality of spacers adapted to rigidly connect the stators.

7. The assembly of claim 6, wherein the input disc is fixed and does not rotate.

8. The assembly of claim 1, further comprising a planetary gear set comprising:

a sun gear rotatable about the longitudinal axis and coupled to the ball cage;

a plurality of planet gears engaged with and adapted to orbit the sun gear, wherein each planet gear rotates about a planet shaft of its own;

a ring gear engaging each planet gear; and

a planet carrier rotatable about and coaxial with the longitudinal axis, wherein the planet carrier retains and positions each of the planet shafts.

9. The assembly of claim 8, wherein the motor is connected to the planet carrier.

10. The assembly of claim 9, wherein each planet shaft extends from the planet carrier and terminates at a connection point with the input disc so that the planet carrier rotates the planet'"'"'s about the sun gear and rotates the input disc about the longitudinal axis.

11. The assembly of claim 1, further comprising an internal combustion engine coupled to the input disc.

12. The assembly of claim 11, further comprising a planetary gear set coupled to the input disc, the output disc, or the ball cage.

13. The assembly of claim 12, wherein a sun gear of the planetary gear set is coupled to the ball cage.

14. A method of manufacturing a power transfer assembly, the method comprising:

arranging a plurality of balls radially about a longitudinal axis of the power transfer assembly, each ball having a tiltable axis about which it rotates;

providing an input, disc adapted to contact the balls, the input disc operationally coupled to a cam flange;

providing an output disc adapted to contact the balls;

mounting an idler coaxially with the longitudinal axis, the idler adapted to contact the balls;

arranging a plurality of cam rollers to contact the input disc and the cam flange;

providing a roller cage to hold the cam rollers;

and arranging the input disc and cam rollers such that the cam rollers are capable of pressing the input disc axially along the longitudinal axis;

providing a ball cage adapted to maintain a radial and axial orientation of the balls about the idler, the ball cage adapted to rotate about the longitudinal axis; and

coupling a motor to the ball cage.

15. The method of claim 14, further comprising providing a cover that cooperates with the roller cage to define a passage for supplying a lubricant to the rollers.

16. The method of claim 15, wherein the cover comprises recesses that correspond to the cam rollers.

17. The method of claim 14, wherein the roller cage comprises grooves, in the axial direction along the longitudinal axis, that correspond to the cam rollers.

18. The method of claim 17, wherein the roller cage comprises holes radially formed through the roller cage.

19. The method of claim 14, further comprising providing an internal combustion engine coupled to the input disc.

20. The method of claim 14, further comprising providing a planetary gear set coupled to the ball cage.