Continuously variable planetary gear set

• US 7,201,694 B2
• Filed: 02/03/2005
• Issued: 04/10/2007
• Est. Priority Date: 08/11/2003
• Status: Expired due to Term

• Current Assignee: Enviolo BV
• Original Assignee: Fallbrook Technologies Incorporated
• Inventors: Allen, David J., Smithson, Robert A., Miller, Donald C., Birchak, Jeffrey A.
• Primary Examiner(s): LEWIS, TISHA D
• Application Number:
  US11/051,063
• Publication Number:
  US 20050176544A1
• Time in Patent Office: 796 Days
• Field of Search: 475/215, 475/189, 475/196, 475/214, 475/216, 476/40, 476/42, 476/36, 476/38, 743/88.PS, 180/6.24, 180/6.44, 180/6.54
• US Class Current: 475/214
• 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 vehicle having a power-assisted steering system, the vehicle comprising:

a chassis adapted for transporting passengers;

a plurality of drive wheels operationally coupled to the chassis;

a rack and pinion steering assembly operationally coupled to the drive wheels;

a steering shaft connected to a pinion of the rack and pinion assembly;

a steering wheel connected to the steering shaft;

a plurality of traction rollers distributed radially about the steering shaft, each roller having a tiltable axis about which it rotates;

an input disc in contact with the rollers;

an output disc in contact with the rollers;

an idler coaxial with and rotatable about the steering shaft, the idler in contact with the rollers;

a cage adapted to maintain a radial and axial orientation of the rollers about the idler, wherein the cage is adapted to rotate about the steering shaft;

a tubular output shaft positioned coaxially about the steering shaft and connected at a first end to the output disc and connected at a second end to the pinion; and

a source of rotational power, wherein the input disc is fixed and does not rotate and wherein the source of rotational power is coupled to the cage;

wherein the axes of the rollers tilt in response to a shift in an angular orientation of the steering shaft; and

wherein the rollers convert the rotational power of the source to an output torque transmitted through the output disc to the output shaft in response to a shift in the angular orientation of the steering shaft.

2. The vehicle of claim 1, further comprising a planetary gear set comprising:

a sun gear rotatable about the steering shaft and coupled to the 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 steering shaft, wherein the planet carrier retains and positions each of the planet shafts;

wherein the source of rotational power is connected to the planet carrier; and

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 planets about the sun gear and rotates the input disc about the steering shaft.

3. The vehicle of claim 1, further comprising a tubular shifter having a first end attached to the idler, the shifter being angularly aligned with the steering shaft, and a second end that engages the output shaft and is positioned axially by the output shaft such that any rotation of the steering shaft with respect to the output shaft moves the shifter axially, which in turn moves the idler axially, and wherein the axial position of the idler controls an angular adjustment of the axes of the rollers.

4. The vehicle of claim 1, further comprising a tubular shifter attached to the idler, the shifter comprising a lead screw, wherein the shifter is angularly aligned with the steering shaft, wherein the lead screw interacts with a set of threads to axially position the idler in response to a rotation of the steering shaft.

5. The vehicle of claim 1, further comprising:

a tubular shifter positioned coaxially about the steering shaft, the shifter attached to the idler;

an axial positioning device attached to the shifter and adapted to move the shifter axially;

a position indicator attached to the steering shaft adapted to indicate the angular position of the steering shaft;

a position detector adapted to detect the angular position of the steering shaft; and

a positioner adapted to axially position the positioning device upon a signal from the position detector.

6. The vehicle of claim 5, wherein the positioning device is a lead screw and the positioner is a motorized nut adapted to drive the lead screw.

7. The vehicle of claim 5, wherein the positioning device is a piston and the positioner is a cylinder.

8. The vehicle of claim 7, wherein the piston and cylinder are hydraulically operated.

9. The vehicle of claim 7, wherein the piston and cylinder are pneumatically operated.

10. The vehicle of claim 1, wherein the source of rotational energy comprises an internal combustion engine.

11. The vehicle of claim 1, wherein the source of rotational energy comprises an electric motor.

12. The vehicle of claim 10, wherein the source of rotational energy comprises an electric motor.

13. The vehicle of claim 1, further comprising an axial force generator adapted to generate a contact force between the input disc, the output disc, the rollers and the idler, the contact force being proportional to an amount of torque transmitted by the transmission.

14. The vehicle of claim 13, wherein the axial force generator further comprises:

a bearing disc rotatable about the longitudinal axis,

the bearing disc having a threaded bore;

a plurality of perimeter ramps attached to the bearing disc near the outer diameter of the bearing disc;

a plurality of bearings adapted to engage the plurality of bearing disc perimeter ramps;

a plurality of input disc perimeter ramps mounted on the input disc, the input disc perimeter ramps adapted to engage the bearings;

a screw coaxial with and rotatable about the longitudinal axis adapted to engage the threaded bore;

a plurality of central screw ramps attached to the screw; and

a plurality of central input disc ramps affixed to the input disc and adapted to engage the plurality of central screw ramps.

15. The vehicle of claim 13, wherein the axial force generator comprises:

a generally disc-shaped thrust washer that is coaxial with the idler and is positioned near the side of the input disc facing away from the rollers, the washer having a first side facing the input disc and having a set of thrust ramps formed on the first side;

a set of thrust-receiving ramps formed on the input disc facing the thrust washer; and

a plurality of thrust elements located between and in contact with the thrust ramps and the thrust-receiving ramps.

16. The vehicle of claim 1, wherein the chassis comprises a passenger bus chassis.

17. The vehicle of claim 1, wherein the chassis comprises a light truck chassis.

18. The vehicle of claim 1, wherein the chassis comprises a race car chassis.