Abstract:
Numerous implementations of variable motion control devices and methods of use thereof. The devices and methods provide variable output to such output devices as vehicles. The variable motion control devices are locatable between output devices and power sources, such as in vehicle transmission applications between the engine and driveline, wherein an output of a power source is input into the device, which, in turn, provides a variable output to the vehicle drive line or other output application.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application claims the benefit of U.S. Provisional Application No. 60/705,490, filed Aug. 5, 2005, titled “VARIABLE CONTROL DEVICE FOR GEAR PUMP AND OTHER IMPLEMENTATION AND MTHODS OF USE THEREOF,” which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to variable motion control devices and methods of use, such as for providing a variable output vehicle transmission and other applications, wherein an output from a power source is input into the device, which then provides a variable output to the output application, such as a vehicle.  
         [0004]     2. Background of the Technology  
         [0005]     There remains an unmet need for variably transmitting the output of a power source to an output device, such as a vehicle or other output device, including where either a fixed or generally uniform input or a variable input is used to generate a variable output therefrom.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention relates to variable motion control devices and methods of use thereof. In particular, the present invention provides several implementations of variable motion control devices for use with transmission applications for vehicles and other applications. The devices of some of the embodiments of the present invention receive as driving input constant or generally uniform output of power sources, or variable output from power sources, and transmit output to the application, such as a vehicle transmission or other output device.  
         [0007]     To receive the constant or variable input and then transmit this input to a variable output, the devices and methods of the various embodiments include use of mechanical components, such as one-way bearings (also interchangeably referred to herein as a sprag clutches, one way clutch bearings, sprag bearings, or sprag clutch bearings), planetary gear systems, various types of dynamic or static brakes, cams and cam related features, devices and features to generate rectifying waveforms, pin and piston assemblies that use the vertical motion of cam followers, and worm gears and worm assemblies.  
         [0008]     Additional advantages and novel features of the invention will be partially set forth in the description that follows, and will also become apparent to those skilled in the art upon examination of the following or upon learning by practice of the invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     In the drawings:  
         [0010]      FIGS. 1A-1B  show side and cross-sectional views of a TVC using a planetary gear type arrangement with most gears having approximately common diameters, in accordance with an embodiment of the present invention;  
         [0011]      FIGS. 2A-2B  present additional cutaway views of the TVC of  FIGS. 1A-2B ;  
         [0012]      FIG. 3  show representative views of features relating to a variable motion control device for an exemplary transmission application, in accordance with an embodiment of the present invention;  
         [0013]      FIG. 4  shows a representative cross-sectional view of the variable motion control device of  FIG. 3 , focusing on input, speed control, and output features;  
         [0014]      FIGS. 5A and 5B  present views of cam control features usable with the variable motion control device of  FIG. 3 , in accordance with embodiments of the present invention;  
         [0015]      FIGS. 6A and 6B  contain views of concentric and eccentric rotation positions of the cam control features of  FIGS. 5A and 5B ;  
         [0016]      FIGS. 7A-7B  show representative cyclic views of cam device and sprag device motion based on eccentric cam revolution, in accordance with an embodiment of the present invention;  
         [0017]      FIG. 8  presents a representative view of cam device and sprag device motion based on concentric cam revolution, in accordance with an embodiment of the present invention;  
         [0018]      FIG. 9  contains a representative cross-sectional view of the variable motion control device of  FIG. 3 , focusing on cam control features, in accordance with an embodiment of the present invention;  
         [0019]      FIG. 10  shows a representative cross-sectional view of the variable motion control device of  FIG. 3 , focusing on sprag output and direction features, in accordance with an embodiment of the present invention;  
         [0020]      FIGS. 11A and 11B  present views of brake cam operation with a brake band, in accordance with an embodiment of the present invention; and  
         [0021]      FIGS. 12 and 13  show cutaway side and cross-sectional views, respectively, of an exemplary transmission, including cam features and brake band directional control, in accordance with embodiments of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0022]     Various exemplary embodiments of the present invention will now be described in conjunction with the appended figures.  
         [0000]     TVC-Type Variations  
         [0023]      FIGS. 1A-2B  illustrate cutaway side and other views of a three variable control (TVC) -type infinitely variable motion control (IVMC) device (also interchangeably referred to herein as a “TVC-type transmission”), in accordance with an exemplary embodiment of the present invention. The TVC device of  FIGS. 1A-2B  includes an input shaft  1  that extends from a power source  2 , such as a motor, into an output sleeve shaft  6 . The input shaft  1  has an extending first input shaft gear  10  (also interchangeably referred to herein as a “sun gear”) having first gear exterior teeth and width w 1 . First gear  10  operatively engages a second gear  11  having second gear exterior teeth and width w 2 , such as by meshable engagement of the gear teeth, the width w 2  being such as to thereby allow the second gear  11  to engage both the first gear  10  and a third planetary gear  12 , having width w 3 . A fourth planetary gear  14  may have width w 2  and a fifth planetary gear  15  may have width w 3  that similarly meshably engage via external teeth, with fourth gear  14  engaging first gear  10  via external teeth.  
         [0024]     Third gear  12  and fifth gear  15  engage sixth gear  17  fixably attached to output sleeve shaft  6 .  
         [0025]     Second gear  11  slidably revolves about axle  20 , third gear  12  slidably revolves about axle  21 , fourth gear  14  slidably revolves about axle  23 , and fifth gear  15  slidably revolves about axle  22 . Axles  20 ,  21 ,  22 , and  23  are mounted to drum gear  30 , having fixably attached external teeth gear portions  31 ,  32 , thereby coupling second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  to drum gear  30 . External teeth gear portions  31 ,  32  of drum gear  30  are engaged, via various features, including each of the embodiments disclosed in the &#39;730 application, by any controller that is capable of applying a variable input to the external teeth gear portions  31 ,  32 , whereby the output of the sleeve shaft  6  is variably controlled.  
         [0026]     In operation, the power source (e.g., output shaft of a driving device, such as an engine) produces revolution of the input shaft  1 , which in turn revolves first gear  10 . First gear  10  in turn engages second gear  11  and fourth gear  14 , second gear  11  and fourth gear  14  in turn engaging third gear  12  and fifth gear  15 , respectively. Third gear  12  and fifth gear  15  in turn engage sixth gear  17 . The output of sleeve shaft  6 , which for example, may be coupled to a vehicle&#39;s drive shaft or other output application, via sixth gear  17  varies depending on the rotational motion of the drum gear  30 .  
         [0027]     In a first exemplary operational mode, when the controller provides minimal input from the controller to the external teeth gear portions  31 ,  32  of the drum gear  30  (e.g., minimal resistance to rotary motion of drum gear  30 ), the drum gear  30  rotates, allowing engaged second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  to revolve about first gear  10  and hence about sixth gear  17 , producing minimal or zero output at sleeve shaft  6 .  
         [0028]     In a second exemplary operational mode, when the controller provides a relatively high input from the controller to the external teeth gear portions  31 ,  32  of the drum gear  30  (e.g., high resistance to rotary motion of drum gear  30 ), rotation of the drum gear  30  is arrested, preventing rotation thereof. As such, second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  are prevented from revolving about first gear  10 . Rotation without revolution of second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  engaged with sixth gear  17  producing maximum rotation of sixth gear  17  and hence maximum output at sleeve shaft  6 .  
         [0029]     In a third exemplary operational mode, when the controller provides a partial input from the controller to the external teeth gear portions  31 ,  32  of the drum gear  30  (e.g., partial resistance to rotary motion of the drum gear  30 ), the rotational motion of drum gear  30  is retarded, but not arrested. As such, second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  are thereby retarded in revolution about first gear  10 . Retarded revolution of second gear  11 , third gear  12 , fourth gear  14 , and fifth gear  15  engaged with sixth gear  17  produces a retarded rotation of sixth gear  17 , and hence an output at sleeve shaft  6  that varies with retardation of revolution of drum gear  30 .  
         [0000]     Ratchet-Type Variations  
         [0030]     A first exemplary implementation of the present invention incorporates several embodiments of the TVC-type or other IVMC devices to provide a vehicle transmission or other output application.  
         [0031]     One embodiment of the IVMC device of the present invention, which may be implemented, for example, further using one or more one-way bearings (also interchangeably referred to herein as a sprag clutch, one way clutch bearing, sprag bearing, a sprag, or sprag clutch bearing; see, for example www.formspring.com/PDF/P-956-FC-Pq6-7.pdf as viewed Jul. 29, 2006, describing an exemplary sprag clutch usable with the present invention, the entirety of which is hereby incorporated by reference).  
         [0032]     One characteristic of the sprag clutch is that the device can connect two subgear shafts or other rotating or otherwise moving bodies together, such that one shaft or body is allowed to move in one direction relative to the other shaft or body, but not in the opposite rotational direction, thereby allowing a load to be placed on one shaft or body and the gear carrier disk, for example, to be powered with an equal torque while the loaded shaft or body moves at the same speed (also interchangeably referred to herein as the shaft having the same “rotational velocity” or the body having the same “frequency” of motion) as the gear carrier disk. Meanwhile, the unloaded shaft or body has a torque applied thereto by the sprag clutch bearing in order to maintain a steady state condition in a single direction of motion only.  
         [0033]     The IVMC device may be attached to, or be incorporated within, the output device, wherein a shaft from the power source is connected to the IVMC device with the output device, so as to convey the input thereto. Alternatively, it is within the scope of the invention to provide the IVMC device within the envelope or housing of the power source, such that the output shaft of the IVMC device serves as the output shaft of the power source. It is further within the scope of the present invention to provide that the output of the power source is conveyed to the IVMC device by a direct gear match, a belt drive, or a bracket having a shaft extending through the center of the device, for example.  
         [0034]     To obtain a full range of speed, some embodiments of the present invention incorporate dynamic braking which is applied to the IVMC device, wherein the brake must slip. It is within the scope of the present invention to implement any one of several suitable dynamic or static braking options to control the IVMC device, such as, hydraulic or fluid based, electromechanical, or mechanical.  
         [0035]     Examples of hydraulic based braking control include, but are not limited to, a viscous plate, a clutch pack, a hydraulic motor having any one of a variable flow, variable fins, or a piston pump, or a damper.  
         [0036]     With respect to electromechanical based braking control, examples include, but are not limited, to a permanent magnet, an electro-magnet using a permanent magnet, a hysteresis brake, a magnetic particle brake, a ferrofluid damper, or an eddy current brake.  
         [0037]     Regarding mechanical based braking control, examples include, but are not limited to, a mechanically, hydraulically, pneumatically, or electro-magnetically actuated friction pad, a band brake or a thrust bearing, both of which could be traction fluid enhanced, a spring force, a gyroscope, a variable length rotation arm, or a friction pad that can be actuated mechanically, hydraulically, pneumatically, or electro-mechanically. Exemplary embodiments of mechanical based braking control are described further below with reference to  FIGS. 3A-13 .  
         [0038]     Consequently, the IVMC device of the present invention varies the rate of the gear pump or vehicle input (e.g., drive shaft), which conventionally had operated at a fixed rate, since, for example, the gear pump may typically have previously operated (i.e., in prior art applications) simply as a fixed gear ratio pump directly powered by the constant or steady rate at which the power source moved.  
         [0039]      FIGS. 3A-3C  show features relating to an exemplary transmission application (also interchangeably referred to herein as a “ratchet type transmission”), in accordance with an embodiment of the present invention. The features shown and described with regard to  FIGS. 3A-13  are generally usable with other embodiments of the applicant&#39;s variable motion control devices, including the variations shown in  FIGS. 1-2  and described herein.  
         [0040]     As shown in  FIG. 3A , the ratchet type transmission includes an input shaft  160 , an output shaft  162 , a speed control drum  164 , and a direction control feature  165 . In one embodiment, as shown in the representative diagram of  FIG. 3C , the speed control and/or direction control features  164 ,  165  include, for example, band type brake portions  170 ,  171  and one or more cam portions  175 ,  176 .  
         [0041]     As shown in  FIG. 4 , the input  160 , such as from a rotating input shaft attached to a driving source (e.g., an engine), is split using a control feature that includes a first planet gear  167 , a second planet gear  168 , and an output sleeve gear  180 , similarly to the embodiments described, for example, in  FIGS. 1 and 2  above. Also shown in  FIG. 4  are speed control output features.  
         [0042]     In  FIG. 4 , a sun gear  160   a  is attached to the input shaft  160 . The sun gear  160   a , via a first sleeve gear  170  and a second sleeve gear  171  rotating about axles  164   a ,  164   b  on the speed control drum gear  164 , engages the output sleeve gear portion  180  at a first sleeve gear  180   a.  The first sleeve gear  180   a  is attached to a second sleeve gear  180   b.    
         [0043]     The second sleeve gear portion  180   b  engages a first planet gear  167 , in turn engaging a second planet gear  168 .  
         [0044]     Alternatively, the device of  FIGS. 3A-4  can be used with input occurring via gear  167 , and control via shaft  160 . Input from gear  167  in thise use is thereby splittably output to gear portion  180   b  and second planet gear  168 .  
         [0045]     Output of the present invention is produced using a plurality of cam features, similarly to as described in Applicant&#39;s U.S. Pat. No. 5,116,292 (“the &#39;292 patent”) and U.S. Pat. No. 5,308,293, the entirety of each of which is incorporated herein by reference. In the &#39;292 patent, circular cams 49, pins 50, 51, circular disks 48, and slotted control disks 31, 32 are used. As shown in  FIGS. 5A and 5B  of the present application, an inner cam  200  (similar to circular disks 48 of the &#39;292 patent) is circularly shaped and mounted off center relative to the input shaft  160 . An outer cam  205  (similar to the circular cams 49 of the &#39;292 patent), which is also circularly shaped, has a pin  206  and an opening  207  off center. The opening  207  receives the inner cam  200  and allows the outer cam  205  to slidably rotate about the inner cam  200 . A slotted gear  210  (similar to slotted control disks 31, 32 of the &#39;292 patent) has a slot  211  for receiving the pin  206  of the outer cam  205 , and an opening  212  for slidably rotatably receiving the input shaft  160 .  
         [0046]     In operation, similarly as to operation described in the &#39;292 patent, positioning of the pin  206  relative to the input shaft may be controlled via relative movement of the outer cam  205  to the inner cam  200  (e.g., using another cam disk, such as or similar to the cam disk 26 having a curved spiral slot 32 of the &#39;292 patent), such that the outer cam  205  either rotates concentrically with the input shaft  160  or revolves about the input shaft  160  eccentrically. The path of revolution thus may be varied by varying the location of the pin  206  relative to the slot  211 , from the concentric position of  FIG. 6A  to the maximum revolution travel (e.g., center of outer cam  205  revolves about input shaft  160  at maximum distance from input shaft  160 ) of  FIG. 6B . Control using another cam disk with a spiral slot may be effectuated, for example, via rotational motion of the control drum  164 .  
         [0047]     As shown in  FIGS. 7A-7B , the outer cam  205  slidably rotates within a cam device  220  (also interchangeably referred to herein as a “cam conrod”), such that the cam conrod  220  either remains motionless (when the outer cam  205  revolves concentrically with the input shaft  160 , as shown in  FIG. 6A ), or the cam conrod  220  moves back and forth (also interchangeably referred to herein as having a “cyclic pivoting motion”) as a result of revolution of the outer cam  220  (when the outer cam  205  revolves eccentrically, as shown in  FIG. 6B ). Revolution of the outer cam  220  causes the back and forth movement of the cam conrod  220 . This motion of the cam conrod  220 , via a pin  225  or other operatively coupling mechanism, in turn causes a sprag device  230  (also interchangeably referred to herein as a “sprag conrod”) to correspondingly move back and forth (in a cyclic pivoting motion) about a sprag  235  sleeving a sprag output shaft  240 . Due to such use of the sprag  235 , the sprag output shaft  240  moves in one rotational direction only.  
         [0048]     Increased speed of movement of the sprag conrod  230  may be obtained by increasing the travel of the revolution of the outer cam  205 , producing corresponding increase in the speed of the back and forth movement (i.e., increased frequency of the back and forth cycle) of the cam conrod  220 . Alternatively, or in addition, rotational speed of the sprag output shaft  240  may be increased by increasing the rotational speed of the input shaft  160  (e.g., by increasing driving engine or other input device speed). Rotational speed of the sprag output shaft  240  may similarly be decreased by reducing travel of the outer cam  205  and/or by decreasing rotational speed of the input shaft  160 .  
         [0049]      FIG. 8  shows positioning of the cam conrod  220  and sprag conrod  230  when the outer cam  205  rotates concentrically with the input shaft  160  ( FIG. 6A ), thereby producing no back and forth motion of the cam conrod  220  or the sprag conrod  230 .  
         [0050]      FIG. 9  shows representative relative positioning of a plurality of cam conrods  220 , sprags  235 , and sprag conrods  230  within an exemplary variable motion control device in accordance with embodiments of the present invention.  
         [0051]      FIGS. 10-11B  illustrate operation of the output shaft  162  for directional control, such as via use of one or more braking cams  175 ,  176  braking or releasing corresponding brake disks  250 ,  251 . Output drum  260  revolves in either a first direction (e.g., braking of the first brake disk  250 ) or a second direction (e.g., braking of the second brake disk  251 ). The absence of braking by either of the brake bands  170 ,  171  allows a neutral to occur. Output  162  therefore is in either a first rotational direction, neutral (no rotation), or a second rotational direction, depending on application of the braking.  
         [0052]     For example, in one embodiment, two braking cams  175 ,  176  are used, one cam  175 ,  176  corresponding to each of the two brake bands  170 ,  171 . When one of the braking cams (e.g., braking cam  175  shown in  FIG. 11A ) is in the orientation shown in  FIG. 11A , minimal compression is provided on the extension  170   a  of the brake band  170  (in this example, the second extension  170   b  is fixably held), allowing the brake disk  250  to rotate unimpeded. When the brake cam  175  is in the orientation of  FIG. 11B , compression is provided by the lobe of the brake cam  175  on the extension  170   a  of the brake band  170 , resulting in frictional braking of the brake disk  250  (e.g., increased frictional resistance via compression of the brake band  170  due to the force applied to the extension  170   a,  while second extension  170   b  remains fixibly held).  
         [0053]     In operation, for example, sprag output shaft  240  has attached sun gears  241 ,  242 . Sun gear  242  meshably engages sleeve gear  261 , which revolves about axle  262  of output drum  260 . Sleeve gear  261  engages second sleeve gear  263  (shown in representative position), which, in turn, engages gear  250   a  attached to brake disk  250 . Absent braking of brake disk  250 , brake disk  250  is free to rotate, resulting in no rotational movement of output drum  260 . Engagement of the first braking cam  175  with the first band  170  produces frictional braking of the brake disk  250 , such that the second sleeve gear  263  revolves about gear  250   a,  thus producing rotational motion of output drum  260  in a first rotational direction.  
         [0054]     Similarly, sun gear  241  meshably engages third sleeve gear  266 , which revolves about axle  267  attached to brake drum  251 . Third sleeve gear  266  engages fourth sleeve gear  268  (shown in representative position), which, in turn, engages gear  260   a  attached to output drum  260 . Absent braking of brake disk  251 , brake disk  251  is free to rotate, resulting in no rotational movement of output drum  260 . Engagement of the second braking cam  176  with the second band  171  produces frictional braking of the brake disk  251 , such that the gear  260   a  revolves in response to rotation of gear  268 , thus producing rotational motion of output drum  260  in a second rotational direction.  
         [0055]     Disengagement of both braking cams  175 ,  176  results in no engagement of either band  170 ,  171 , thereby producing a neutral position (non-rotation of the output drum  260 , and thus non-rotation of the output shaft  160  meshably engaged therewith).  
         [0056]     In one embodiment, both braking cams  175 ,  176  are located on a single engagement shaft  165 . Control of cam orientation may be made, for example, via mechanical, electrical, or other rotational engagement of the cams. For example, in one embodiment, one or more servo motors electrically control orientation of the cams in response to lever movement or depression of one or more buttons. In another embodiment, a direct mechanical link (e.g., lever) or links with the cams cause change in cam orientation in response to lever movement.  
         [0057]      FIGS. 12 and 13  show cutaway side and end cross-sectional views of an exemplary transmission, including cam features and brake band directional control, in accordance with embodiments of the present invention.  
         [0058]     Operation using the variable motion control device of  FIGS. 3A-13  will now be described with respect to an exemplary vehicle application. In operation in a vehicle, input to the transmission is received from a running engine shaft output. The speed of output from the transmission is controlled by, for example, a lever (or for example, travel of a foot-controlled accelerator) that allows variation in the revolution of the outer cam, thereby varying, via the cam conrod, the amount of ratchet motion, and thus, along with variation in engine speed (producing corresponding control of input shaft speed), speed of rotational output in a single direction from the sprag conrod. A second lever (or, for example, a button) to partly or fully engage the braking feature may be used to cause the resulting output to be in a first rotational direction, neutral, or a second rotational direction. The resulting output (via the output shaft) may be connected, for example, via a drive shaft and differential to one or more vehicle wheels, allowing forward, neutral, and reverse operation of the vehicle via the wheels.  
         [0059]     Similarly, the first and second lever could be combined, for example, in a single control mechanism. For example, an accelerator pedal that pivots about a central point could cause the vehicle to go forward and accelerate when pivoted in a first rotational direction about the pivot (e.g., by an operator depressing the top of the pedal with the ball of the operator&#39;s foot) and in a reverse direction and accelerate in reverse when pivoted in a second rotational direction about the pivot (opposite the first rotational direction, such as by the operator depressing the bottom of the pedal with the heel of the operator&#39;s foot). This method of operation may be especially useful, for example, to allow the vehicle to be rocked forward and backward so as to escape being stuck (e.g., in mud or snow).  
         [0060]     Example embodiments of the present invention have now been described in accordance with the above advantages. It will be appreciated that these examples are merely illustrative of the invention. Many variations and modifications will be apparent to those skilled in the art.