Abstract:
A simple stepless variable transmission in which rotation of an input shaft is translated into circular motion of an input stage arm which is then converted into periodic rotation of an intermediate linkage around a center of rotation that is displaced from the center of circular motion of the input stage arm. The periodic rotation of the intermediate linkage drives an output stage arm into periodic circular motion about a center that is displaced from the center of rotation of the intermediate stage linkage. An overrunning clutch then transmits the useful portion of the periodic circular motion to an output shaft. Simultaneously controllably varying the distances between the centers of motion for the input stage arm, the intermediate linkage and the output stage arm controllably varies the ratio of the transmission.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a simple stepless variable transmission. 
     There has been a long felt but unmet need for an efficient, durable and mechanically simple stepless variable transmission, as evidenced by the number of prior inventions related to the subject. Many machines, based on a variety of principles, have been proposed or built in an effort to achieve these goals, yet to date there has not been a truly successful simple stepless variable transmission. 
     U.S. Pat. No. 1,257,479 to Grant discloses a transmission mechanism providing for multiple partial rotations of a tubular shaft and disks that can be moved from concentric to eccentric positions. The disks also have yokes, cams and racks. 
     U.S. Pat. No. 2,254,195 to Cicin discloses a stepless mechanical torque converter that converts rotations into turning motions, linear reciprocating movements, rotating oscillations and into uniform rotation. 
     U.S. Pat. No. 2,691,896 to Stageberg discloses a variable speed power transmission using a crank mechanism that includes a plurality of connecting rods and ratchet mechanisms. 
     U.S. Pat. No. 3,448,627 to Brooks discloses a gearless variable drive mechanism utilizing a rotating disk with an eccentric groove, a plurality of one way clutches and circumferentially spaced members engaging each of the clutches and the eccentric groove, each of the clutches having cam surfaces. 
     U.S. Pat. No. 3,881,362 to Beezer discloses a device for transmitting controlled movements in both an X axis and a Y axis direction including a rotatable shaft with separate drive cams for separately driving levers connected through slides to a first member which is guided for movement in an X direction and also connected through a cam drive and an adjustable slide to a second member which is mounted for movement along the Y axis. 
     U.S. Pat. No. 3,924,478 to Takasu discloses a speed reduction mechanism utilizing an eccentric with a driving disk mounted freely for rotation on the eccentric. 
     U.S Pat. No. 4,112,778 to Korosue discloses a variable speed power transmission provided with rotary units that are mounted on an input axis and an output axis and parallel with each other with a phase angle difference between the rotary units, each of the rotary units having eccentric cams and a clutch. 
     U.S. Pat. No. 4,411,172 to DeMarco discloses a variable speed reducing and torque transmitting mechanism including a pair of counter rotating low speed impellers being driven from a spider shaft rotating at relatively high speed. 
     U.S. Pat. No. 4,493,222 to Heine discloses a gearless speed and torque converter using an input member mounted on a rotatable input shaft that has an Archimedes spiral groove bearing surface with an adjacently exposed output member with a complementary Archimedes spiral groove bearing surface where the grooves have different pitches. The shafts are coaxially mounted and a plurality of balls are disposed between the respective spiral grooves. 
     U.S. Pat. No. 4,765,195 to Takami discloses a stepless transmission mechanism ;sing intermeshing noncircular gears and multiple shafts. 
     Traction machines have shown some success in light duty applications but have failed in heavy duty service. Torque converters have been used in more demanding situations but with considerable loss of efficiency. Purely mechanical, modified motion mechanisms have suffered either from complexity of design or from lack of smooth motion at the output shaft, resulting in limited and specialized applications. 
     The basic approach to purely mechanical, non-friction type stepless transmissions utilizing cams, linkages, noncircular gears and other members is, first, to use an input to drive a plurality of intermediate stages through cycles phased appropriately with the input. A selector mechanism then extracts and recombines the desired portion of the driven cycle of each of the parallel intermediate stages to drive the output shaft, usually through one way (overrunning) clutches and/or differentials (Takami, Brooks, Korosue, Stageberg). Other types of more complicated coupling through timed gear engagement can be found (Grant), as well as yet more complicated arrangements with conversion of rotary motion to linear and back to rotary (Cicin). 
     A key characteristic of prior stepless variable transmissions is the required plurality of parallel intermediate modules. Each parallel module creates a full cycle of a periodic motion for each revolution of the input shaft, subsequently transferring a portion of that motion to the output shaft (FIG. 8). The general shortcoming of these devices is that, at the transition point, when the driving force switches from one intermediate module to the next, there is an abrupt change in the magnitude and direction of the velocity and/or accelerating force reflected on the output shaft. In most cases (Brooks, Korosue, Stageberg) there also exists a large difference between the maximum and minimum velocity of each module during the power portion of the cycle (FIG. 5), which is transmitted to the output shaft. The end result is that the output shaft motion is the summation of a series of impulses, usually smoothed out only by drive line inertia. The final result is that the impulses produce shock loads requiring oversize components even in light duty applications. There are instances where force and velocity discontinuities are not carried in the power portion of the mechanism (Takami&#39;s angular velocity modulation mechanism). Nevertheless, there is shock loading in the transition of the drive components from one exponential ratio to another, a weakness inherent in the design if the number of parallel intermediate stages is to be minimized. 
     It is therefore an objective of this invention to achieve stepless rotational speed variation between an input shaft and an output shaft with high mechanical efficiency and a minimum of intermediate modules. 
     It is another objective of this invention to produce smooth motion at the output shaft, eliminating step changes in velocity and in acceleration of moving parts, thereby eliminating shock loads on the transmission components. 
     It is yet a further objective of this invention to achieve stepless speed variation by using a very small number of easily fabricated parts, capable of competing commercially with existing multiple fixed ratio speed variators. 
     It is yet a further objective of this invention to achieve stepless speed variation of high accuracy with minimum added mechanical complexity. 
     It is yet another objective to provide a simple means of controlling the steplessly variable mechanism, capable of easily interfacing with existing automatic control schemes, to produce an automatic stepless variable transmission. 
     BRIEF SUMMARY OF THE INVENTION 
     These and other objectives are obtained by a device comprising a minimum of two modules, each module having three stages: an input stage, an intermediate stage and an output stage. 
     The input stages of each module are all mounted on a single input stage subframe, the intermediate stages of each module are all mounted on a single intermediate stage subframe and the output stages of each module are all mounted on a single output stage subframe. The intermediate and the output modules are connected to a control mechanism that preferably regulates their positions with respect to the input module and thus effects speed variation. 
     The input stage translates rotation of an input shaft into circular motion of an input stage arm. The output stage translates circular motion of an output stage arm into rotation of an output shaft through a one way overrunning clutch. The clutch is necessary because (preferably) two complementary modules that are (preferably) 180° out of phase are used. The clutch transfers the rotation of the faster (or driving) module at that time to the output and allows the slower module at that time to complete its rotation until it becomes the faster (or driving) module. Thus, the input and output stages are complementary and mechanically very simple. 
     The intermediate stage couples the input stage arm to the output stage arm through a rotating slotted intermediate disk. The input stage arm and the output stage arm are engaged in opposite sides of the slot in the intermediate disk. The center on rotation of the intermediate stage slotted disk is displaced from and is between the centers of circular motion of the input stage arm and the output stage arm. 
     The intermediate disk is rotatably driven into a periodic motion, that, depending on the control settings, may become either full circle rotation or oscillation. Both types of motion are hereinafter referred to as &#34;periodic rotation&#34; or &#34;periodic rotational motion.&#34; Motion of the input stage arm along the slot is not transmitted. In complementary fashion, the output stage arm is driven into a periodic circular motion by the periodic rotation of the intermediate disk; motion of the output stage arm along the slot is not transmitted. 
     The distance between the center of the input shaft and the center of the intermediate disk (the input-intermediate center distance) and the distance between the center of the intermediate disk and the center of the output shaft (the intermediate-output center distance) then are set so that the desired periodic circular motion of the output stage shaft is obtained, namely nearly constant velocity through at least 180° of rotation of the input shaft (see FIG. 9). This setting of the two distances is easily accomplished by displacing the intermediate stage subframe in relation to the input stage subframe (to change the input-intermediate center distance) and by displacing the output stage subframe in relation to the intermediate stage subframe (to change the intermediate-output center distance). Of course, the input stage subframe also could be displaced in relation to the intermediate stage subframe. The key is simultaneously controlling both the input-intermediate center distance and the intermediate-output center distance. 
     The output stage shafts from a plurality of modules then are combined to drive the output shaft. This is easily accomplished in a two module device by simply coupling each of the output stage shafts to output stage gears through one way overrunning clutches, mounting an output gear on the output shaft and having both output stage gears drive the output gear (the clutches allow the faster module to drive the output shaft while the slower module completes its return cycle). Belts or other means can be used for a device with more than two modules. 
     As can be seen from the above, this invention translates the circular motion of the input stage arm into a periodic rotation of the intermediate stage disk because the center of the circular motion of the input stage arm is displaced from the center of rotation of the intermediate stage disk by the input-intermediate center distance. That periodic rotation is then corrected by being translated into periodic circular motion of the output stage arm about a center of circular motion that i; displaced from the center of rotation of the intermediate stage disk by the intermediate-output center distance. This flattens the portion of the velocity curve that is transferred to the output (FIG. 9) if the input-intermediate center distance and the intermediate-output center distance are appropriately set. 
     As a result, even a minimum configuration of two parallel modules (each transmitting power over 180° of the input cycle) can produce motion with no discontinuities and with amplitude variations much smaller than comparable four module arrangements encountered in prior art devices (Brooks, Korosue, Stageberg), without the mechanical complications of multiple sets of stepped noncircular gears (Takami). 
     Changing the drive ratios between the input and output shafts is accomplished by simultaneously controlling two parameters: the input-intermediate center distance and the intermediate-output center distance. The changes in the input-intermediate center distance and the intermediate-output center distance are dependent on each other because the device would not function properly or efficiently if the two distances are varied independently. It is anticipated that the changes in the input-intermediate center distance will be substantially linearly related to the changes in the intermediate-output center distance. However, if extreme accuracy is required, some departure from linearity may be required. Preferably, this constrained interdependent control of the two distances is accomplished by coupling the two distances to a single screw having two sections on its shaft, each section having a different pitch. The dual control accomplishes not only the average speed regulation that prior art devices accomplish, it also extends control over the instantaneous ratio, which provides the means for smooth motions and eliminates shock loads. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of the driving arrangement for a single 180° module of a preferred embodiment of a stepless variable transmission in accordance with this invention, the arrangement for the complementary 180° module and the subframes for the input and output modules being for clarity. 
     FIG. 2 is an elevational view of the input module of a preferred embodiment of a stepless variable transmission in with this invention. 
     FIG. 3 an elevational view of the intermediate module of a preferred embodiment of a stepless variable transmission in with this invention. 
     FIG. 4 an elevational view of the output module of a preferred embodiment of a stepless variable transmission in with this invention. 
     FIG. 5 in an elevational view of the complete assembly of the module of FIGS. 2, 3 and 4. 
     FIG. 6 is a sectional plan view of the complete assembly of FIG. 5. 
     FIG. 7 is an elevational view along the line 7--7 of FIG. 6. 
     FIGS. 8(a), 8(b) and 8(c) are graphical representations of typical output modes of prior stepless variable transmissions; 
     FIGS. 9(a), 9(b), 9(c) and 9(d) are graphical representations of the motions of a stepless variable transmission according to this invention FIG. 9(a) shows periodic rotational motion of the intermediate disk. FIG. 9(b) shows periodic circular motion of one output stage arm. FIG. 9(c) shows the addition of the periodic circular motion of two output stage arms. FIG. 9(d) shows motion of the output shaft. 
     FIG. 10 is a diagram showing the geometery of this invention. 
     FIG. 11 a graph showing expected control curve tuning. 
     FIG. 12 is a graph showing an expected control curve. 
     FIG. 13 is a diagram illustrating a conceptual oscillating stepless variable transmission. 
     FIG. 14(a) is a top plan view of a control system using cams. 
     FIG. 14 an elevational view of the control system of FIG. 14(a). 
     FIG. 15(a) is a top plan view of an embodiment in which the intermediate module has a fixed radius and the slot has been moved input or output stage arms. 
     FIG. 15(b) is an elevational view of the embodiment of FIG. 15(a). 
     FIG. 16(a) is an elevational view of an embodiment in which the input and output radii are varied for control and the distances between the shafts remain fixed, with details of the mechanism for controlling the radii omitted for clarity. 
     FIG. 16 is a top plan view of the embodiment of FIG. 16(a). 
     FIG. 17(a) is a top plan view of an embodiment showing control of the position of two modules using a straight linkage that at one end. 
     FIG. 17(b) is an elevational view of the embodiment of FIG. 17(a). 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1 to 7, an input shaft 10, supported by bearings 11 is rigidly connected to an input gear 12, which drives an identical set of gears 13A and 13B, supported by input stage shafts 14A and 14B respectively. Input stage shafts 14A and 14B are supported by input stage shaft bearings 15A and 15B and are rigidly connected to input stage driver arms 16A and 16B. The input stage driver arms 16A and 16B engage slotted intermediate disks 20A and 20B, respectively, through input stage engagement members, preferably antifriction rollers 17A and 17B. The intermediate disks 20A and 20B are rotatably supported in the movable intermediate subframe 21 through the intermediate disk bearing assemblies 22A and 22B. 
     Referring to FIG. 7, the intermediate subframe has slots 23 which engage the main frame 50 through rails 51. 
     The intermediate disks 20A and 20B engage output stage arms 30A and 30B through output stage antifriction rollers 31A and 31B. The output stage arms 30A and 30B are rigidly connected to output stage engagement members, preferably shafts 32A and 32B, which are supported by output stage shaft bearings 33A and 33B, mounted on output subframe 34. 
     The output stage shafts 32A and 32B drive output stage gears 35A and 35B through one way output stage roller clutches 36A and 36B. The output stage gears 35A and 35B are coupled to output shaft 37 through output gear 38. 
     The output shaft 37 is supported by output shaft bearings 33C, mounted in the movable output stage subframe 34, having output stage slots 39 which engage the fixed rails 52 of the main frame 50 (see FIG. 7). 
     A control screw 40 with two different pitches 41 and 42 controls the position of the intermediate subframe 21 and output stage subframe 34 through screw blocks 43 and 44, which are rigidly attached to the output subframe 34 and the intermediate subframe 21. The control screw 40 is supported by bearings 45 and 46, which are mounted on the main frame 50. The springs 47 and 48 push of the subframes and the threads 41 and 42 to minimize backlash. The control screw 40 is controlled by hand crank 49. 
     Referring to FIGS. 17(a) and 17(b), instead of a hand crank, control can be effected by using a straight linkage 49 that is pivoted at one end, with the subframes being pivotably attached along the length of the linkage 49. Preferably the subframes are attached to a slot along the linkage 49 to allow some movement along the linkage 49 as the linkage 49 itself is pivoted so that the subframes will not be forced to move transversely. 
     Components identified with a numeral and a suffix A or B are associated with intermediate modules A and B respectively. The components are identical; the only difference is that the driver arms 16A and 16B are phased 180° apart on the input shaft 10. From this point on the suffix will be dropped and the assumption will be made that reference is made to the module through which power is transmitted at the time. 
     Input stage driver arm 16, input stage roller 17 and the intermediate disk 20 comprise a slider linkage that produces a cyclically varying motion on the intermediate stage generally shown in FIG. 9. The intermediate disk 20, output stage roller 31 and output stage arm 30 also comprise a slider linkage, complementary to the first, which performs the conversion of the motion of intermediate disk 20 into the smooth output at the output shaft 37. The introduction of the second slider linkage, when properly coupled to the continuously varying rotation of the intermediate disk 20 (through proper selection of the input-intermediate center distance and the intermediate-output center distance), reduces the error of output velocity fluctuations to very low levels. Prior art devices would require a large number of parallel modules to approach the linearity of the present invention, with the shock probles in the transition from one stage to the other still unsolved (Brooks, Stageberg), or they would require complicated mechanisms using modulation of different motion curves (Takami, exponential velocity addition, Cicin, sin 2  and cos 2  analysis and recombination). 
     MATHEMATICAL PRINCIPLES THAT THE INVENTOR BELIEVES GOVERN THIS INVENTION 
     For the convenience of the reader, a mathematical description of the invention now follows, but this is only a description of how the inventor presently believes the invention works, and not a definitive explanation. Accordingly, even if the description and explanation are erroneous, the validity and enforceability of this patent shall not be affected. Further, no limitations are to be implied or inferred from the description or explanation. 
     The basic geometry of FIG. 1 to 7 is extracted and redrawn on FIG. 10. The center of input stage shaft 14 is at point A, the input stage driver arm 16 extends from A to B, the center of intermediate disk 20 is at 0, the centerline of the slot on disk 20 is indicated by the line MN, the centerline of the output stage shaft 32 is at G, the output stage arm 30 is EG. The input-intermediate center distance is AO and the intermediate-output center distance is GO. It should be noted though that any pair of the group AO, AB, OG, EG can be used. The three centers G, 0, A are colinear along the axis YZ. For simplicity, consider first the starting position with the slot MN horizontal, which in turn force the driver and driven arms in horizontal alignment (not shown). When the input shaft turns through an angle θ1, a corresponding rotation θ2 is produced on the intermediate disk, indicated by the rotated slot centerline MN. The mathematical relationship between θ1 and θ2 is given by equ. 10: 
     
         θ2=arctan[(AB*sin(θ1))/(AB*cos(θ1)+AO)]  (10) 
    
     The rotation θ2 of the intermediate disk results in a rotation θ3 of the driven arm EG. The magnitude of θ3 can be determined in two steps as shown by equations 20 and 30: 
     
         EO=OF+FE=OG*cos(82)+(EG.sup.2 -(GO*sin(θ2).sup.2,    (20) 
    
     
         θ3=arctan[(ED)/(OD-OG)]==arctan[(EO*SIN(θ2))/(EO*COS(θ2)-OG)]                                                       (30) 
    
     Since the value of θ3 is obtained the ratio θ3/θ1 can be compared to the theoretical ratio given by equ. 40: 
     
         R=(EG+OG)/(AB+AO)                                          (40) 
    
     The deviation of θ3 from the ideal value that would correspond with equ. 40 results in an error which can be found from equ. 50: 
     
         E=R-θ3/θ1                                      (50) 
    
     The basic achievement of this invention is accomplished through minimizing the magnitude of the error in 50, accomplished through optimization of the control parameters OG and OA. Mathematically this can be accomplished by differentiating the error function with respect to the desired variable; in order to avoid the very lengthy equations that substitution of 10, 20, 30 and 40 in 50 would produce, an iterative process is used instead, better suited for the capabilities of state of the art computers. The results of the inventor&#39;s iterative calculation are shown in FIG. 11 and FIG. 12, with FIG. 11 showing a typical error variation for two different settings of the second center distances, :nd FIG. 12 showing the total results, showing an optimum relationship between the two control parameters OA and OG. Qualitatively the error is minimized by selecting AO and OG in such a manner that the nonlinearity encountered in obtaining θ2 from θ1 is offset by the nonlinearity developed in producing θ3 from θ2. The error cancellation is usually possible when the intermediate angle θ2 has a value between θ1 and θ3; that is true because then one of the ratios θ3/θ2 and η2/θ1 would be less than unity, while the other would be greater than unity, and, as θ1 increases toward the 90 degree mark, the ratio that is greater than 1 tends to decrease while the ratio that is less than 1 tends to increase, resulting in a more or less constant product. 
     The process of using a second stage translation of motion essentially to invert the first stage translation of motion differentiates this invention from devices similar to Brooks, Korosue etc. providing much smoother performance. The process is also clearly different from the process in devices that utilize a fixed speed variation curve and subtract its value at phase shifted points to obtain constant output (Takami). The working mechanical elements are by far simpler than any noncircular gear or cam arrangement and far fewer than impulse type devices, thus achieving the goal of simple and durable components. 
     It is theoretically possible to adjust the error as close to zero as would be desired. Such accuracy would require continuous adjustment of some of the controlling parameters through each rotation of the input shaft and would result in mechanically complicated structures. The simpler approach has been taken for the preferred embodiment of this invention, which, for each ratio, maintains a fixed relationship between the center distances OA and OG, independent from input shaft rotation angle. Adjustment is easily obtainable with a single shaft 40 driving two different pitch screws 42 and 43, controlling the position of the movable subframes 21 and 34, which in turn dictate the magnitude of OA and OG. The accuracy of the simpler control is satisfactory for most but the most demanding applications. Should greater accuracy be required, addition of a third parallel module in the subframes 21 and 34 can achieve the desired result, reducing the operating cycle to 120° of rotation for each, resulting in maximum error of the order of 0.02%, without changing the control method- 
     POSSIBLE MODIFICATIONS AND VARIATIONS 
     The invention has been described above with respect to a particular preferred embodiment. However, it will be appreciated by those skilled in the art that many modifications and variations can be made without departing from the spirit and scope of the invention. Some of these modifications and variations are as follows. 
     Depending on the relationship between the drive arm radius AB and the magnitude of the input-intermediate center distance OA, the intermediate disk will undergo either a full rotation or oscillation. The inherent range of ratios for the case of oscillation ranges from zero to 0.5:1. A different preferred embodiment possessing such capabilities is shown in FIG. 13, utilizing the added feature of zero output velocity to provide clutchless engagement and disengagement. 
     The case of complete intermediate disk rotation can also be implemented in a variety of ways, some of which will be briefly discussed below. Typically the variations are also applicable in the oscillating disk domain. 
     The two modules can be placed in an inline arrangement, with one parallel module relocated to one side of the other module, in an assembly more compact than FIG. 1. 
     The rollers 17 and 31 can be replaced with sliding bearings. Similarly, the slider linkage can be replaced with a roller linkage. 
     The speed adjustment mechanism can be replaced with a different mechanical assembly utilizing multiple screws, multiple screw types, linkages, circular and/or plate cams, servomotors, air/oil systems, hydraulic actuators, etc, achieving relative motions of two stages similar to FIG. 9. Cam mechanisms can be used instead of the screw threads 41 and 42, which more easily allows deviations from a strictly linear relationship between OG and OA, further improving the accuracy. 
     Servos and/or fixed and/or adjustable cams etc., can be used for dynamic adjustment of OA and OG, achieving high precision out of few parallel modules. As can be seen from FIG. 11, there are minor errors in the rotation of the output shaft that vary depending on the rotation of the input shaft. These minor errors can be compensated for by appropriately adjusting the position of the subframes (or the radii of the input and output arms) during appropriate portions of each cycle. Thus, the optimal positioning of each subframe (or the optimal radius of each arm) varies during each cycle. For high precision, therefore, additional control mechanisms can be added in order to appropriately adjust the positioning of each subframe (or the radius of each arm). For example, appropriately configured cams can be attached to the input or output shafts and linked to the controls for positioning the subframes or altering the radii of the arms. 
     More stages can be added to each module, which can improve the range and/or accuracy of the system. 
     The radii AB and/or EG can be varied as well. Then any two of the distances OA and OG or the radii AB and EG can be used to control and effect speed variation. Any apparatus or method known in the art can be used to vary the radii and no specific apparatus or method is strongly preferred. Examples of such radii variation mechanisms are shown in FIGS. 16(a) and 16(b), in Grant and in prior art shaper tools. 
     The slot/roller location at the slider joints could be reversed, causing the intermediate radii GB and GE to become the fixed radii, while AG and GO become the slider links. Equations 10--40 require some modifications when this arrangement is used. 
     Of course, more parallel modules could be added to the system. 
     Use of differentials to extract the useful part of the cycle of each module in the less than unity ratio applications leads to yet another possible embodiment. 
     Differentials and/or timed gears could be used instead of the overrunning clutches. 
     Of course, passive and/or dynamic vibration control devices, constant velocity or other types of universal joints can be added to provide a smoother coupling between the input and output shafts. 
     Because of the numerous modifications that can be made without departing from the spirit and scope of the invention, no limitations are to be implied or inferred except as specifically and explicitly set forth in the appended claims. Without limitation to the foregoing, the terms circular motion and rotational motion shall be deemed to mean and include oscillating circular motion and oscillating rotational motion. Further, a device could use changes in the input-intermediate center distance for one control parameter and changes in the radius of the output stage arm for another control parameter, and vice versa. The term &#34;arm&#34; also shall be deemed to mean any member that provides a moment arm for action of circular or rotational motion, including a disk, gears or the like.