Patent ID: 7291089

Claim:
A method of designing an optimized toroidal transmission, comprising: a) determining a desired input/output ratio of the transmission; b) determining a desired torque of the transmission; c) deriving a stator diameter; d) deriving a worm diameter that is designed to be disposed within the stator and attachable to an input shaft; e) determining dimensions and bending strength of stator walls which form, at least in part, helical stator races such that the stator walls do not fail during transmission use; f) determining dimensions of sufficiently robust rotor units including a total number of arms of each rotor unit and a diameter of a plurality of drive rollers that are carried by sufficiently robust mounting pins carried by each rotor arm, the drive rollers being configured to be in rolling engagement with the stator races and driven by the worm, the diameter of the plurality of drive rollers dictating a width of grooves defining the stator races; g) determining a maximum number of the rotor units based on load-sharing requirements; h) determining a total number of the grooves that define the stator races; i) determining precise angular displacements of the rotors on a yoke that carries the rotors and is attached to an output shaft; and j) examining operation of the rotor units within the stator races so as to arrive at lead angles in both the worm and the stator to assure non-self-locking peak operating efficiency such that the toroidal transmission has an optimum geometric construct which includes an optimum number of grooves to achieve the desired input/output ratio, sufficiently robust stator walls, and the rotor units are mounted on the yoke at precise positions such that drive rollers of the rotor units are in rolling engagement with the stator races.