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Roller Gearing and Power Transmission Mechanism

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Example Designs - what it can be used for ... Ships and boats: gearboxes, generators, dredger drives etc. Airplanes, fixed and rotating wings ... – PowerPoint PPT presentation

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Title: Roller Gearing and Power Transmission Mechanism


1
Roller Gearing and Power Transmission Mechanism
  • Pál Bogár
  • Sincroll Drive Technologies

1
2
Agenda
  • The Innovative Idea - what new we do
  • Realisation of the Idea - how we do it
  • Example Designs - what it can be used for
  • Benefits and Advantages - why we do it / how good
    it can get
  • Prototype Tests - how much we achieved so far
  • Potential Applications - what business potential
    we foresee
  • The Sincroll Company - who we are business,
    skills, facilities
  • Potential for Collaboration - what Nissan and us
    can do together

2
3
The Innovative Idea
  • Brand new technology
  • - 4 months in the market
  • Trivial problem non-trivial solution
  • Rollers connect the wheels
  • wheels do not connect directly
  • (there are no teeth)
  • Rollers roll along grooves on both wheels
    simultaneously
  • rigid coupling between the wheels
  • Rollers do pure rolling motion without sliding
  • ensured by the shape of the grooves

3
4
Realisation of the Idea
  • Force and torque are transmitted through the
    contact points between the rollers and the
    grooves
  • Properly selected line of contact points i.e. the
    curve of the grooves ensure proper forces acting
    and thus pure rolling motion
  • The ensemble of grooves determines the shape of
    the wheel

4
5
Realisation of the Idea - continued
  • Complex physics
  • G the roller (ball)
  • P1, P2 contact points between the balls and the
    wheels
  • gp path travelled by the balls centre when in
    coupling
  • g1, g2 paths travelled by the contact points
  • u, v various velocity vectors
  • w1, w2 angular velocity vectors of the two wheels

5
6
non-intersecting axes axes angle 90o gearing
ratio 11 ball diameter 4mm contact factor
8
6
7
intersecting axes axes angle 90o gearing ratio
1115 ball diameter 4mm contact factor 9
7
8
parallel axes axes angle 0o gearing ratio
1223 ball diameter 4mm contact factor 8
8
9
parallel axes direction of rotation
same gearing ratio 15 ball diameter
4mm contact factor 9
9
10
parallel axes direction of rotation
opposite gearing ratio 2325 ball diameter
4mm contact factor 19
10
11
non-intersecting axes axes angle 45o gearing
ratio 12 ball diameter 4mm contact factor
8
11
12
non-intersecting axes axes angle 45o gearing
ratio 12 ball diameter 4mm contact factor
8
12
13
non-intersecting axes axes angle 50o gearing
ratio 1325 ball diameter 4mm contact factor
18
13
14
parallel axes gear rack axes angle 45o gearing
ratio n/a ball diameter 4mm contact factor
16
14
15
perpendicular axes gear rack axes angle
90o gearing ratio n/a ball diameter
4mm contact factor 10
15
16
internal coupling non-intersecting axes axes
angle 45o gearing ratio 12 ball diameter
5mm contact factor 7
16
17
micro-rollers non-intersecting axes axes angle
45o gearing ratio 15 ball diameter
0mm contact factor 8
17
18
worm gear axes angle 90o gearing ratio
150 ball diameter 4mm contact factor n/a
18
19
planetary gear system axes angle
collinear gearing ratio 1300 ball diameter
4mm contact factor 8
19
20
Main Advantages
  • Three main advantages plus their implications
  • Power efficiency close to 100
  • due to pure rolling motion done by the rollers
  • sliding friction is practically eliminated
  • Contact factor up to 20 or more
  • load distributes over many rollers
  • Back-lash free
  • easy to eliminate back-lash by forcing the wheels
    together
  • compromise in performance i.e. efficiency
    in-significant

20
21
Implied Advantages
  • High power efficiency
  • No sliding friction
  • Lower energy losses
  • Lower starting torque
  • Smaller motor needed
  • Friendlier to the environment a green
    technology
  • Lower operating costs
  • Reduced heating up
  • Reduced abrasion
  • Less cooling and lubrication needed
  • Less wear and deterioration
  • Longer lifetime
  • Less vibration and noise
  • High contactor factor
  • Smaller size
  • Special shape (e.g. very thin) - more flexibly
    adjustable
  • Higher power density
  • Smoother and steadier movements
  • Precise movements
  • Lower noise
  • Greater reliability
  • No back-lash
  • Precise movements
  • Less vibrations and resonances
  • Longer lifetime

21
22
Other Selected Features
  • Flexibility in design
  • more control parameters for the designer
  • a richer and more adjustable system
  • one gear problem but many solutions
  • New framework new intuition
  • conventional gear design intuition may not work
    here
  • this is more like a generalised ball screw or
    roller bearing
  • Lot of potential for further RD advances in the
    future
  • e.g. optimisation of roller movement, parallel
    grooves, non-ball rollers, micro roller liquid
    etc.
  • a lot of applications need to be developed

22
23
Other Selected Features - continued
  • Performance determined on the micro level at
    the contact of the rollers and the grooves
  • performance relatively insensitive to overall
    gear geometry
  • e.g. can change gearing ratio without changing
    the wheel diameters directly
  • can also change direction of rotation without
    adding extra wheels
  • Hertz stress benign
  • curvature of balls and grooves are similar and
    are the same sign
  • point-like contact expands into a surface-like
    contact and Hertz stress drops
  • yet frictional losses do not increase much
    because of low relative velocities of the (now
    sliding) contact surfaces

23
24
Prototype Tests
  • Prototype tested was 110 ratio,
    non-intersecting, 45o axes
  • Made of steel with nitriding finish of grooves
    surfaces
  • Made by Sincroll
  • Test lab was at the Budapest University of
    Technology
  • Tests supervised by the Department of Machine and
    Product Design
  • Tests performed All this was done
  • Basic checks of operations - With and without
    back-lash
  • Kinematics and noise checks - For both
    directions of rotation
  • Static power efficiency - For both directions
    of load
  • Dynamic power efficiency - For various
    angular velocities
  • Movement precision

24
25
non-intersecting axes T E S T P R O T O T Y P
E axes angle 45o gearing ratio 110 ball
diameter 4mm contact factor 19
25
26
non-intersecting axes axes angle 45o gearing
ratio 110 ball diameter 4mm contact factor
19
26
27
non-intersecting axes axes angle 45o gearing
ratio 110 ball diameter 4mm contact factor
19
27
28
non-intersecting axes axes angle 45o gearing
ratio 110 ball diameter 4mm contact factor
19
28
29
non-intersecting axes axes angle 45o gearing
ratio 110 ball diameter 4mm contact factor
19
29
30
The Test Rig
30
31
Test Data for Movement Precision
31
32
Summary of Test Results
  • Basic operations, kinematics, noise and
    reliability
  • no particular issues, performance was quite good
    in all respect
  • All tests were insensitive (in terms of
    statistical significance) to
  • changing direction of rotation
  • changing the direction of the load
  • and whether the back-lash was eliminated or not
  • Static efficiency at least 98 - this was
    independent of
  • roller recycling device being in place or not
  • back-lash has been eliminated or not (surprise!)

32
33
Summary of Test Results
  • Dynamic efficiency
  • first measurement 92
  • after improving the surface quality of the roller
    recycling channel the efficiency went up to 94
  • groove surfaces were sub-optimal as a result of
    nitriding
  • we will re-test again soon with polished groove
    finish and improved roller recycling device
  • Movement precision showed a periodic structure
    that where the periodicity was the same as the
    period of revolutions of the larger wheel in the
    gear. This shows there was a manufacturing error
    in the larger wheel.
  • the error was about /- 0.2 degrees looks like
    a normal amount of inaccuracy and should not be a
    cause for alarm
  • we want to retest with a higher precision
    electronics to see if anything else besides the
    larger wheel has an effect on precision

33
34
parallel axes A L U M I N I U M P R O T
O T Y P E axes angle 0o gearing ratio
2623 ball diameter 4mm contact factor 8
34
35
parallel axes axes angle 0o gearing ratio
2623 ball diameter 4mm contact factor 8
35
36
Potential Applications
  • High-power drives
  • due to low operating costs, small size and great
    reliability
  • All Vehicles
  • due especially to high efficiency and high power
    density
  • Material handling machines
  • due especially to smaller starting torque
  • Machine tools
  • due to no back-lash
  • an alternative to ball-screw drives
  • Wind power generators
  • high energy efficiency, high gear-up ratio and
    backlash-free adjustments
  • Standard gear and transmission families

36
37
Applicable Industries
  • Cement, stone and ore industries
  • Grinding machines, rolling mills, presses,
    separators, mixers, elevators etc
  • Chemical and environmental industries
  • Agitators, mixers, pumps and compressors, cooling
    towers, dryers, turbines, aerators and thickeners
    in sewage treatment etc.
  • Electric power generation
  • Wind, gas, coal, oil, water and nuclear power
    generators etc.
  • Food and agri industries
  • Cutters, feeders, mixers, harvesters, combines,
    sewage treatment machinery etc.
  • Machine tools industries
  • Table movers, rotators, dividers, gear racks,
    spindle drives etc.

37
38
Applicable Industries - continued
  • Materials handling machines
  • Various kind of cranes, lifts, hoisters,
    elevators, escalators, excavators, conveyors,
    ropeways, factory assembly lines etc.
  • Mining industries
  • Excavators, conveyors, lifters, hoisters etc.
  • Paper, packaging and printing machines
  • Cutters, feeders, dryers etc.
  • Plastics and rubber industries
  • Extruders etc.
  • Steel and iron industries
  • Conveyors, elevators, metal working machinery etc.

38
39
Applicable Industries - continued
  • Sugar industries
  • Cutters, feeders, shredders, mills etc.
  • Textile industries
  • Cutters, feeders, dryers, spinning machines etc.
  • Vehicles
  • Cars, motorbikes, bicycles gearboxes, steering
    gears, differential gears etc.
  • Trucks and special purpose vehicles gearboxes,
    steering gears, differential gears etc.
  • Railway vehicles such as trams, locomotives,
    regional railways, metro-underground etc.
  • Ships and boats gearboxes, generators, dredger
    drives etc.
  • Airplanes, fixed and rotating wings
  • Wood and forestry industries
  • Special purpose vehicles, cranes, conveyors etc.

39
40
The Sincroll Company
  • Our primary business is
  • research and development
  • commercialisation
  • technology transfer of the new roller gear
    technology
  • This includes
  • continued independent work same as what we have
    been doing thus far
  • as well as new collaborations with partners via
    e.g. license agreements
  • Our skills and tens of years of experience are in
    design and development including
  • theoretical research and computer design and
    simulation
  • applications design and development, evaluation,
    lab experiments and testing

40
41
The Sincroll Company - continued
  • Our management skills come from 10-20 years of
    scientific research, corporate and
    entrepreneurial experiences
  • We also have direct access to limited but
    high-quality machining facilities
  • we manufacture high-quality prototypes and
    perform basic tests
  • we also do production on a relatively small scale
    (secondary business)
  • In this way we can offer a wide range of services
    to our customers and our partners
  • starting from basic RD, theoretical and
    experimental work
  • all the way up to prototype and equipment
    manufacture and pilot and small scale production

41
42
Potential for Collaboration
  • Looking for a partner is a new idea
  • we came to the market four months ago only
  • Following about five years of intensive RD
  • We believe the technology is mature enough now to
    be successfully applied in commercial
    applications
  • We need partners to help us to find the best
    applications that we can develop with the
    ultimate target of a commercial product in the
    focus
  • We also need partners to contribute in the
    partnership with production capacity and skills
    as well as market knowledge, sales and marketing
    networks and customer relationships

42
43
Potential for Collaboration continued
  • In return we provide the technology through e.g.
    a licence agreement as well as our RD and pilot
    production services in order to progress the
    developments of the technology further

43
44
THANK YOU
44
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