WO2007051827A1 - Continuously variable ratio transmission drive - Google Patents

Continuously variable ratio transmission drive Download PDF

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Publication number
WO2007051827A1
WO2007051827A1 PCT/EP2006/068051 EP2006068051W WO2007051827A1 WO 2007051827 A1 WO2007051827 A1 WO 2007051827A1 EP 2006068051 W EP2006068051 W EP 2006068051W WO 2007051827 A1 WO2007051827 A1 WO 2007051827A1
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WO
WIPO (PCT)
Prior art keywords
variator
end load
input
race
races
Prior art date
Application number
PCT/EP2006/068051
Other languages
French (fr)
Inventor
Christopher John Greenwood
Original Assignee
Infinitrak, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Infinitrak, Llc filed Critical Infinitrak, Llc
Publication of WO2007051827A1 publication Critical patent/WO2007051827A1/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H61/00Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing
    • F16H61/66Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing specially adapted for continuously variable gearings
    • F16H61/664Friction gearings
    • F16H61/6649Friction gearings characterised by the means for controlling the torque transmitting capability of the gearing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H15/00Gearings for conveying rotary motion with variable gear ratio, or for reversing rotary motion, by friction between rotary members
    • F16H15/02Gearings for conveying rotary motion with variable gear ratio, or for reversing rotary motion, by friction between rotary members without members having orbital motion
    • F16H15/04Gearings providing a continuous range of gear ratios
    • F16H15/06Gearings providing a continuous range of gear ratios in which a member A of uniform effective diameter mounted on a shaft may co-operate with different parts of a member B
    • F16H15/32Gearings providing a continuous range of gear ratios in which a member A of uniform effective diameter mounted on a shaft may co-operate with different parts of a member B in which the member B has a curved friction surface formed as a surface of a body of revolution generated by a curve which is neither a circular arc centered on its axis of revolution nor a straight line
    • F16H15/36Gearings providing a continuous range of gear ratios in which a member A of uniform effective diameter mounted on a shaft may co-operate with different parts of a member B in which the member B has a curved friction surface formed as a surface of a body of revolution generated by a curve which is neither a circular arc centered on its axis of revolution nor a straight line with concave friction surface, e.g. a hollow toroid surface
    • F16H15/38Gearings providing a continuous range of gear ratios in which a member A of uniform effective diameter mounted on a shaft may co-operate with different parts of a member B in which the member B has a curved friction surface formed as a surface of a body of revolution generated by a curve which is neither a circular arc centered on its axis of revolution nor a straight line with concave friction surface, e.g. a hollow toroid surface with two members B having hollow toroid surfaces opposite to each other, the member or members A being adjustably mounted between the surfaces

Definitions

  • the present invention relates to continuously variable ratio transmission devices
  • variable of toroidal-race, rolling-traction type, and in particular to means for applying the "end load” needed to provide traction between rollers and races in such variators.
  • Variators are used in transmissions - particularly but not exclusively in
  • a pair of co-axially mounted circular races have respective semi-toroidally recessed surfaces which together define a generally toroidal cavity, within which is mounted a plurality of rollers.
  • the rollers are sandwiched between the races, running upon their recessed faces, and serve to
  • variable axis which will be referred to as the "variator axis" the relative speeds of the two races - and hence the variator 1 s drive ratio - can be altered in a stepless manner.
  • rollers are caused to steer themselves to suitably vary their inclinations.
  • End load This force will be referred to herein as the "end load".
  • the rollers and races do not actually contact each other, being separated by a thin film of traction fluid which is maintained by continuously jetting the fluid onto these parts. Traction results from shear within the fluid layer, when subject to a suitably high pressure due to the end load. End load is typically provided by applying an axial force to one of
  • reaction pressure A common pressure (the "reaction pressure") is applied to each actuator, and determines a force (the “reaction force”) applied to each
  • reaction torque is proportional to reaction pressure.
  • the end load is provided by means of a hydraulic actuator exerting an axial force on one of the races, and the fluid pressure supplied to this end load actuator is equal to, or at least controlled by, the reaction pressure, so that the end load is
  • the traction coefficient is defined as the ratio of (i) the force parallel to the interface to (ii) the force normal to
  • End load adjustment must in some situations be carried out with little time lag. Externally created events, such as rapid vehicle braking, can abruptly create a requirement for an increase of end load, and failure to respond with sufficient speed could result in catastrophic slip within the variator.
  • the known hydraulic system provides the required speed of response.
  • variableators are not hydraulically controlled.
  • the present invention has been devised in connection with a relatively simple variator in which roller displacement is instead controlled through a direct mechanical coupling.
  • control end load through some form of mechanical coupling which translates the reaction force applied to the roller's mountings into end load, but in reality this is not considered to be practical. Therefore some other way of suitably adjusting end load is required.
  • end load is adjusted in dependence upon reaction torque.
  • end load could instead be adjusted in dependence upon either input torque alone or output torque alone, and in fact it is known to vary end load in proportion to input torque. This is done in variators of the so-called "half toroidal" type but proves less appropriate in full toroidal variators. The difference
  • variator axis 16 and the rollers lie along a diameter of the circle generating the torus.
  • the centres 17 of the rollers 18 lie upon, or close to, the centre of this circle, and the
  • variable continuously variable ratio transmission device
  • variable comprising an input race operatively coupled to a variator input shaft and an output race operatively coupled to a variator output shaft, the input and output races being mounted for rotation about
  • the " races having respective part-toroidally shaped surfaces which together define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with mountings which permit the roller's inclination to the common axis to vary, in order to vary the ratio of input shaft speed to output shaft
  • the variator being characterised in that the end load arrangement comprises (a) a first end load device for applying a first end load component which varies in accordance with torque applied to the input race and (b) a second end load device for applying a second end load component which is
  • the first and second end load devices acting upon the same variator race so that the total end load is the sum of the first and second end load components.
  • variable continuously variable ratio transmission device
  • the input and output races being mounted for rotation about a common axis, the races having respective part-toroidally shaped surfaces which together define a substantially toroidal cavity containing at least two rollers, each ⁇ roller running upon the shaped surfaces of both races to transfer drive from one to the
  • the variator being characterised in that the
  • end load arrangement comprises (a) a mechanical actuator which applies to one of the
  • variator races an axial force which varies according to the torque applied to the input
  • variable continuously variable ratio transmission device
  • part-toroidally shaped surfaces which together define a substantially toroidal cavity
  • each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with mountings
  • the method comprising applying to the same variator race (a) a substantially constant end load component and (b) an end load component which varies with variator input torque.
  • the first end load component is substantially proportional to the absolute value of the torque applied to the input race.
  • Absolute value is used here to refer to the magnitude of the torque, regardless of its sign (direction).
  • the second end load component is preferably substantially constant. It may
  • the first end load device forms a coupling which
  • the coupling serves both to transmit torque from the variator input shaft to the input race and to apply the first end load component, the coupling comprising first and second parts,
  • the ramp surface could in principle be part of a screw thread.
  • the ramp acts upon a force-transmitting part in the form of a ball which
  • the coupling comprises at least two ramp surfaces which are oppositely inclined to said plane perpendicular to the common axis, such that the axial force is applied in the same direction regardless of the direction of action of the torque applied to the input race.
  • the first and second coupling parts have respective ramp surfaces, the force-transmitting part being formed separately from both coupling parts and being retained between their respective ramp surfaces.
  • One of the coupling parts may be formed by the input race itself.
  • first and second end load devices are both anchored to the variator input shaft ,and the variator output race is mounted around and axially restrained relative to the input shaft, so that the end load force is borne in
  • Figures Ia and Ib are highly simplified sections, in an axial plane, through a full toroidal and a half toroidal variator respectively;
  • Figure 2 is a graph of the variation of axial load in a known variator;
  • Figure 3 is a graph of traction coefficient against ratio for variators using different end load control strategies
  • Figure 4a is a section in an axial plane through a variator embodying the present invention.
  • Figure 4b is a section in a radial plane through the same variator
  • Figure 5 is a view along a radial direction of a ball ramp device used in the same variator
  • Figure 6 is a perspective illustration of a thrust disc of the ball ramp device
  • Figure 7 is a perspective view of the rear of a race used in the same variator
  • Figure 8 is a perspective view of the front of the same race
  • Figure 9 is a graph of end load against input torque for a variator embodying the present invention.
  • Figure 10 is a perspective illustration of a registration disc used in the ball ramp device of Figures 4 and 5.
  • the present invention has been devised following an analysis of full-toroidal variator performance, and in this connection reference is directed to Figure 3, which represents variation of variator traction coefficient, on the vertical axis, with ratio, on the horizontal axis, for a full-toroidal type variator.
  • the calculation has been based on the assumption that variator output torque is constant. This assumption is
  • variator input torque can be calculated from the chosen constant output torque and the variator
  • line L 0 represents the case of a constant end load
  • the constant end load would have to be chosen to avoid this even at the high traction coefficient end of the curve (at high negative ratios) and as a result the variator would be inefficient when working elsewhere on the curve, at lower ratios.
  • Line L 1 represents the alternative strategy in which end load is proportional to variator " input torque. Ih this case traction coefficient is greatest at low negative variator ratios and the constant of proportionality of end load to input torque would
  • Line LR represents the strategy where end load is proportional to reaction
  • the range of variation of traction coefficient with ratio is relatively small, and consequently the ratio of end load to reaction torque can be chosen to provide good variator efficiency throughout the ratio range. This is highly desirable and can be achieved, as already explained, in a hydraulically controlled variator.
  • line L INV represents the variation of traction coefficient achieved using a strategy in accordance with the present invention. Note that it approximates to line L R , and shows a similarly small range of traction
  • the variator has an input race 100 with a part toroidal face 102 f and an output race 104
  • the thrust disc 118 rotatably mounted upon a hollow spigot 116 of a thrust disc 118.
  • the thrust disc 118 is rotatably mounted upon a hollow spigot 116 of a thrust disc 118.
  • the variator' s output race 104 is mounted on a collar 111 which in turn is mounted upon the input shaft 112 though a bearing 120 . and rotates freely relative
  • this gear typically couples to an epicyclic gear train through which drive is taken to motor vehicle wheels.
  • gear trains are well known in the art and will not be described herein.
  • This particular variator has two rollers controlled by a simple mechanical
  • the mechanism comprises a lever 130 whose outer end 132 extends outside variator casing 134 to couple to a control mechanism. Variator ratio is determined by the position of this lever.
  • a flexible diaphragm 136 serves as a cover for an opening in the casing through which the lever emerges.
  • the lever is pivoted around a pin 136 mounted in a web 138 formed as part of the casing.
  • the lever is also able to move radially, for reasons which will shortly be explained.
  • the lever has laterally extending arms 142, 144 on either side of the pin 136 which carry respective carriages 146, 148 in
  • variator rollers 150, 152 are journalled through bearings 154, 156.
  • rollers are also able to turn as indicated by curved arrows in Figure 4b to change their inclinations to the variator axis, and thereby change variator drive ratio.
  • the rollers always seek an inclination at which then-
  • rollers 150, 152 are consequently subject to a steering effect by the races 100, 104, changing their inchnations to restore
  • rollers need some freedom to move relative to each other to equalise
  • This freedom is provided in the illustrated mechanism by virtue of the freedom of the lever 130 to move radially through a small distance.
  • the illustrated variator has three different devices for biasing the races 100, 104 toward each other to provide roller/race traction:
  • the ball ramp device 200 is formed by the thrust disc 118 and the input race 100. As Figures 5 and 7 show, the rear face of the input race 100 has a set of
  • the illustrated embodiment has four such
  • each recess can be thought of as being formed by two helical regions or ramps
  • the input shaft 112 is driven from some rotary power source, which is typically an internal combustion engine but could in principle be an electric motor, external combustion engine etc. If zero torque is applied to the input shaft 112, then the rotational position of the input race 100 relative to the thrust disc 118 is such that
  • the force is substantially proportional to the input torque. Note also that by virtue of the "V" section of the recesses, input torque in either rotational direction (clockwise or anti-clockwise) creates a force in the same axial direction (toward the output race 104).
  • a registration disc 211 is positioned between the thrust disc 118 and the input race 100, receiving the balls in respective through-going holes 213.
  • the end load spring 202 acts upon the input race 100 to urge it toward the output race 104. Its contribution to the end load is thus added to that of the ball ramp
  • end load spring 202 is mounted between the thrust disc 118 and the input race 100, serving to urge these two parts away from
  • the end load spring 202 acts upon the thrust disc through a thrust bearing 203.
  • the thrust disc 118 and the race 100 the end load spring 202 acts upon the thrust disc through a thrust bearing 203.
  • the end load spring 202 acts against a bearing 203.
  • the end load spring 202 is formed as a resilient metal disc, known to those skilled in the art as a Belleville washer and widely commercially available.
  • end load spring 202 tends to separate the parts making up the ball ramp device - the input disc 100 and thrust disc 118. In the absence of sufficient
  • the pre-load spring 204 prevents this. It acts upon the output race 104 to urge it toward the input disc 100. Hence the pre-load spring 204 acts in opposition to the ball ramp
  • the end load spring 202 and the pre-load spring 204 are referred to the shaft, which is thus in tension.
  • the force of the pre-load spring 204 is sufficient to overcome that of the end
  • Line L INP represents the end load component contributed by the ball ramp device 200.
  • Dotted line L ELS represents the end load component contributed by the end load spring 202.
  • the solid line L EL represents the actual end load. At low input torque the minimum end load value is determined by the pre-load spring at a value PLS.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Friction Gearing (AREA)

Abstract

The Invention is concerned with control of end load in a continuously variable ratio transmission device ('variator') of the type having part-toroidally recessed input and output races (100, 104) defining a toroidal cavity (108) containing rollers (150, 152) which run upon the races to transfer drive from one to the other, and whose inclination is variable to provide continuous variation in the relative speeds of the races. An end load is applied to urge the races into engagement with the rollers. This end load comprises (a) a first end load component which varies according to torque applied to the variator's input race (100) and (b) a second end load component which is substantially constant. This can be achieved using a constructionally simple arrangement but is nonetheless capable of providing good variator efficiency.

Description

DESCRIPTION CONTINUOUSLY VARIABLE RATIO
TRANSMISSION DRIVE
The present invention relates to continuously variable ratio transmission devices
("variators") of toroidal-race, rolling-traction type, and in particular to means for applying the "end load" needed to provide traction between rollers and races in such variators.
Variators are used in transmissions - particularly but not exclusively in
motor vehicle transmissions - to provide continuous variation of transmission drive ratio. In a toroidal-race, rolling-traction type variator a pair of co-axially mounted circular races have respective semi-toroidally recessed surfaces which together define a generally toroidal cavity, within which is mounted a plurality of rollers. The rollers are sandwiched between the races, running upon their recessed faces, and serve to
transmit drive from one to the other. By changing the rollers' inclination to the races'
common axis (which will be referred to as the "variator axis") the relative speeds of the two races - and hence the variator1 s drive ratio - can be altered in a stepless manner.
One might envisage controlling roller inclination directly by application of a
suitable turning moment to the roller bearings, but this turns out to be impractical.
Instead, the rollers are caused to steer themselves to suitably vary their inclinations.
One way to achieve this (although not the only way, it should be noted) is to mount the rollers such that they each have some limited freedom to move back and forth
along a circumferential path about the variator axis. Displacement along this path results in a steering moment upon the roller, changing its inclination, and in this way a relationship is created between (i) roller displacement and (ii) roller inclination.
Hence by moving the roller back and forth along its circumferential path, variator
drive ratio is adjusted.
Transfer of drive between rollers and races relies upon traction between them, and to provide this a force must be applied to bias these components toward each
other. This force will be referred to herein as the "end load". The rollers and races do not actually contact each other, being separated by a thin film of traction fluid which is maintained by continuously jetting the fluid onto these parts. Traction results from shear within the fluid layer, when subject to a suitably high pressure due to the end load. End load is typically provided by applying an axial force to one of
the races, urging it toward the other.
In what follows, reference will be made to torques applied to the variator races, which requires some clarification. External torques are of course applied to the variator input, through its coupling to the vehicle engine, and to the variator output,
through its coupling to the driven vehicle wheels. Each variator race is also subject
to an internal torque by the rollers. The net torque on both races due to the external and internal torques is small (or zero, at constant speed). However references herein to the torque applied to the race are to the externally applied torque.
The size of the end load has an important effect on variator performance and
longevity. Excessive end load reduces efficiency and causes premature wear, leading
eventually to variator failure. Inadequate end load can lead to excessive - and even catastrophic - slip between the rollers and the races. The end load required to prevent excessive slip varies with the torques exerted upon the races. In principle a constant end load can be used, but this must be large enough to sustain traction when the variator is subject to the maximum expected torques, so that under all other
conditions the end load is larger than is necessary. Improved efficiency and variator
lifetime can be achieved by adjusting the end load in sympathy with the torques handled by the variator.
A known way to achieve this is described in some detail in Torotrak
(Development) Ltd's published International Patent Application WO 02/079675 (Application No. PCT/GB02/01551). This describes a relatively sophisticated variator in which the rollers are hydraulically controlled. Each roller is coupled to
a respective hydraulic actuator. A common pressure (the "reaction pressure") is applied to each actuator, and determines a force (the "reaction force") applied to each
roller, urging it along the aforementioned circumferential path. At equilibrium, this force is balanced by an equal and opposite force applied to each roller by the action of the races. Put simply, the effect of the reaction pressure is to urge the rollers one way (clockwise or anti-clockwise) while the races urge the roller the" other way.
Consideration of the variator's geometry shows that the force exerted by the races on each roller is proportional to the sum of the torques acting on the two races (the
"reaction torque"). Hence, at equilibrium, reaction torque is proportional to reaction pressure. The end load is provided by means of a hydraulic actuator exerting an axial force on one of the races, and the fluid pressure supplied to this end load actuator is equal to, or at least controlled by, the reaction pressure, so that the end load is
proportional to the reaction torque. Ih fact WO 02/079675 also explains how this relationship could be adjusted to further refine end load control. However, proportionality of end load to reaction torque is, with some provisos, a highly
efficient mode of end load control since, for any given variator ratio, it provides a constant traction coefficient at the roller/race interface. The traction coefficient is defined as the ratio of (i) the force parallel to the interface to (ii) the force normal to
the interface. Note that (i) is proportional to the reaction force. The normal force,
item Qi), is proportional to end load although, since the direction of the normal to the interface varies with the roller inclination, it is also proportional to the cosine of the roller's angle to the variator axis.
End load adjustment must in some situations be carried out with little time lag. Externally created events, such as rapid vehicle braking, can abruptly create a requirement for an increase of end load, and failure to respond with sufficient speed could result in catastrophic slip within the variator. The known hydraulic system provides the required speed of response.
It is conventional to provide a "pre-load", which is a minimum end load
provided "even when the" tbfqϋe-dependerit component of the" end load is zero, either
because the torque on which it is based is very low, or because (particularly at startup) the device providing it is inactive. This is achieved using a spring 19 acting upon
one of the races to provide a pre-load force P (see Figure Ia). Note that the end load force F and the pre-load force P are applied in opposite directions and to different
races. Consequently the variation of the total axial load has the form represented in
Figure 2, in which the total axial load is on the vertical axis and the reaction torque is on the horizontal axis. The total load is proportional to torque, except that because of the pre-load spring the load does not fall to zero at very low torque, as indicated by the dotted line representing the end load contribution, but is instead sustained at
a minimum level PL by the pre-load spring. Outside this low torque area, the pre¬
load spring is overcome by the end load, and makes no contribution to the total axial load.
Some variators are not hydraulically controlled. The present invention has been devised in connection with a relatively simple variator in which roller displacement is instead controlled through a direct mechanical coupling. Hence
hydraulic end load control is not appropriate. In principle it would be possible to
control end load through some form of mechanical coupling which translates the reaction force applied to the roller's mountings into end load, but in reality this is not considered to be practical. Therefore some other way of suitably adjusting end load is required.
In the hydraulic system described above, end load is adjusted in dependence upon reaction torque. In principle, end load could instead be adjusted in dependence upon either input torque alone or output torque alone, and in fact it is known to vary end load in proportion to input torque. This is done in variators of the so-called "half toroidal" type but proves less appropriate in full toroidal variators. The difference
between half and full toroidal variators is illustrated in Figure 1. In the full toroidal variator 10 of Figure Ia, the races 12, 14 define an almost complete torus about the
variator axis 16 and the rollers lie along a diameter of the circle generating the torus.
The centres 17 of the rollers 18 lie upon, or close to, the centre of this circle, and the
effect of the end load force F is to keep the rollers in position, even while their inclinations change as indicated by curved arrows in the drawing, hi the half-toroidal
variator 20 of Figure Ib, the centres 27 of the rollers 28 are radially inwardly offset from the center 29 of the circle generating the torus. The effect of end load force F
is to urge the rollers radially outwardly, and to resist this each roller requires a thrust bearing 30. The races 22, 24 only define the radially inner part of the torus.
Consideration of the geometry and performance of half-toroidal variators
shows that an end load which is proportional to torque T at the variator input shaft 32 provides efficient performance. However the same manner of end load control proves less efficient when applied to full-toroidal type variators.
It is an object of the present invention to provide a simple but efficient means and method of controlling the end load.
In accordance with a first aspect of the present invention, there is a continuously variable ratio transmission device ("variator") comprising an input race operatively coupled to a variator input shaft and an output race operatively coupled to a variator output shaft, the input and output races being mounted for rotation about
a common axis, the" races having respective part-toroidally shaped surfaces which together define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with mountings which permit the roller's inclination to the common axis to vary, in order to vary the ratio of input shaft speed to output shaft
speed, and an end load arrangement for biasing the races into engagement with the
rollers to provide traction between them, the variator being characterised in that the end load arrangement comprises (a) a first end load device for applying a first end load component which varies in accordance with torque applied to the input race and (b) a second end load device for applying a second end load component which is
independent of input and output torques, the first and second end load devices acting upon the same variator race so that the total end load is the sum of the first and second end load components.
In accordance with a second aspect of the present invention there is a continuously variable ratio transmission device ("variator") comprising an input race
operatively coupled to a variator input shaft and an output race operatively coupled
to a variator output shaft, the input and output races being mounted for rotation about a common axis, the races having respective part-toroidally shaped surfaces which together define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the
other and being provided with mountings which permit the roller's inclination to the common axis to vary, in order to vary the ratio of input shaft speed to output shaft speed, and an end load arrangement for biasing the races into engagement with the rollers to provide traction between them, the variator being characterised in that the
end load arrangement comprises (a) a mechanical actuator which applies to one of the
variator races an axial force which varies according to the torque applied to the input
race and (b) a pre-stressed spring acting axially upon the same variator race.
In accordance with a third aspect of the present invention there is a method of controlling end load in a continuously variable ratio transmission device ("variator") comprising an input race operatively coupled to a variator input shaft and
an output race operatively coupled to a variator output shaft, the input and output races being mounted for rotation about a common axis, the races having respective
part-toroidally shaped surfaces which together define a substantially toroidal cavity
containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with mountings
which permit the roller's inclination to the common axis to vary, in order to vary the ratio of input shaft speed to output shaft speed, and an end load arrangement for
biasing the races into engagement with the rollers to provide traction between them,
the method comprising applying to the same variator race (a) a substantially constant end load component and (b) an end load component which varies with variator input torque.
Preferably the first end load component is substantially proportional to the absolute value of the torque applied to the input race. "Absolute value" is used here to refer to the magnitude of the torque, regardless of its sign (direction).
The second end load component is preferably substantially constant. It may
in particular be provided by means of a pre-stressed spring, and so may be subject to some degree of variation as the relevant parts move somewhat.
It is especially preferred that the first end load device forms a coupling which
serves both to transmit torque from the variator input shaft to the input race and to apply the first end load component, the coupling comprising first and second parts,
which are capable of relative rotational movement, at least one ramp surface which
extends along the circumferential direction and is inclined to a plane perpendicular to the common axis, and a force-transmitting part which contacts the ramp surface and is caused to move along it by said relative rotational movement, and so to apply between the first and second coupling parts an axial force which varies according to the torque applied to the input race.
The ramp surface could in principle be part of a screw thread. Preferably, however, the ramp acts upon a force-transmitting part in the form of a ball which
serves to urge the first and second coupling parts apart.
It is further preferred that the coupling comprises at least two ramp surfaces which are oppositely inclined to said plane perpendicular to the common axis, such that the axial force is applied in the same direction regardless of the direction of action of the torque applied to the input race.
Preferably the first and second coupling parts have respective ramp surfaces, the force-transmitting part being formed separately from both coupling parts and being retained between their respective ramp surfaces.
One of the coupling parts may be formed by the input race itself.
It is particularly preferred that the first and second end load devices are both anchored to the variator input shaft ,and the variator output race is mounted around and axially restrained relative to the input shaft, so that the end load force is borne in
tension by the variator input shaft. By arranging for the end load to be borne by the shaft, one dispenses with the need for thrust bearings to transmit the load to the variator casing.
Specific examples of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:-
Figures Ia and Ib are highly simplified sections, in an axial plane, through a full toroidal and a half toroidal variator respectively; Figure 2 is a graph of the variation of axial load in a known variator;
Figure 3 is a graph of traction coefficient against ratio for variators using different end load control strategies;
Figure 4a is a section in an axial plane through a variator embodying the present invention;
Figure 4b is a section in a radial plane through the same variator;
Figure 5 is a view along a radial direction of a ball ramp device used in the same variator;
Figure 6 is a perspective illustration of a thrust disc of the ball ramp device;
Figure 7 is a perspective view of the rear of a race used in the same variator;
Figure 8 is a perspective view of the front of the same race;
Figure 9 is a graph of end load against input torque for a variator embodying the present invention; and
Figure 10 is a perspective illustration of a registration disc used in the ball ramp device of Figures 4 and 5.
The present invention has been devised following an analysis of full-toroidal variator performance, and in this connection reference is directed to Figure 3, which represents variation of variator traction coefficient, on the vertical axis, with ratio, on the horizontal axis, for a full-toroidal type variator. The calculation has been based on the assumption that variator output torque is constant. This assumption is
particularly appropriate for low speed vehicles, where output torque need not be limited by the power available from the vehicle engine, and the maximum wheel
torque (which is the torque that would cause the vehicle wheels to spin) is available throughout the transmission's ratio range. Based upon this assumption, variator input torque can be calculated from the chosen constant output torque and the variator
ratio. In the resulting graph, line L0 represents the case of a constant end load, which
could for example be provided by a simple spring, and exhibits large (and undesirable) variation of traction coefficient with ratio. Recall that an inadequate end load (or equivalently an excessively high traction coefficient) can lead to excessive
slip between the variators and races. The constant end load would have to be chosen to avoid this even at the high traction coefficient end of the curve (at high negative ratios) and as a result the variator would be inefficient when working elsewhere on the curve, at lower ratios.
Line L1 represents the alternative strategy in which end load is proportional to variator" input torque. Ih this case traction coefficient is greatest at low negative variator ratios and the constant of proportionality of end load to input torque would
have to be chosen to avoid excessive slip at this end of the ratio range, but again the curve shows large traction coefficient variation with variator ratio.The result would necessarily be poor variator efficiency when running at higher ratios.
Line LR represents the strategy where end load is proportional to reaction
torque. The range of variation of traction coefficient with ratio is relatively small, and consequently the ratio of end load to reaction torque can be chosen to provide good variator efficiency throughout the ratio range. This is highly desirable and can be achieved, as already explained, in a hydraulically controlled variator.
Unfortunately, again as noted above, this strategy is difficult to achieve in less sophisticated variators using mechanical control. However, refer now to line LINV, which represents the variation of traction coefficient achieved using a strategy in accordance with the present invention. Note that it approximates to line LR, and shows a similarly small range of traction
coefficient variation. This is achieved using an end load which is the sum of (a) a
first component proportional to the variator input torque and b) a second, constant component.
The physical construction of a variator which implements this end load control strategy will now be described with reference to Figures 4 to 8
This is a low cost variator intended to handle moderate torques. It has been developed for use in a ride-on lawnmower. However the invention could be applied
to transmissions for other types of vehicle and for handling higher power. The variator has an input race 100 with a part toroidal face 102f and an output race 104
with a part toroidal face 106. Together the races define a substantially toroidal cavity 108 about a common axis 110, defined by an input shaft 112. The input race 100,
best seen in Figures 5, 7and 8 has a through-going bore 114 through which it is
rotatably mounted upon a hollow spigot 116 of a thrust disc 118. The thrust disc 118
is splined to input shaft 112 and is prevented from moving axially by a flange 113 upon the shaft.
The variator' s output race 104 is mounted on a collar 111 which in turn is mounted upon the input shaft 112 though a bearing 120 . and rotates freely relative
to the shaft. Power take-off from the output disc is through a gear 113 formed as part
of the collar 111. In a complete transmission this gear typically couples to an epicyclic gear train through which drive is taken to motor vehicle wheels. However such gear trains are well known in the art and will not be described herein.
This particular variator has two rollers controlled by a simple mechanical
lever mechanism, which will now be described for the sake of completeness.
However it is to be understood that other means of roller control can be adopted in
practice and the mechanism in question is presented by way of example and not limitation. The mechanism comprises a lever 130 whose outer end 132 extends outside variator casing 134 to couple to a control mechanism. Variator ratio is determined by the position of this lever. A flexible diaphragm 136 serves as a cover for an opening in the casing through which the lever emerges. The lever is pivoted around a pin 136 mounted in a web 138 formed as part of the casing. By virtue of a
slot 140 through which is engages with the pin, the lever is also able to move radially, for reasons which will shortly be explained. The lever has laterally extending arms 142, 144 on either side of the pin 136 which carry respective carriages 146, 148 in
which variator rollers 150, 152 are journalled through bearings 154, 156. The rollers
and their associated carriages are also able to turn as indicated by curved arrows in Figure 4b to change their inclinations to the variator axis, and thereby change variator drive ratio. As is well known,the rollers always seek an inclination at which then-
axes 158 intersect the variator axis 110. Moving the lever 132 moves the rollers circumferentially about the variator axis and transiently takes the roller axes away
from intersection with the variator axes. The rollers 150, 152 are consequently subject to a steering effect by the races 100, 104, changing their inchnations to restore
intersection of the aforementioned axes and producing a change in variator drive
ratio. As a result drive ratio is a function of lever position. A well known design issue with toroidal variators, known as "equalisation" is addressed by virtue of the slot 140.
To explain, the rollers need some freedom to move relative to each other to equalise
the ratios at which the rollers are running (to allow e.g. for minor manufacturing tolerances in the mechanism) and so equalise the load the rollers carry. This freedom is provided in the illustrated mechanism by virtue of the freedom of the lever 130 to move radially through a small distance.
The illustrated variator has three different devices for biasing the races 100, 104 toward each other to provide roller/race traction:
(1) a ball ramp device 200;
(2) an end load spring 202 and
(3) a pre-load spring 204. These will now be considered in turn.
The ball ramp device 200 is formed by the thrust disc 118 and the input race 100. As Figures 5 and 7 show, the rear face of the input race 100 has a set of
circumferentially extending recesses 206. The illustrated embodiment has four such
recesses. The front face of the thrust disc has a corresponding set of recesses 208, best seen in Figure 6. Viewed in a sectional plane containing the races' common axis (Figures 4a and 8) the recesses are part-circular, to receive respective balls 210. Viewed along the radial direction (Figure 5) they each have a shallow "V" form. Hence each recess can be thought of as being formed by two helical regions or ramps
212, 214 of opposite pitch.
The input shaft 112 is driven from some rotary power source, which is typically an internal combustion engine but could in principle be an electric motor, external combustion engine etc. If zero torque is applied to the input shaft 112, then the rotational position of the input race 100 relative to the thrust disc 118 is such that
the deepest regions 216, 218 of the respective recesses are aligned. The balls 210 lie
in these deepest regions and the separation of the input race from the thrust disc is minimised.
If a torque is then applied to the input shaft 112, this is directly transmitted to the thrust disc 118, but it is only transmitted to the input race 100 through the balls 210. The race 100 is caused to rotate through a small angle relative to the thrust disc
118. Because the deepest regions of the recesses are now mis-aligned, as in Figure 5, the ball 210 is forced away from these regions and rides up the ramp-like surfaces of the recesses, forcing the input race 100 away from the thrust disc 118. The thrust disc 118 cannot move because it is fixed upon the shaft 112. Hence the input race 100
is urged toward the output race 104, contributing to the end load. It will be apparent that the force applied by the ball ramp device 200 is related to the input torque. The
precise relationship depends on the shapes chosen for the recesses, but in the present embodiment, the force is substantially proportional to the input torque. Note also that by virtue of the "V" section of the recesses, input torque in either rotational direction (clockwise or anti-clockwise) creates a force in the same axial direction (toward the output race 104).
To keep the balls 210 properly located relative to each other, a registration disc 211 is positioned between the thrust disc 118 and the input race 100, receiving the balls in respective through-going holes 213.
The end load spring 202 acts upon the input race 100 to urge it toward the output race 104. Its contribution to the end load is thus added to that of the ball ramp
device 200. In the present embodiment the end load spring 202 is mounted between the thrust disc 118 and the input race 100, serving to urge these two parts away from
each other. To accommodate relative rotation of the thrust disc 118 and the input race 100, the end load spring 202 acts upon the thrust disc through a thrust bearing 203. To accommodate relative rotation of the thrust disc 118 and the race 100, the
end load spring acts against a bearing 203. The end load spring 202 is formed as a resilient metal disc, known to those skilled in the art as a Belleville washer and widely commercially available. The characteristic of force against axial length of
such a spring typically does not follow Hooke's law closely but instead has a region
where force is substantially constant despite changes of length, and the spring is arranged to operate in this region so that its force can be taken to be approximately constant.
Of course, the end load spring 202 tends to separate the parts making up the ball ramp device - the input disc 100 and thrust disc 118. In the absence of sufficient
input torque to cause the ball ramp device to overcome the end load spring, this could cause the balls 210 to be left loose, creating unwanted backlash in the device. The pre-load spring 204 prevents this. It acts upon the output race 104 to urge it toward the input disc 100. Hence the pre-load spring 204 acts in opposition to the ball ramp
device 200 and the end load spring 202. As Figure 4 shows, it is mounted upon the
collar 111, being retained between a shoulder 205 formed upon the sleeve and the rear face of the output race 104. Note that the forces from the ball ramp device 200,
the end load spring 202 and the pre-load spring 204 are referred to the shaft, which is thus in tension.
The force of the pre-load spring 204 is sufficient to overcome that of the end
load spring 202 acting on its own. Hence when input torque is zero, or has a sufficiently low value, the pre-load spring dominates, keeping the parts of the ball
ramp device 200 in engagement with each other. When sufficient input torque is applied to the variator, the total force exerted together by the ball ramp device and the end load spring 202 exceeds the force from the pre-load spring, and consequently the pre-load spring then contributes nothing to the end load.
The resultant end load/input torque characteristic is represented in Figure 9, where input torque is on the graph's horizontal axis and force on the vertical axis.
Line LINP represents the end load component contributed by the ball ramp device 200. Dotted line LELS represents the end load component contributed by the end load spring 202. The solid line LEL represents the actual end load. At low input torque the minimum end load value is determined by the pre-load spring at a value PLS. Away
from this range, end load increases monotonically with end load. Note however that this characteristic is not equivalent to that shown in Figure 2, since the end load outside the low input torque region is vertically offset by the force ELS contributed
by the end load spring. It is by virtue of this offset that the desirable traction coefficient/variator ratio characteristic already described with reference to Figure 3 is achieved.

Claims

1. A continuously variable ratio transmission device ("variator") comprising an input race operatively coupled to a variator Input shaft and an output race operatively coupled to a variator output shaft, the input and output races being mounted for rotation about
a common axis, the races having respective part-toroidally shaped
surfaces which together define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and
being provided with mountings which permit the roller's
inclination to the common axis to vary, in order to vary the ratio of
input shaft speed to output shaft speed, and an end load arrangement for biasing the races Into engagement with the rollers
to provide traction between them, the variator being characterised
in that the end load arrangement comprises (a) a first end load
device for applying a first end load component which varies In
accordance with torque applied to the input race and (b) a second
end load device for applying a second end load component which
is independent of input and output torques, the first and second end
load devices acting upon the same variator race so that the total
end load is the sum of the first and second end load components.
2. A variator as claimed in claim 1 in which the first end load
component is substantially proportional to the absolute value of the torque applied to the input race.
3. A variator as claimed in claim 1 or claim 2 in which the second end load component is substantially constant.
4. A variator as claimed in any preceding claim in which the rollers
are operatively coupled to a common movable member by means of which they are movable along circumferential paths about the common axis.
5. A variator as claimed in claim 4 in which the movable member is
a pivotably mounted lever.
6. A variator as claimed in claim 5 in which the lever is able to move radially with respect to the common axis.
7. A variator as claimed in any preceding claim in which the first end load device forms a coupling which serves both to transmit torque
from the variator input shaft to the input race and to apply the first
end load component, the coupling comprising first and second
parts, which are capable of relative rotational movement, at least
one ramp surface which extends along the circumferential direction
and is inclined to a plane perpendicular to the common axis, and
a force-transmitting part which contacts the ramp surface and is
caused to move along it by said relative rotational movement, and
so to apply between the first and second coupling parts an axial
force which varies according to the torque applied to the input
race.
8. A varlator as claimed in claim 7 wherein the force-transmitting part is a ball which urges the first and second coupling parts apart..
9. A variator as claimed in claim 7 or claim 8, wherein the coupling comprises at least two ramp surfaces which are oppositely inclined to said plane perpendicular to the common axis, such that the axial
force is applied in the same direction regardless of the direction of action of the torque applied to the input race.
10. A variator as claimed in any of claims 7 to 9, wherein the first and
second coupling parts have respective ramp surfaces, the force- transmitting part being formed separately from both coupling parts
and being retained between their respective ramp surfaces.
11. A variator as claimed in any of claims 7 to 10, wherein the input
race forms one of the first and second coupling parts.
12. A variator as claimed in any preceding claim wherein the second
end load device comprises a spring.
13. A variator as claimed in claim 12 wherein the spring comprises a
resilient conical plate.
14. A variator as claimed in claim 12 or claim 13 wherein the spring
is pre-stressed against the input race.
15. A variator as claimed in any preceding claim wherein the first and
second end load devices are both anchored to the variator input
shaft ,aiid the variator output race is mounted around and axially
restrained relative to the input shaft, so that the end load force is borne in tension by the variator input shaft.
16. A variator as claimed in any preceding claim, wherein the variator
is of full toroidal type.
17. A continuously variable ratio transmission device ("variator") comprising an input race operatively coupled to a variator input shaft and an output race operatively coupled to a variator output
shaft, the input and output races being mounted for rotation about
a common axis, the races having respective part-toroidally shaped
surfaces which together define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with mountings which permit the roller's
inclination to the common axis to vary, in order to vary the ratio of
input shaft speed to output shaft speed, and an end load
arrangement for biasing the races into engagement with the rollers to provide traction between them, the variator being characterised
in that the end load arrangement comprises (a) a mechanical
actuator which applies to one of the variator races an axial force
which varies according to the torque applied to the input race and
(b) a pre-stressed spring acting axially upon the same variator race,
18. A method of controlling end load in a continuously variable ratio
transmission device ("variator") comprising an input race
operative!], coupled to a variator input shaft and an output race operatively coupled to a varlator output shaft, the input and output races being mounted for rotation about a common axis, the races
having respective part-toroidally shaped surfaces which together
define a substantially toroidal cavity containing at least two rollers, each roller running upon the shaped surfaces of both races to transfer drive from one to the other and being provided with
mountings which permit the roller's inclination to the common axis to vary, in order to vary the ratio of input shaft speed to output
shaft speed, and an end load arrangement for biasing the races into engagement with the rollers to provide traction between them, the method comprising applying to the same variator race (a) a substantially constant end load component and (b) an end load
component which varies with variator input torque.
PCT/EP2006/068051 2005-11-02 2006-11-02 Continuously variable ratio transmission drive WO2007051827A1 (en)

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GB0522361.5 2005-11-02

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US8771133B2 (en) 2006-08-07 2014-07-08 Torotrak (Development) Limited Drive mechanism for infinitely variable transmission
US8986150B2 (en) 2012-09-07 2015-03-24 Dana Limited Ball type continuously variable transmission/infinitely variable transmission
WO2015130659A1 (en) * 2014-02-28 2015-09-03 Dana Automotive Systems Group, Llc Low loss lubrication system
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US9347532B2 (en) 2012-01-19 2016-05-24 Dana Limited Tilting ball variator continuously variable transmission torque vectoring device
US9541179B2 (en) 2012-02-15 2017-01-10 Dana Limited Transmission and driveline having a tilting ball variator continuously variable transmission
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US9599204B2 (en) 2012-09-07 2017-03-21 Dana Limited Ball type CVT with output coupled powerpaths
US9638296B2 (en) 2012-09-07 2017-05-02 Dana Limited Ball type CVT including a direct drive mode
US10088026B2 (en) 2012-09-07 2018-10-02 Dana Limited Ball type CVT with output coupled powerpaths
US10006527B2 (en) 2012-09-07 2018-06-26 Dana Limited Ball type continuously variable transmission/infinitely variable transmission
US9353842B2 (en) 2012-09-07 2016-05-31 Dana Limited Ball type CVT with powersplit paths
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US9416858B2 (en) 2012-09-07 2016-08-16 Dana Limited Ball type continuously variable transmission/infinitely variable transmission
US9052000B2 (en) 2012-09-07 2015-06-09 Dana Limited Ball type CVT/IVT including planetary gear sets
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US9556943B2 (en) 2012-09-07 2017-01-31 Dana Limited IVT based on a ball-type CVP including powersplit paths
US8986150B2 (en) 2012-09-07 2015-03-24 Dana Limited Ball type continuously variable transmission/infinitely variable transmission
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US9404414B2 (en) 2013-02-08 2016-08-02 Dana Limited Internal combustion engine coupled turbocharger with an infinitely variable transmission
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