WO2020122850A1

WO2020122850A1 - Hybrid reducer system

Info

Publication number: WO2020122850A1
Application number: PCT/TR2019/051064
Authority: WO
Inventors: Kemal YILDIZLI; Ahmed Elnour Mohammed MOZAMEL
Original assignee: Ondokuz Mayis Üni̇versi̇tesi̇ Rektörlük
Priority date: 2018-12-12
Filing date: 2019-12-11
Publication date: 2020-06-18
Also published as: TR201819248A2; DE112019006213T5

Abstract

The present invention relates to a hybrid reducer system providing auto-system protection against overloading and consisting of gear assembly combination different from each other. The present invention particularly relates to a hybrid reducer system combining planet gear and magnetic gear transmission systems and minimizing friction losses and planet gear system failure during overload.

Description

HYBRID REDUCER SYSTEM

Technical Field of the Invention

The present invention relates to a hybrid reducer system providing auto-system protection against overloading and consisting of gear assembly combination different from each other .

The present invention particularly relates to a hybrid reducer system combining planet gear and magnetic gear transmission systems and minimizing friction losses and planet gear system failure during overload.

State of the Art

Systems that change the revolution/torque ratio of the rotational movement by the help of gears are called reducers. Reducers consist of parts such as gears, wheels, shafts and bearings which are positioned in body in terms of structure. The reducers are especially used in electric motors and are connected to the motor output portion for the purpose of obtaining rotational movement at different speeds from drivers such as diesel engine and gasoline engine.

Reducers are utilized by taking factors such as cycle rate, efficiency, size and weight into account. The classification of the reducers is usually carried out according to the number of stages or to the utilized gear type. The most commonly used gear structures are worm reducers, worm screw reducers and planet gear reducers. Planet gears are useful for transmitting high speed ratios via medium-sized gears in a relatively smaller area. Gearboxes have applications in industry, civil and military vehicles, for instance they are commonly used in helicopters, wind turbines, track type loaders and milling machines. In industrial applications, and gearboxes can operate under constant working conditions or variable working conditions.

As a result of the preliminary search conducted in the state of the art, the patent document numbered "2018/05790" has been examined. In the abstract section of the aforementioned invention, it is disclosed that "wave generator in the harmonic drive is formed by giving the elliptical geometry of the externally rotating FDA motor to the driven part at the sizes to flex the flexible gear so that it can fit to the rigid gear 5 without any play. The elliptical part of the externally rotating FDA motor can flex the flexible gear and the flexible gear, rigid gear is mounted without any play, harmonic drive is mounted on the rigid holder and a harmonic drive reducer with wave-generated externally rotating brushless dc motor is obtained."

As a result of the preliminary search conducted in the state of the art, the patent document numbered "US3301091" has been examined. Said invention discloses a gear system which can solve the existing problems observed in gear systems. Gears and even new or improved type of gear means are in the focal point of said invention. The subject matter product is economical to produce, reliable and has a minimum maintenance and repair cost, as well as has silent and vibration-free operation in the desired configuration and at high gear ratio. The gear system produced provides the necessary power transmission for the desired torque value by easily performing the clutching even when working under heavy load. When the maximum torque is exceeded, the gear system is not subjected to any strain and wearing. Because in this case, it makes a freewheeling movement. In the gear system, the components work without contact and perform the power transmission. Since all forms of mechanical contact between driving and driven members has been eliminated, the necessity for precision machining and the resultant cost thereof have also been eliminated as well as wearing and noise.

As a result of the preliminary search conducted in the state of the art, the patent document numbered "US3382386" has been examined. Said invention discloses a magnetic gear system using driving and driven gear pairs. These components are housed in a box. It is disclosed that the magnetic resistance varies with the positions of the driving and driven gears in the operation. Thus, the coupling elements generate the coupling forces in relation with this magnetic resistance. The gear ratio is obtained by dividing the magnet number of the magnetic field in the driving gear by the ones in driven gear.

As a result of the preliminary search conducted in the state of the art, the patent document numbered "US20180163337 " has been examined. Said invention discloses a magnetic gear system for washing machine. The washing machine includes a cabinet at its outer portion, a drum into which laundry is placed in inner portion, and a power unit for rotating the drum. The power unit is used to generate the required magnetic field and flux to rotate the drum.

Mechanical gear systems are determined to be noisy and vibrating during operation as well as being expensive for power transmission after the discovery of the magnetic gear systems used in the state of the art. Moreover, the gears are subjected to wear. For that reason, mechanical gears need maintenance and require lubrication frequently. The first magnetic gear systems used, contained the magnetic gear system consisting of driving and driven gears and were externally protected by a box. There was also a certain distance between the magnetic gears. The invention shows the importance of using magnetic gears in engineering applications. For example, the magnetic gear system used for the washing machine is integrated into a cabinet which is for the external appearance of the washing machine, a drum in which the laundry is placed and the power transmission unit.

As a result, due to the above-mentioned problems and because of the inadequacy of the existing solutions, it became necessary to make an improvement in the technical field.

Objects of the Invention

The main object of the present invention is to provide a hybrid gearbox system in which the planet gear system and the concentric magnetic gear system are used together. Thus, contactless operation of magnetic gears provides advantages in terms of vibration, noise and maintenance costs compared to the mechanical gears .

Another object of the present invention is to minimize the failure of the planet gear system during overloading by means of the contactless transmission of the magnetic gear.

Another object of the present invention is to create a contactless transmission via magnetic rotors.

Another object of the present invention is to provide auto system protection against overload, thereby reducing the mechanical loss of the transmission system by eliminating the friction losses.

A further object of the present invention is to ensure that it may utilze magnetic spur gears for the generation of magnetic force by using the magnetic planet gear system and the integrated mechanical planet gear system together. By this means, as magnetic gears do not interlock with each other, vibration, noise and maintenance costs are reduced compared to the mechanical gears .

Another object of the present invention is that it provides both high torque densities and high efficiency by using concentric magnetic gear system. As a result, magnetic gear technology can be used in commercial applications.

Structural and characteristic features and all advantages of the present invention will be understood more clearly by means of following figures and detailed descriptions written by referencing to those figures. Therefore, respective assessment should be done by taking these figures and detailed description into consideration.

Description of the Figures

FIGURE 1 is the illustration showing the general view of the subject matter hybrid reducer system.

FIGURE 2 is the illustration showing the perspective view of the gearbox of the subject matter hybrid reducer system.

FIGURE 3 is the illustration showing the perspective view of the magnetic brake of the subject matter hybrid reducer system.

FIGURE 4 is the illustration showing the perspective view of the gears of the subject matter hybrid reducer system.

FIGURE 5 is the illustration showing the side view of the magnetic brake of the subject matter hybrid reducer system. FIGURE 6 is the illustration showing the perspective view of the external rotor of the magnetic brake of the subject matter hybrid reducer system.

FIGURE 7 is the illustration showing the perspective view of the internal rotor of the magnetic brake of the subject matter hybrid reducer system.

Reference Numerals

100. Hybrid Reducer System

101. Elastic Coupling

102. Input Shaft

103. Output Shaft

110. Electric Motor

111. Motor Holder

120. Hybrid Gearbox

121. Gearbox Holder

122. External Rotor

123. Ring Gear

124. Planet Gear

125. Sun Gear

126. External Rotor Magnet Pairs

127. Internal Rotor Magnet Pairs

128. Internal Rotor 129. Magnet Channel

130. Magnetic Brake System

131. Brake Box Holder

Description of the Invention

The subject matter hybrid reducer system (100) consists of a hybrid gearbox (120) and a magnetic brake system (130) connected to an electric motor (110) . The electric motor (110), hybrid gearbox (120) and magnetic brake system (130) are connected to each other by an input shaft (102), an output shaft (103), and an elastic coupling (101) .

The input power and rotational motion are generated by the electric motor (110) directly connected to the hybrid gearbox (120) and located on the motor holder (111) .

One side of the hybrid gearbox (120) comprises a ring gear (123), a planet gear (124) and a sun gear (125) as shown in

Figure 2 while other side of it comprises an internal rotor (128), located on an external rotor, and accommodating external rotor magnet pairs (126) and internal rotor magnet pairs (127) . Consequently, a hybrid system is achieved by using both gear and magnetic system together in an external rotor (122) . In the subject matter reducer system (100), in the first stage, planet gear (124) system and in the second stage, concentric magnetic gear system is used. The neodymium external rotor magnet pairs (126) and the internal rotor magnet pairs (127) transmit the power coming from the planet gear (124) system to the output shaft (103) in a contactless manner with a 2mm air gap via the magnetic gear system. The elastic coupling (101) is used to provide a smoother power transmission over the hybrid gearbox (120) and other components thereof. The input shaft (102) is used to transfer the speed and torque of the electric motor (110) to the hybrid gearbox (120), while the output shaft (103) connects the hybrid gearbox (120) to each other by the determined load. The alignment and levels of the input shaft (102) and the output shaft (103) are controlled by the motor holder (111), the gear holder (121) and the magnetic brake system holder (131) . Furthermore, the motor holder (111), the gearbox holder (121), and the magnetic brake system holder (131) are used in order that they absorb vibrations and maintain at a fixed level.

When the central sun gear (125) is rotated by the electric motor (110) at high speed, the speed is lowered by planet gears (124) and transmitted to the ring gear (123) . The ring gear (123) is rigidly connected from its rear side with the geared external rotor (122) of the magnetic gearwheel, and the entire system is secured by the gear component holders. A contactless magnetic force is generated by the external rotor magnet pairs (126) and the internal rotor magnet pairs (127) placed in the external rotor (122) and the internal rotor

(128), and the rotational movement from the external rotor

(122) to the internal rotor (128) is transmitted by being accelerated. The output shaft (103) is rigidly connected to the internal rotor (128) and transmits the power of the internal rotor (128) to the magnetic brake system (130) shown in Figure 1. The central sun gear (125) and the planet gears (124), a ring gear (123) and the planet gears (124) are in simultaneous contact. The sun gear (125) is located in the center and transmits its torque to the planet gears (124) rotating around the sun gear (125) . Planet gears (124) are able to transmit torque at higher speed ratios than medium sized gears in a relatively small area. The number of teeth and the angular velocity of each tooth are used in kinematic equations that allow them to perform their duties. These equations determine the distribution of dangerous contact points for accurate analysis of the reliability of a tooth and are used to obtain a random loading history for each gear.

The input shaft (102) is rigidly connected to the sun gear (125) in the center. The electric motor (110) transmits power to the sun gear (125) . It is transmitted from the sun gear (125) to the planet gears (124) and then to the ring gear (123) .

Figure 5 shows concentric magnetic gear system comprised of external rotor (122) . The external rotor (122) is rigidly connected to the ring gear (123) from its rear side, while the internal rotor (128) is rigidly connected to the output shaft (103) of the hybrid gearbox (120) . The internal rotor (128) transmits the power from the external rotor (122) to the output shaft (103) in a contactless manner via the external rotor magnet pairs (126) and the internal rotor magnet pairs (127) .Furthermore, magnet channels (129) which ensure that the external rotor magnet pairs (126) and the internal rotor magnet pairs (127) are placed around the inner surface and the outer surface of the internal rotor (128) and the external rotor ( 122 ) .

Figure 6 shows the array and assembly of neodymium fixed external rotor magnet pairs (126) around the inner surface of external rotor (122) . Figure 7 shows the array and assembly of neodymium fixed internal rotor magnet pairs (127) around the outer surface of internal rotor (128) connected by the output shaft (103) . All the components are concentric, and the system has an air gap. The external rotor magnet pairs (126) and the internal rotor magnet pairs (127) are positioned at equal intervals to the inner surface of the external rotor (122) and to the outer surface of the internal rotor (128) . When the external rotor (122) is started, the internal rotor (128) is rotated in the same direction as the external rotor (122) by the magnetic field the force in the air gap.

The speed ratio in the first stage of the planet gears (124) is 4:1 and the speed ratio in the second stage of the magnetic internal rotor (128) is 1:2. The output of the input shaft (102) and the output shaft (103) is a distance of 25 mm. The maximum power transmitted by the input shaft (102) is 200 W at 3000 rpm. The combined shock and fatigue factor are 1.5 in torsion and is 2 in bending. The permitted shear stress for the input shaft (102) and output shaft (103) material is 40 kN/mm2. The input shaft (102) and the output shaft (103) used are significant components and are designed such that they can resist bending and shear stresses. Although the input shaft (102) and the output shaft (103) are designed according to the criteria of strength, they are also properly supported on their sides. Thus, they are prevented from buckling or sudden unstable state. Due to the loads exerted, an internal shear force changing from point to point along the axis on the input shaft (102) and the output shaft (103), and moment occurred as result of this shearing force come into being.

The planet gear system (124) provides higher torque load due to load sharing between multiple gear pairs. Although having equal or smaller volume than conventional gear pairs, they produce a bigger transmission rate. All gears are made of steel, whereas the external rotor (122) and the internal rotor (128) are made of aluminum.

Claims

1. A hybrid reducer system (100) consisting of gear assembly combination different from each other characterized in that, it comprises; a gearbox holder (121) ensuring the alignment of an input shaft (102) and an output shaft (103) and determination of their levels; an external rotor (122) having a magnet channel (129) for positioning external rotor magnet pairs (126) which enables generating a magnetic force in a contactless manner at its one side, transmitting rotational movement to an internal rotor (128) by accelerating it, and having a ring gear (123) to which torque from an electric motor (110) is transmitted at its other side; the ring gear

(123) rigidly connected from its rear side with the geared external rotor (122) of magnetic gearwheel, and securing the entire system by gear component holders; planet gears (124) enabling the speed taken from a central sun gear (125) to be reduced and transmitted to the ring gear (123); the central sun gear (125), to which the input shaft (102), which transfers the speed and torque received from the electric motor (110) to the gears, is connected and which transmits this speed and torque from the electric motor (110) to the planet gears

(124); a hybrid gearbox (120) which comprises the internal rotor (128) having a magnet channel (129) for positioning internal rotor magnet pairs (127), which enables generating a magnetic force in a contactless manner, and connected with the output shaft (103) rigidly, and transmitting the power it received to a magnetic brake system (130); and which ensures that a hybrid system using both gear and magnetic system together is achieved.

2. Hybrid reducer system (100) according to Claim 1, characterized in that, it further comprises an elastic coupling (101) used to provide a smoother power transmission over the hybrid gearbox (120) . 3. Hybrid reducer system (100) according to Claim 1, characterized in that, it further comprises a gearbox holder (121) making vibrations to be absorbed and kept at a fixed level.

4. Hybrid reducer system (100) according to Claim 1, characterized in that, it further comprises a hybrid gearbox (120) which ensures that the central sun gear (125) and the planet gears (124), a ring gear (123) and the planet gears (124) are in simultaneous contact.

5. Hybrid reducer system (100) according to Claim 1, characterized in that, it further comprises an electric motor (110) in which input power and rotation movement is generated and which is connected to the hybrid gearbox (120) via the input shaft (102), the hybrid gearbox (120), and the magnetic brake system (130) connected with the hybrid gearbox (120) via the output shaft (103) .