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Roller Gearing and Power Transmission Mechanism

Roller Gearing and Power Transmission Mechanism. P á l Bog á r Sincroll Drive Technologies. 1. 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

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Roller Gearing and Power Transmission Mechanism

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  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. 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 The Innovative Idea 3

  4. 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 Realisation of the Idea 4

  5. Complex physics G: the roller (ball) P1, P2: contact points between the balls and the wheels gp: path travelled by the ball’s 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 Realisation of the Idea - continued 5

  6. non-intersecting axes axes angle = 90o gearing ratio = 1:1 ball diameter = 4mm contact factor = 8 6

  7. intersecting axes axes angle = 90o gearing ratio = 11:15 ball diameter = 4mm contact factor = 9 7

  8. parallel axes axes angle = 0o gearing ratio = 12:23 ball diameter = 4mm contact factor = 8 8

  9. parallel axes direction of rotation = same gearing ratio = 1:5 ball diameter = 4mm contact factor = 9 9

  10. parallel axes direction of rotation = opposite gearing ratio = 23:25 ball diameter = 4mm contact factor = 19 10

  11. non-intersecting axes axes angle = 45o gearing ratio = 1:2 ball diameter = 4mm contact factor = 8 11

  12. non-intersecting axes axes angle = 45o gearing ratio = 1:2 ball diameter = 4mm contact factor = 8 12

  13. non-intersecting axes axes angle = 50o gearing ratio = 13:25 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 = 1:2 ball diameter = 5mm contact factor = 7 16

  17. micro-rollers non-intersecting axes axes angle = 45o gearing ratio = 1:5 ball diameter = 0mm contact factor = 8 17

  18. worm gear axes angle = 90o gearing ratio = 1:50 ball diameter = 4mm contact factor = n/a 18

  19. planetary gear system axes angle = collinear gearing ratio = 1:300 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. 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 Implied Advantages • 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. 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 R&D 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 Other Selected Features 22

  23. 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 Other Selected Features - continued 23

  24. Prototype tested was 1:10 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 Prototype Tests 24

  25. non-intersecting axes T E S T P R O T O T Y P E axes angle = 45o gearing ratio = 1:10 ball diameter = 4mm contact factor = 19 25

  26. non-intersecting axes axes angle = 45o gearing ratio = 1:10 ball diameter = 4mm contact factor = 19 26

  27. non-intersecting axes axes angle = 45o gearing ratio = 1:10 ball diameter = 4mm contact factor = 19 27

  28. non-intersecting axes axes angle = 45o gearing ratio = 1:10 ball diameter = 4mm contact factor = 19 28

  29. non-intersecting axes axes angle = 45o gearing ratio = 1:10 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 = 26:23 ball diameter = 4mm contact factor = 8 34

  35. parallel axes axes angle = 0o gearing ratio = 26:23 ball diameter = 4mm contact factor = 8 35

  36. 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 Potential Applications 36

  37. 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. Applicable Industries 37

  38. 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. Applicable Industries- continued 38

  39. 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. Applicable Industries- continued 39

  40. 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 The Sincroll Company 40

  41. 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 R&D, theoretical and experimental work all the way up to prototype and equipment manufacture and pilot and small scale production The Sincroll Company - continued 41

  42. Looking for a partner is a new idea we came to the market four months ago only Following about five years of intensive R&D 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 Potential for Collaboration 42

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

  44. THANK YOU 44

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