Note: Descriptions are shown in the official language in which they were submitted.
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SIMPLIFIED GEARBOX MECHANISM
BACKGROUND OF THE INVENTION
Technical Field of the Invention
The present invention relates to a universal gearbox mechanism featuring cam-
actuated gear block assemblies that periodically engage the output gear
causing power
transfer. It has particular, but not exclusive, application for use in
servomotor
assemblies.
Description of the Related Art
Conventional machines typically consist of a power source and a power
transmission system, which provides controlled application of the power. A
variety of
proposals have previously been made in the art of power transmission systems.
The
simplest transmissions, often called gearboxes to reflect their simplicity
(although
complex systems are also called gearboxes in the vernacular), provide gear
reduction (or,
more rarely, an increase in speed), sometimes in conjunction with a change in
direction of
the powered shaft. A transmission system may be defined as an assembly of
parts
including a speed-changing gear mechanism and an output shaft by which power
is
transmitted from the power source (e.g., electric motor) to an output shaft.
Often
transmission refers simply to the gearbox that uses gears and gear trains to
provide speed
and torque conversions from a power source to another device.
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Gearboxes have been used for many years and they have many different
applications In general, conventional gearboxes comprise four main elements:
power
source; drive train; housing and output means. The power source places force
and
motion into the drive train. The power source may be a motor connected to the
drive
train through suitable gearing, such as a spur, bevel, helical or worm gear.
The drive train enables the manipulation of output motion and force with
respect
to the input motion and force provided by the power source. The drive train
typically
comprises a plurality of gears of varying parameters such as different sizes,
number of
teeth, tooth type and usage, for example spur gears, helical gears, worm gears
and/or
internal or externally toothed gears.
The gearbox housing is the means which retains the internal workings of the
gearbox in the correct manner. For example it allows the power source, drive
train and
output means to be held in the correct relationship for the desired operation
of the
gearbox. The output means is associated with the drive train and allows the
force and
motion from the drive train to be applied for an application. Usually, the
output means
exits the gearbox housing.
The output means typically can be connected to a body whereby the resultant
output motion and force from the drive train is transmitted via the output
means (e.g., an
output shaft) to the body to impart the output mean's motion and force upon
the body.
Alternatively, the output means can impart the motion and force output from
the drive
train to the gearbox housing whereby the output means is held sufficiently as
to allow the
gearbox housing to rotate.
Rotating power sources typically operate at higher rotational speeds than the
devices that will use that power. Consequently, gearboxes not only transmit
power but
also convert speed into torque. The torque ratio of a gear train, also known
as its
mechanical advantage, is determined by the gear ratio. The energy generated
from any
power source has to go through the internal components of the gearbox in the
form of
stresses or mechanical pressure on the gear elements. Therefore, a critical
aspect in any
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gearbox design comprises engineering the proper contact between the
intermeshing gear
elements These contacts are typically points or lines on the gear teeth where
the force
concentrates. Because the area of contact points or lines in conventional gear
trains is
typically very low and the amount of power transmitted is considerable, the
resultant
stress along the points or lines of contact is in all cases very high. For
this reason,
designers of gearbox devices typically concentrate a substantial portion of
their
engineering efforts in creating as large a line of contact as possible or
create as many
simultaneous points of contacts between the two intermeshed gears in order to
reduce the
resultant stress experienced by the respective teeth of each gear.
Another important consideration in gearbox design is minimizing the amount of
backlash between intermeshing gears. Backlash is the striking back of
connected wheels
in a piece of mechanism when pressure is applied. In the context of gears,
backlash
(sometimes called lash or play) is clearance between mating components, or the
amount
of lost motion due to clearance or slackness when movement is reversed and
contact is
re-established. For example, in a pair of gears backlash is the amount of
clearance
between mated gear teeth.
Theoretically, backlash should be zero, but in actual practice some backlash
is
typically allowed to prevent jamming. It is unavoidable for nearly all
reversing
mechanical couplings, although its effects can be negated. Depending on the
application
it may or may not be desirable. Typical reasons for requiring backlash include
allowing
for lubrication, manufacturing errors, deflection under load and thermal
expansion.
Nonetheless, low backlash or even zero backlash is required in many
applications to
increase precision and to avoid shocks or vibrations. Consequently, zero
backlash gear
train devices are in many cases expensive, short lived and relatively heavy.
Weight and size are yet another consideration in the design of gearboxes. The
concentration of the aforementioned stresses on points or lines of contact in
the
intermeshed gear trains necessitates the selection of materials that are able
to resist those
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forces and stresses. However, those materials are oftentimes relatively heavy,
hard and
difficult to manufacture.
Thus, a need exists for an improved and more lightweight gearbox mechanism,
which is capable of handling high stress loads in points or lines of contact
between its
intermeshed gears. Further, a need exists for an improved and more lightweight
gearbox
mechanism having low or zero backlash that is less expensive to manufacture
and more
reliable and durable.
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SUMMARY OF THE INVENTION
The present invention overcomes many of the disadvantages of prior art gearbox
mechanisms by utilizing a plurality of cam-actuated gear block assemblies to
transfer
power from a power shaft to a secondary or output gear element. In a first
embodiment,
each gear block assembly includes a gear block having a surface that
periodically
interfaces with a secondary or output gear element. In a preferred embodiment
the
interface surface comprises a plurality of projections or teeth which
correspond to
complementary projections or gear teeth on the output gear element Each gear
block
assembly further includes a plurality of linkage assemblies, which connect or
link the
gear block to a cam assembly, which in turn is connected to a power source.
The cam
assembly includes about its circumference a unique pathway or groove for each
linkage
assembly of a particular gear block assembly so that the movement of the gear
block may
be controlled in two dimensions in accordance with a certain design parameter.
Each linkage assembly comprises a linkage mechanism, which at its proximal end
is pivotally attached end to its respective gear block and at its distal end
maintains contact
with its respective pathway or groove formed in the cam assembly. In a
preferred
embodiment, each linkage mechanism includes two pivotally coupled connector
arms.
An upper connector arm includes a first pivot point that is pivotally coupled
to its
respective gear block element and a second pivot point pivotally coupled to a
lower
connector arm. The lower connector arm includes a cam follower element at its
distal
end that maintains contact with its respective pathway or groove formed in the
cam
assembly. The lower connector arm further includes a pivot point having a
fixed axis of
rotation relative to the central axis of rotation of the cam assembly.
In a preferred embodiment, each gear block assembly includes three linkage
assemblies pivotally coupled to the gear block and in constant contact with
the cam
assembly. The gear block includes pivot bars configured on opposing ends that
serve to
pivotally couple the linkage assemblies to the gear block. Two linkage
assemblies are
coupled to a pivot bar on one end while a single linkage assembly is coupled
to the pivot
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bar on the opposing end. Each of the linkage assemblies includes a pivot point
that is
rotatively coupled to a fixed axis of rotation relative to the central axis of
rotation of the
cam assembly. In one embodiment, this fixed pivot point comprises a pivot bar
fixably
contained between two stationary plates. Each of the linkage assemblies is
biased so that
its respective cam follower element maintains contact with the surface of its
respective
pathway or groove formed in the cam assembly throughout the rotation cycle of
the cam
assembly.
The gear block assembly is designed to drive its respective gear block through
a
two-dimensional circuit in response to rotation of the cam assembly. Broadly
speaking,
the two-dimensional circuit includes urging the gear block to engage a
secondary or
output gear element and move or rotate a specified quantum distance prior to
disengaging
from the output gear element, and returning back the specified quantum
distance to again
reengage the secondary or output gear element once again and repeat the
process. The
travel path or circuit of each gear block is controlled by adjusting the
length and
configuration of the various linkage assemblies and altering the pathways or
grooves
formed in the cam assembly.
When adapted to a gearbox mechanism a plurality of gear block assemblies are
configured about a central axis of the cam assembly. The cam assembly is
rotatively
coupled with a power source. As the cam assembly rotates, the cam follower
elements of
the respective linkage assemblies of each gear block assembly maintain contact
with a
particular pathway or groove formed in the circumferential surface of the cam
assembly.
The variance of distance from the center of rotation of the different pathways
or grooves
of the cam assembly causes the respective linkage assemblies to work in
concert to move
their respective gear block through a predetermined circuit of movement. This
predetermined circuit of movement of the gear block can be precisely
calibrated to meet
specific engineering requirements. For example, the torque ratio and speed
reduction
may be regulated and controlled by adjusting the circuit of movement of each
gear block
assembly.
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A second embodiment of a gearbox mechanism of the present invention may
include a main body, an output element, and a plurality of simplified gear
block
assemblies. Additionally, the gearbox mechanism may have a retainer that
interfaces
with the main body and the output element. Each simplified gear block assembly
includes a gear block, a torque lever, cam follower(s), and/or socket (or a
portion of a
socket). The cam actuated gear block assemblies are configured about a central
axis.
The rotational force on the cam element allows for a driving or rotative force
on the cam
actuated gear block assemblies.
In a preferred embodiment, the torque lever also has a set of cam followers
allowing for the following of a specified path formed along a planer surface
of the cam
element. The cam element includes at least one unique pathway or groove that
interfaces
with the cam follower of gear block or torque lever so that as the cam element
rotates, the
movement of the gear block or torque lever is controlled in two dimensions in
accordance
with at least one certain design parameter.
By varying the radius of the pathway or grooves on the cam element, the cam
actuated gear block assemblies drive respective gear block(s) through a two-
dimensional
circuit in response to rotation of the cam element. Broadly speaking, the two-
dimensional circuit includes urging the gear block to engage the output
element and
move and/or rotate the output element a specified distance prior to
disengaging from the
output element, and returning back the specified distance to again reengage
the output
element once again, and repeat the process. The travel path or circuit of each
gear block
is controlled by adjusting the length, width, height, and/or size of the
respective gear
block and/or torque lever and/or altering the pathways or grooves formed in
the cam
element. In a preferred embodiment, there is at least one pivot point for both
the gear
block and the torque lever that allows each to pivot separately from each
other.
A third embodiment of the gearbox mechanism of the present invention may
include a cam element, a main body and output element and a plurality of
simplified gear
block assemblies. In at least one example, the output element is retained
within the main
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body by a retainer. The gear block assemblies are placed within the main body
and
interface with the output element and cam element. The gear block assemblies
can
include a torque lever, a gear block, a first cam follower, and a second cam
follower. The
cam followers follow pathways in the cam element to generate forces on the
torque lever,
and/or the gear block(s) generating a pivoting motion for the both the torque
lever and the
gear block(s). In at least one version, the pivoting motion can be generally
square pivot
path for the gear block(s). While in other versions, the pivot path of the
gear block(s)
will generally be oval or circular.
In at least one version, a central aperture aligned with a central axis may be
a part
of the gearbox mechanism. Each gear block assembly includes a gear block, a
torque
lever, and at least one cam follower, which connect the gear block to the
planer surface of
the cam element. The torque lever, and/or gear block can interact to be
pivotally
attached, and correspond to the interaction and/or engagement of the cam
follower(s)
with the cam element. The rotation of the output element may also be
controlled through
a reverse or tension engagement (i.e., negative bias) of gear block(s) that
are not in a
driving or positive bias rotational engagement in order to reduce and/or
element backlash.
In at least one version, the main body provides a housing for the gear
assemblies.
The gear block assemblies rest and/or are supported by the main body retaining
surface.
The gear block(s) may also be retained and/or supported by the main body gear
block
interface surface. The torque lever(s) may also be supported and/or retained
by the main
body torque lever interface surface, and/or the main body torque lever void as
defined by
the main body. The pivoting motion of the torque lever can also coincide with
a pivoting
motion of the gear block that allows for the interfacing, engaging, and/or
rotating of an
output element.
Numerous embodiments of gearbox mechanisms are possible using the gear block
assembly of the present invention. The plurality of gear block assemblies
configured
about the central axis of the cam assembly can comprise either an odd or even
number of
gear block assemblies. At least two, and preferably three gear block
assemblies are
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required for a gearbox mechanism of the present invention. The movement of the
gear
block assemblies typically move in a rotational series to one another. At
least one gear
block assembly is always engaged with the output gear element at any
particular instance
in time. Preferably, only one gear block assembly is disengaged with the
output gear
element at any particular instance in time. However, in another preferred
embodiment
wherein the plurality of gear block assemblies comprises four or more even-
numbered
gear block assemblies, the gear block assemblies configured on opposing sides
of the cam
assembly engage and disengage in unison from the secondary or output gear
element.
The design of the gear block assemblies of the present invention enable a
greater
number of gear teeth to engage the output gear at any given time, thereby
spreading the
stresses associated therein across a greater area. By dramatically increasing
the contact
area between the gear block and the output gear at any given time the
mechanical stress
level is significantly decreased. in addition, the gear block assemblies of
the present
invention reduce backlash to zero and even preloaded conditions to create a
tight
connection between the power source and the powered device. This is an
extremely
desirable feature especially for high vibration applications. By reducing
backlash to zero
or preloaded condition, the mechanical impedance may also be reduced at a
broad range
of high vibration frequencies. Moreover, because the stresses associated with
engagement of the gear block against the output gear are distributed across a
greater area,
the gear block mechanism may be manufactured of lighter weight, more flexible
materials, which are less expensive and easier to manufacture, with no
degradation in
reliability. Indeed, using flexible materials further reduces the mechanical
impedance at
low frequencies. By reducing its weight and size, the gearbox mechanism of the
present
invention is adaptable to a broad range of applications that were previously
impractical
because of weight and space limitations.
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BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the method and apparatus of the present
invention may be had by reference to the following detailed description when
taken in
conjunction with the accompanying drawings, wherein:
FIG. 1A is a perspective view of a first embodiment of the gearbox mechanism
of
the present invention attached to a power source;
FIG. 1B is a side elevation view thereof;
FIG. 2 is an exploded perspective view thereof;
FIG. 3 is an end view thereof with the outer stationary plate removed;
FIG. 4A is a close-up side elevation view of a gear block assembly shown in
FIG.
3A;
FIG. 4B is a perspective view of a gear block assembly shown in FIG. 3A;
FIG. 4C is an exploded perspective view thereof
FIG. 4D is close-up cross-sectional view of a gear block assembly shown in
FIG.
4A engaged with an output gear.
FIG. 5 is a perspective view of the embodiment of the gearbox mechanism shown
in FIG. 3A;
FIG. 6 is a close-up perspective view of a gear block assembly shown in FIG.
5,
FIGS. 7A-7C are end views with the outer stationary' plate removed of
different
variant embodiments of the gearbox mechanism of the present invention shown in
Fig. 1;
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FIG. 8 is an exploded view of a second embodiment of a gearbox mechanism of
the present invention;
FIG. 9A is a perspective view of a cam element along with the torque lever,
socket, and gear block of the gearbox mechanism shown in Fig 8;
FIG. 9B is a partial-cutaway, perspective view of a cam element, torque lever,
and cam followers of the gearbox mechanism shown in Fig 8;
FIG. 10A is a close-up side view of a gear block and the output element of the
gearbox mechanism shown in Fig 8;
FIG. 10B is a close-up side view of a gear block and the output element of the
gearbox mechanism shown in Fig 8;
FIG. IOC is a side view of a gear block and the output element of the gearbox
mechanism shown in Fig 8;
FIG. 11 is an exploded view of a third embodiment of a gearbox mechanism of
the present invention;
FIG. 12A is an exploded view of a main body, output element and retainer of
the
gearbox mechanism shown in Fig. 11.
FIG. 12B is a perspective view of a main body of the gearbox mechanism shown
in Fig. 11.
FIG. 12C is an exploded perspective view of a main body, and gear block
assemblies of the gearbox mechanism shown in Fig. 11.
FIG. 13 is a perspective view of a cam element of the gearbox mechanism shown
in Fig. 11; and
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FIG. 14 is a perspective view of the gear block assemblies of the gearbox
mechanism shown in Fig H.
Where used in the various figures of the drawing, the same numerals designate
the
same or similar parts. Furthermore, when the terms "top," "bottom," "first,"
"second,"
"upper," "lower," "height," "width," "length," "end," "side," "horizontal,"
"vertical," and
similar terms are used herein, it should be understood that these terms have
reference
only to the structure shown in the drawing and are utilized only to facilitate
describing
the invention
All figures are drawn for ease of explanation of the basic teachings of the
present
invention only; the extensions of the figures with respect to number,
position,
relationship, and dimensions of the parts to form the preferred embodiment
will be
explained or will be within the skill of the art after the following teachings
of the present
invention have been read and understood. Further, the exact dimensions and
dimensional
proportions to conform to specific force, weight, strength, and similar
requirements will
likewise be within the skill of the art after the following teachings of the
present
invention have been read and understood.
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DETAILED DESCRIPTION OF THE INVENTION
With reference to the Figures, and in particular Figs. 1A, 1B and 2, an
embodiment of a machine 10 utilizing the gearbox mechanism 20 of the present
invention is depicted. The machine 10 includes a power source or actuator 2,
which
includes an output device 4 that transmits the power generated by the power
source 2.
While the embodiment shown in the Figure generally depicts the power source 2
as an
electric motor and the output device 4 as an output shaft of the electric
motor, it is
understood that there are numerous possible embodiments. For example, output
device 4
need not be directly connected to the power source 2 but may be rotatively
coupled by
means of gears, chains, belts or magnetic fields. Likewise, the power source 2
may
comprise an electric motor, an internal combustion engine, or any conventional
power
source that can be adapted to generate rotative power in an output device 4.
Moreover,
the power source 2 may also comprise the output gear of a preceding gear train
mechanism.
The output device 4 comprises a central shaft that connected to the gearbox
mechanism 20 through a central aperture 32 in the cam assembly 30 of the
gearbox
mechanism 20. The gearbox mechanism 20 is configured about the central axis 6
of the
central shaft of the output device and comprises two stationary plates 40
between which
are configured an output or power gear 50, a cam assembly 30 and a plurality
of cam-
actuated gear block assemblies 60, which transfer power from the cam assembly
30 to an
output or power gear element 50. Two bearing assemblies 22 isolate the cam
assembly
from the stationary plates 40 so that the cam assembly 30 can rotate freely
between
the two stationary plates 40. Likewise, spacer elements 46 configured between
the two
stationary plates 40 ensure that movement of the power gear element 50 is not
impeded
25 by the
stationary plates 40. The gear block assemblies 60 are evenly spaced about the
circumference of the cam assembly 30. Each gear block assembly 60 includes a
gear
block 62 and a plurality of linkage assemblies, which connect the gear block
62 to the
outer circumferential surface of the cam assembly 30. Each linkage assembly
comprises
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a linkage mechanism, which at its proximal end is pivotally attached to its
respective gear
block 62 and at its distal end includes a cam follower element, which
maintains contact
with its respective pathway or groove formed in the circumferential surface 34
of the cam
assembly 30. Each linkage assembly includes a fixed axis pivot point that is
connected to
the two stationary plates 40. While each linkage assembly can pivot about its
respective
fixed axis pivot point 48 the alignment and configuration of the pivot point
remains fixed
in relation to the two stationary plates 40.
As shown in the embodiment depicted in the Figures, the plurality of cam-
actuated gear block assemblies 60 transfer power from the power shaft 4 to an
annular
secondary or output gear element 50. In a preferred embodiment, each gear
block
assembly 60 includes a gear block 62 having an interface surface 63 (e.g., a
plurality of
projections or teeth 66) which correspond to a complementary interface surface
54 (e.g.,
projections or gear teeth) configured on an inner circumferential surface 53
of the annular
secondary or output gear element 50. It is understood that the interface
between the gear
block 62 and the inner circumferential surface 53 of the output gear element
50 of the
present invention comprises not only the preferred gear teeth as depicted, but
also any
complementary arrangement such as pins and holes or even friction fit
surfaces.
While the annular output or power gear element 50 is depicted as two circular
rings held apart by spacer elements 55, it is understood that the output or
power gear
element 50 may comprise a single circular ring. The output or power gear
element 50
includes apertures or holes 58 for attaching to an output shaft or power
takeoff (not
shown). In addition, it is understood that the outer circumference 51 of the
output or
power gear element 50 may also comprise a surface to interface with some other
gear
train mechanism.
In addition, it is understood that the gear block 62 may include a
divider/alignment block 68 dividing the interface surface 63 into two separate
sections.
The variant of the gear block 62 featuring the alignment block 68 is
particularly suitable
to embodiments which feature output or power gear elements 50 comprised of two
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circular rings.
The gear blocks 62 of the present invention are specifically designed to
enable a
greater surface area (e.g., greater number of gear teeth) to engage the output
gear 50 at
any given time, thereby spreading the stresses associated therein across a
greater area.
By dramatically increasing the contact area between the gear block 62 and the
output
gear 50 at any given time the mechanical stress level is significantly
decreased. In
addition, the gear block 62 assemblies of the present invention reduce
backlash to zero
and even preloaded conditions to create a tight connection between the power
source 2
and the powered device. This is an extremely desirable feature especially for
high
vibration applications. Moreover, because the stresses associated with
engagement of the
gear block 62 against the output gear 50 are distributed across a grater area,
the gear
block 62 may be manufactured of lighter weight materials, which are typically
less
expensive and easier to manufacture, with no degradation in reliability. For
example, per
Hertz Contact Theory a typical stress result for spur gears are in the range
from 450MPa
to 600MPa. High grade steels are the best fitted materials for handling such
high stress
levels. Other materials like low grade steel or aluminum will deform under the
similar
conditions. However, by distributing the stresses across a large areas of
contact in
accordance with the gearbox mechanism of the present invention, the levels of
stress
under the similar conditions can be reduced to about 20MPa. These low stress
levels
allow the gearbox mechanism of the present invention to be manufactured using
low
grade steels, aluminums or even plastics for the same application. By reducing
its weight
and size, the gearbox mechanism of the present invention is adaptable to a
broad range of
applications that were previously impractical because of weight and space
limitations.
The cam assembly 30 is coupled to the power source 2 by means of the output
device or power shaft 4. Thus, power generated by the power source 2 is
transferred to
the power shaft 4, which causes the cam assembly 30 to rotate about the
central axis 6.
The cam assembly 30 includes about its circumferential surface 34 a plurality
of unique
pathways or grooves which each interface with the cam follower element of a
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linkage assembly of each gear block assembly 60 so that as the cam assembly 30
rotates,
the movement of the gear block 62 is controlled in two dimensions in
accordance with a
certain design parameter. By varying the radius of the pathway or grooves on
the cam
assembly 30 the linkage assemblies of the gear block assembly 60 drive
respective gear
block 62 through a two-dimensional circuit in response to rotation of the cam
assembly
30. Broadly speaking, the two-dimensional circuit includes urging the gear
block to
engage the output gear element 50 and move or rotate the output gear element
50 a
specified quantum distance prior to disengaging from the output gear element
50, and
returning back the specified quantum distance to again reengage the output
gear element
50 once again and repeat the process. The travel path or circuit of each gear
block 62 is
controlled by adjusting the length and configuration of the various linkage
assemblies and
altering the pathways or grooves formed in the cam assembly 30.
in a preferred embodiment, each linkage mechanism includes two pivotally
coupled connector arms. An upper connector arm includes a first pivot point
that is
pivotally coupled to its respective gear block 62 and a second pivot point
pivotally
coupled to a lower connector arm. The lower connector arm includes a cam
follower
element at its distal end that maintains contact with its respective pathway
or groove
formed in the cam assembly 30. The lower connector arm further includes a
pivot point
having a fixed axis of rotation relative to the central axis 6 of rotation of
the cam
assembly 30.
With reference now to Figs. 4A-4D, a preferred embodiment of the gear block
assembly 60 is shown. In the depicted preferred embodiment, each gear block
assembly
60 includes three linkage assemblies 70, 80, 90, which are each pivotally
coupled to the
gear block 62 and include a cam follower element 74, 84, 94, respectively,
which
maintain constant contact with the cam assembly 30. The gear block 62 includes
pivot
bars configured on opposing ends that serve to pivotally couple the linkage
assemblies
70, 80, 90 to the gear block 62. For example, two linkage assemblies 70, 80
are pivotally
coupled to a pivot bar 64a on one end while a single linkage assembly 90 is
pivotally
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coupled to the pivot bar 64b on the opposing end. Each of the linkage
assemblies 70, 80,
90 includes a pivot point 78, 88, 98, respectively, that is rotatively coupled
to a fixed axis
of rotation relative to the central axis 6 of rotation of the cam assembly 30.
As depicted,
each fixed axis of rotation comprises a pivot pin 48 that is secured in
matching alignment
holes 44 configured in the two stationary plates 40. While each of the linkage
assemblies
70, 80, 90 can pivot about its respective fixed axis pivot point 78, 88, 98,
respectively,
the alignment and configuration of the pivot points remains fixed in relation
to the two
stationary plates 40. Each of the linkage assemblies 70, 80, 90 is biased so
that its
respective cam follower element 74, 84, 94, respectively, maintains contact
with the
surface of its respective pathway or groove formed in the cam assembly 30
throughout
the rotation cycle of the cam assembly 30.
In the depicted preferred embodiment, each of the linkage assemblies may
further
comprise at least two connector arms. For example, the first linkage assembly
70 may
include a lower connector arm 72 that is pivotally connected to an upper
connector arm
74, which is also pivotally connected to the gear block 62. A pivot pin 71
serves to
pivotally connect the lower connector arm 72 to the upper connector arm 74.
The lower
connector arm 72 includes a cam follower element 74 at its distal end. In a
preferred
embodiment the cam follower element 74 comprises a bearing wheel 75 rotatively
coupled at the distal end of the lower connector arm by means of an axle 76.
The lower
connector arm 72 further includes a pivot point 78 that is rotatively coupled
to a fixed
axis of rotation relative to the central axis 6 of rotation of the cam
assembly 30. For
example, a pivot pin 48a secured in matching alignment holes 44 configured in
the two
stationary plates 40 serves as a fixed axis of rotation relative to the
central axis 6 of
rotation of the cam assembly 30. While the lower connector arm 72 may pivot
about its
fixed axis pivot point 78, the alignment and configuration of the pivot point
78 remains
fixed in relation to the two stationary plates 40. Each of the pivotal
connections in the
first linkage assembly 70 is biased so that the cam follower element 74
maintains contact
with the surface of its respective pathway or groove 36 formed in the
circumferential
surface 34 of the cam assembly 30 throughout the rotation cycle of the cam
assembly 30.
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For example, the pivotal connections may further include torsional spring
elements (not
shown) which bias the first linkage assembly 70 so that the cam follower
element 74
maintains contact with the surface of its respective pathway or groove 36
formed in the
circumferential surface 34 of the cam assembly 30 throughout the rotation
cycle of the
cam assembly 30. Alternatively, the cam follower element of each linkage
assembly may
include conjugate cams to bias the pivotal connections in the linkage
assembly.
Alternatively or in addition, a ring spring connecting all of the gear blocks
62 in a gear
train may be used as a biasing mechanism in accordance with the present
invention.
Similarly, the second linkage assembly 80 may include a lower connector arm 82
that is pivotally connected to an upper connector arm 84, which is also
pivotally
connected to the gear block 62. The upper connector arm 84 is pivotally
connected to the
gear block 62 by means of the same pivot bar 64a used to pivotally connect the
upper
connector arm 74 of the first linkage assembly 70. A pivot pin 81 serves to
pivotally
connect the lower connector arm 82 to the upper connector arm 84. The lower
connector
arm 82 includes a cam follower element 84 at its distal end. In a preferred
embodiment
the cam follower element 84 comprises a bearing wheel 85 rotatively coupled at
the distal
end of the lower connector arm by means of an axle 86. The lower connector arm
82
further includes a pivot point 88 that is rotatively coupled to a fixed axis
of rotation
relative to the central axis 6 of rotation of the cam assembly 30. For
example, a pivot pin
48b secured in matching alignment holes 44 configured in the two stationary
plates 40
serves as a fixed axis of rotation relative to the central axis 6 of rotation
of the cam
assembly 30. While the lower connector arm 82 may pivot about its fixed axis
pivot
point 88, the alignment and configuration of the pivot point 88 remains fixed
in relation
to the two stationary plates 40. Each of the pivotal connections in the second
linkage
assembly 80 is biased so that the cam follower element 84 maintains contact
with the
surface of its respective pathway or groove 37 formed in the circumferential
surface 34 of
the cam assembly 30 throughout the rotation cycle of the cam assembly 30. For
example,
the pivotal connections may further include torsional spring elements (not
shown) which
bias the second linkage assembly 80 so that the cam follower element 84
maintains
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contact with the surface of its respective pathway or groove 37 formed in the
circumferential surface 34 of the cam assembly 30 throughout the rotation
cycle of the
cam assembly 30. Alternatively or in addition, a ring spring connecting all of
the gear
blocks 62 in a gear train may be used as a biasing mechanism in accordance
with the
present invention.
Likewise, the third linkage assembly 90 may include a lower connector arm 92
that is pivotally connected to an upper connector arm 94, which is also
pivotally
connected to the gear block 62. The upper connector arm 94 of the third
linkage
assembly 90 is pivotally coupled to a pivot bar 64b configured on the opposing
end of the
gear block 62 as the pivot bar 64a to which the upper connector arms 74, 84 of
the first
and second linkage assemblies 70, 80 are rotatively coupled. A pivot pin 91
serves to
pivotally connect the lower connector arm 92 to the upper connector arm 94 The
lower
connector arm 92 includes a cam follower element 94 at its distal end. In a
preferred
embodiment the cam follower element 94 comprises a bearing wheel 95 rotatively
coupled at the distal end of the lower connector arm by means of an axle 96.
The lower
connector arm 92 further includes a pivot point 98 that is rotatively coupled
to a fixed
axis of rotation relative to the central axis 6 of rotation of the cam
assembly 30. For
example, a pivot pin 48c secured in matching alignment holes 44 configured in
the two
stationary plates 40 serves as a fixed axis of rotation relative to the
central axis 6 of
rotation of the cam assembly 30. While the lower connector arm 92 may pivot
about its
fixed axis pivot point 98, the alignment and configuration of the pivot point
98 remains
fixed in relation to the two stationary plates 40. Each of the pivotal
connections in the
second linkage assembly 90 is biased so that the cam follower element 94
maintains
contact with the surface of its respective pathway or groove 38 formed in the
circumferential surface 34 of the cam assembly 30 throughout the rotation
cycle of the
cam assembly 30. For example, the pivotal connections may further include
torsional
spring elements (not shown) which bias the second linkage assembly 90 so that
the cam
follower element 94 maintains contact with the surface of its respective
pathway or
groove 38 formed in the circumferential surface 34 of the cam assembly 30
throughout
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the rotation cycle of the cam assembly 30. Alternatively or in addition, a
ring spring
connecting all of the gear blocks 62 in a gear train may be used as a biasing
mechanism
in accordance with the present invention.
Each of the linkage assemblies 70, 80, 90 is biased so that its respective cam
follower element 74, 84, 94 maintains contact with the surface of its
respective pathway
or groove formed in the cam assembly 30 throughout the rotation cycle of the
cam
assembly 30. For example, cam follower element 74 maintains contact with the
surface
of a first pathway 36, cam follower element 84 maintains contact with the
surface of a
second pathway 37, and cam follower element 94 maintains contact with the
surface of a
third pathway 38. Each pathway has a unique circumference, the radius of which
varies
over the course of the pathway. Thus, for example as shown in Figs. 5 and 6,
the first
pathway 36 has a first radius ii at one part of its circumference that is
greater than a
second radius r2 at another part of its circumference. This creates a unique,
undulating
path for each pathway as the cam assembly 30 rotates. While the cam assembly
30
depicted in the Figures, appears to be a single disc or unit having a
plurality of pathways
or grooves formed in the circumferential surface 34 of the cam assembly 30, it
is
understood that the cam assembly 30 may also comprise a plurality of separate
discs,
each having a unique pathway formed in its circumferential surface, which are
mechanically coupled to one another to assemble a single cam assembly 30.
As the cam assembly 30 rotates, the cam follower element follows its
respective
pathway maintaining contact with the circumferential surface of the respective
pathway.
As the radius of the pathway changes, the respective linkage assembly pivots
about its
fixed axis pivot point to compensate. This pivoting of the linkage assembly
about its
fixed axis pivot point induces similar movement in the pivotal connection with
the gear
block 62, which results in movement of the gear block 62 Thus, as the cam
assembly 30
rotates, the movement of the gear block 62 is controlled by the induced
pivoting of the
plurality linkage assemblies. For example, by varying the radius of the first
pathway or
groove 36 on the cam assembly 30, the first linkage assembly 70 pivots about
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axis pivot point 78 to compensate and maintain contact between the first cam
follower 74
and the surface of the first pathway or groove 36. This pivoting of the first
linkage
assembly 70 about its fixed axis pivot point 78 induces movement in the
pivotal
connection with the gear block 62. Each linkage assembly acts independently of
the
other linkage assemblies due to the cam follower element of each linkage
assembly
following a distinct pathway formed in the circumferential surface of the cam
assembly.
By varying the radius of each pathways or grooves 36, 37, 38 on the cam
assembly 30, linkage assemblies 70, 80, 90 drive their respective gear block
62 through a
two-dimensional circuit in response to rotation of the cam assembly 30. As
shown in
Fig. 4A, in general, the two-dimensional circuit 65 includes urging the gear
block to
engage the output gear element 50 and move or rotate the output gear element
50 a
specified quantum distance prior to disengaging from the output gear element
50, and
returning back the specified quantum distance to again reengage the output
gear element
50 once again and repeat the process. It is understood that the two-
dimensional circuit 65
depicted in the drawings is not to scale and is somewhat exaggerated to
illustrate the
general principal of the invention. For example, the distance A-B would
typically be
much smaller than depicted. The travel path or circuit 65 of each gear block
62 is
controlled by adjusting the length and configuration of the various linkage
assemblies and
altering the pathways or grooves formed in the cam assembly 30.
When adapted to a gearbox mechanism 20, a plurality of gear block assemblies
80
are configured about the central axis 6 of the cam assembly 30. The cam
assembly 30 is
coupled with a power source 2 by means of output device 6. As the cam assembly
30
rotates, the cam follower elements (e.g., 74, 84, 94) of the respective
linkage assemblies
(e.g., 70, 80, 90) of each gear block assembly 60 maintain contact with a
particular
pathway or groove (e.g., 36, 37, 38) formed in the circumferential surface 34
of the cam
assembly 30. The variance of distance from the center of rotation of the
different
pathways or grooves (e.g., 36, 37, 38) of the cam assembly 30 causes the
linkage
assemblies pivotally attached to its respective gear block 60 to work in
concert to move
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their respective gear block through a predetermined circuit of movement 65.
This
predetermined circuit of movement 65 of the gear block 60 can be precisely
calibrated to
meet specific engineering requirements. For example, the torque ratio and
speed
reduction may be regulated and controlled by adjusting the circuit of movement
65 of
each gear block assembly 60.
Numerous embodiments of gearbox mechanisms are possible using the gear block
assembly 60 of the present invention. All embodiments of gearbox mechanisms
constructed in accordance with the present invention feature a plurality of
gear block
assemblies 60 configured about the central axis 6 of the cam assembly 30 and
may
comprise either an odd or even number of gear block assemblies 60. At least
two, and
preferably three gear block assemblies are required for a gearbox mechanism of
the
present invention. For example, as shown in Fig. 7A, a variant embodiment of
the
gearbox mechanism 100 featuring three gear block assemblies 60 is depicted.
Fig. 7B
depicts a variant embodiment of the gearbox mechanism 110 featuring five gear
block
assemblies 60. The movement of the gear block assemblies 60 typically moves in
a
rotational series to one another.
However, in a preferred embodiment of the present invention wherein the
plurality of gear block assemblies comprises four or more even-number gear
block
assemblies 60, the gear block assemblies 60 configured on opposing sides of
the cam
assembly 30 engage and disengage in unison from the secondary or output gear
element
50. For example as shown in Fig. 3, an embodiment of the gearbox mechanism 20
featuring four gear block assemblies 60 is depicted. Similarly, Fig. 7C
depicts a variant
embodiment of the gearbox mechanism 120 featuring six gear block assemblies
60. This
is accomplished by ensuring that the individual pathways or grooves formed in
the
circumferential surface of the cam assembly are in phase with one another on
opposing
sides of the cam assembly circumference.
With reference now to Fig. 8, a second embodiment of a gearbox mechanism 120
of the present invention is shown. The gearbox mechanism 120 can include a
main body
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140, an output element 150 and a plurality of simplified gear block assemblies
160.
Additionally, the gearbox mechanism 120 may have a retainer 112 that
interfaces with
the main body 140 and the output element 150. This interface allows for the
output
element 150 to be connected to an output device and/or a rotatable device as
part of the
gearbox mechanism. The output device and/or the rotatable device can be an
electric
motor, an internal combustion engine, or any conventional power source, that
can be
adapted to generate or receive rotative power. Additionally, the output device
and/or
rotatable device may be rotatively coupled by means of gears, chains, belts,
or magnetic
fields. The output element 150 interfaces with the gear blocks 162 via an
interfacing
surface, where an output element 150 can have an internal interface surface or
external
interface surface. An internal or external interface surface can include gear
teeth, friction
based geometric engagement, friction wedges, or any other forms of mating
surfaces,
including but not limited to, pole and hole.
With reference now to Figs. 8 and 9, the cam actuated gear block assembly 160
can include a gear block 162, a torque lever 199, cam follower(s) 194, and/or
socket 189
(or a portion of a socket 189). The cam actuated gear block assemblies 160 are
configured about a central axis 106. A shaft, gears, belts, or magnetic fields
(not
illustrated) may be utilized along the central axis 106 to couple an input
device and/or
rotating device with a cam element 130 to generate a force or rotative force
on the cam
element 130. The rotational force on the cam element 130 allows for a driving
or rotative
force on the cam actuated gear block assemblies 160. In a preferred
embodiment, the
main body 140 is stationary or is a stationary plate with respect to the cam
actuated gear
block assemblies 160 and/or the output element 150.
While the output element 150 is depicted as a single circular ring, it is
understood
that the output element or power gear element 150 may comprise two circular
rings held
apart by spacer elements (not illustrated). The output element 150 includes
apertures or
holes 158 defined along an outer surfaces and/or within the output element 150
for
attaching to an output shaft or power takeoff (not illustrated). In addition,
it is
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understood that the outer circumference 151 of the output element 150 may also
comprise a surface to interface with some other gear train mechanism, or other
output
devices through belts, or gears.
The gear blocks 162 of the present invention are specifically designed to
enable a
greater surface area (e.g., greater number of gear teeth) to engage the output
element 150
at any given time, thereby spreading the stresses associated therein across a
greater area.
By dramatically increasing the contact area between the gear block 162 and the
output
element 150 at any given time the mechanical stress level is significantly
decreased. In
addition, the gear block 162 assemblies of the present invention reduce
backlash to zero
and even preloaded conditions to create a tight connection between the power
source
and/or the powered device (not illustrated). This is an extremely desirable
feature
especially for high vibration applications. Moreover, because the stresses
associated with
engagement of the gear block 162 against the output element 150 are
distributed across a
greater area, the gear block 162 may be manufactured of lighter-weight
materials, which
are typically less expensive and easier to manufacture, with no degradation in
reliability.
For example, per Hertz Contact Theory a typical stress result for spur gears
are in
the range from 450MPa to 600MPa. High grade steels are the best fitted
materials for
handling such high stress levels. Other materials like low grade steel or
aluminum will
deform under the similar conditions. However, by distributing the stresses
across a large
areas of contact in accordance with the gearbox mechanism of the present
invention, the
levels of stress under the similar conditions can be reduced to about 20MPa.
These low
stress levels allow the gearbox mechanism of the present invention to be
manufactured
using low grade steels, aluminums or even plastics for the same application.
By reducing
its weight and size, the gearbox mechanism 120 of the present invention is
adaptable to a
broad range of applications that were previously impractical because of weight
and space
limitations.
In at least one embodiment of the present disclosure, the gear blocks 162 may
also
rest inside or be surrounded by a socket 189. The socket 189 may also be
associated or
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coupled with the torque lever 199. In some embodiments, the torque lever 199
can also
have a set of cam followers 194 allowing for the following of a specified
pathway(s)
formed in or along a planer surface of the cam element 130. The cam element
130 can
also have an input hub 114 or a ball bearing assembly 116 that allows the cam
element
130 to rotate freely based upon an input device such as a shaft or rotatable
elements such
as a set of other gearing, belts, levers, magnetic or electrical fields, etc.
The socket 189
can also have a central guide 124 that rests in the center that allows a shaft
and/or
rotatable element to be passed through of the output element, main body,
retainer, gear
blocks, torque levers, and/or cam element along a central axis 106. The gear
blocks 162,
cam followers 194, central guide 124, socket 189, torque levers 199, and cam
element
130 can comprise a gear block assembly 160. The gear block assembly 160 allows
for
the gear block 162 to be rotated in a manner that engages with the output
element 150 by
an intersection of the cam followers 194, and cam element 130. The interface
surfaces of
the gear block 162 can engage with the output element interface surface (not
illustrated)
of the output element 150. In some embodiments, the gear blocks are rotated by
the
socket and an associated movement of the torque lever 199.
The cam element 130 includes at least one unique pathway or groove that
interfaces with the cam follower 194 of gear block 162 or torque lever 199 so
that as the
cam element 130 rotates, the movement of the gear block 162 or torque lever
199 is
controlled in two dimensions in accordance with at least one certain design
parameter.
By varying the radius of the pathway or grooves on the cam element 130, the
cam
actuated gear block assemblies 160 drive respective gear block(s) 162 through
a two-
dimensional circuit in response to rotation of the cam element 130. Broadly
speaking,
the two-dimensional circuit includes urging the gear block(s) 162 to engage
the output
element 150 and move and/or rotate the output element 150 a specified distance
prior to
disengaging from the output element 150, and returning back the specified
distance to
again reengage the output element 150 once again, and repeat the process. The
travel
path or circuit of each gear block 160 is controlled by adjusting the length,
width, height,
and/or size of the respective gear block and/or torque lever and/or altering
the pathways
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or grooves formed in the cam element 130.
The torque lever is pivoted around a specific pivot point by the cam follower
199,
which traverses the path in the cam element 130. Additionally, the socket
and/or the gear
blocks may also have a cam follower 199 that follows the same or a separate
path along
the cam element 130 that also triggers a pivot point for the socket or gear
block(s). In at
least one embodiment, there is at least one pivot point for both the gear
block and the
torque lever that allows each to pivot separately from each other and while
also being in a
moving conjunction to create a specific pattern of movement for the gear
blocks. The
movement of a gear block, in at least one example, is a cyclical, annular or
closed loop
movement that may have a generally rectangular, elliptical, circular, square,
conical,
oval, ovoid, truncated circular pattern, or any combination thereof, design
specified
pattern of movement.
With reference now to Fig. 9A, a perspective view is depicted of the cam
element
130 along with the torque lever 199, socket 189, and gear block 162. Central
axis 106
can pass through the central guide 124 at the center of the socket 189, cam
element 130,
and/or output element 150. The socket 189 can include individual pieces that
also
correspond to each individual gear block 162. In at least one embodiment of
the present
disclosure, the socket 189 interacts with the toque lever 199 along with the
gear block
162 to rotate and cause a movement of the gear block 162 to have a cyclical,
annular or
closed loop movement having a generally rectangular, elliptical, circular,
square, conical,
oval, ovoid, truncated circular pattern, or any combination thereof, design
specified
pattern of movement based upon the pathways in the cam element 150 that may
allow a
cam follower (not illustrated) attached to the torque lever 199 to traverse
along the
pathway to generate movement of the gear block(s).
The cam follower (not illustrated) can also be attached to a gear block and/or
socket allowing a force to be generated against them as well. Each of the cam
followers
can have a separate path or, in some embodiments, may have a single path. The
gear
block(s) 162 can be pivotally connected to the torque lever 199, and/or the
socket 199.
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Alternatively or in addition, a ring spring connecting all of the gear blocks
162 in a gear
train may be used as a biasing mechanism in accordance with the present
invention. In at
least one embodiment of the present disclosure, the paths in the cam element
130 can be
in the same plane where they are parallel paths, or paths of different
distances from the
central axis 106, or the paths can be in separate planes stacked in the
direction of the
central axis 106.
With reference now to Fig. 98, a perspective view of the cam element 130,
torque
lever 199, cam followers 194 coupled to the torque lever 199 as well as the
cam follower
194 coupled with the gear block 162. In at least one embodiment, the first
pathway 136
along cam element 130 as well as a second pathway 137 along the cam element
130
allow for movement and rotation of the gear blocks allowing for the interface
surfaces of
the gear blocks 162 to engage, interface and/or interact with the output
element (not
illustrated). Cam follower(s) 194 maintain contact with the surface of their
respective
pathways or grooves formed in the cam element 130. The first pathway 136 has a
first
radius ri at one part of its plane that is greater than a second radius r2 at
another part of its
plane. This creates a unique, undulating path for each pathway as the cam
element 130
rotates. While the cam element 130 depicted in the Figures, appears to be a
single disc or
unit having a plurality of pathways or grooves formed in the planer surface
134 of the
cam element 130, it is understood that the cam element 130 may also comprise a
plurality
of separate discs, each having a unique pathway formed in its circumferential
surface,
which are mechanically coupled to one another to assemble a single cam
assembly 130
As the cam element 130 rotates, the cam follower(s) 194 follow their
respective
pathways maintaining contact with the planar surface of the respective pathway
or groove
136/137. As the radius of the pathway changes, the respective gear block 162,
and/or
torque lever 199 pivots or moves about its pivot point to compensate for the
change in the
pathway or groove. In at least one version, the torque lever 199 may pivot
about its pivot
point inducing a movement or pivoting of the socket (not illustrated) and/or a
gear block
162 to which is it pivotally coupled to, and results in a movement of the gear
block 162.
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Thus, as the cam element 130 rotates, the movement of the gear block 162 is
controlled
by the induced pivoting of the torque lever 199, and/or socket (not
illustrated). For
example, by varying the radius of the first pathway or groove 136 on the cam
element
130, the torque lever 199 pivots about its pivot point to compensate and
maintain contact
between torque lever 199 and the socket (not illustrated). This pivoting or
moving of the
torque lever 199 about its pivot point induces movement in the pivotal
connection with
the socket (not illustrated) and/or gear block 162. Each torque lever 199 acts
independently of the other torque lever(s) 199 due to the cam follower(s) 194
of each
torque lever 199 following and/or traversing first pathway 136 formed in the
planar
surface of the cam element 130 at their respective distinct points.
With regards to the cam element 130, the first pathway 136 and the second
pathway 137 can be in the same plane and at times be parallel and/or
nonparallel with
each other, wherein the first pathway is on an outer radius of the cam element
130. In the
second pathway 137 along an inner radius and is closer to the central axis of
the cam
element 130. It is understood, that in some embodiments the pathways can be
stacked in
separate planes such that the first plane and second plane are stacked one on
top of the
other in a Z direction or central axis 106. As the cam followers for the gear
block and the
torque lever follow their respective pathways, the torque lever can pivot at
specific point
causing a socket and/or the gear block itself to rotate around a specific
point. Cam
follower(s) for the gear block also allow for the gear block to transition in
certain present
and/or predetermined directions. For example, the pivot point of the torque
element will
trigger a left, right, or a linear motion, or a latitudinal motion while the
cam follower
following the second pathway coupled to the gear block 162 can allow for a
longitudinal
movement of the gear block. Associated together they allow for a cyclical,
annular or
closed-loop movement of the gear block and the interfacing surface that has a
generally
rectangular, elliptical, circular, square, conical, oval, ovoid, truncated
circular pattern, or
any combination thereof, design specified pattern of movement.
With reference now to Fig. 10A, an illustration of a gear block 162
interacting
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with the output element 150 is depicted illustrating the variable bias which
may be
programmed or designed into the interaction between the gear block 162 and the
output
element 150. The interaction of the gear block 162 with the output element 150
may be
biased either positively (i.e., in the direction of rotation), negatively
(i.e., in the opposite
direction of rotation) or neutrally. While applicable to all interface
surfaces, variable
biasing is especially important when the interface surfaces are gear teeth.
Gear block 162
is illustrated in Fig. 10A as having a positive bias so that the advancing
face 164a of each
interface element (e.g., gear tooth) is biased to positively engage a
respective advancing
face 150a of the interface element (e.g., gear tooth) of the output element
150 so as to
transfer rotational movement from the gear block 162 to the output element 150
In Fig.
10B the gear block 162 is illustrated as having a negative bias so that the
following face
164b of each interface element (e.g., gear tooth) is biased to engage a
respective
following face 150b of the interface element (e.g., gear tooth) of the output
element 150.
The negative bias induced by the gear block 162 can impart a slight tension on
the output
element 150 to reduce and/or eliminate backlash along the output element as
the gear
block 162 rotates the output element 150. For example, a gear block on one
side of an
output element can be in a positively biased configuration 126 while a gear
block
interfacing on the opposite side or offset from the positively biased gear
block, can be in
a negatively biased configuration 127.
A gear block may also be configured in a neutral or balanced configuration 125
(Fig. 10C) wherein the gear block interface element (e.g., gear tooth) is
neither positively
nor negatively biased towards the interface element or surface of the output
element 150.
For example, when the gear block 162 is moving from a positively biased
configuration
126 (Fig. 10A) to a negatively biased configuration 127 (Fig. 10B), the gear
block 162
can be in a balanced and/or neutral configuration which decreases the
rotational tension
or engagement of the gear block interface surface with the output element
interface
surface. Additionally, when the gear block transitions, repositions and/or
returns from a
negative bias configuration 127 to a positive bias configuration 126, or vice
versa, the
gear block 162 can be unloaded and/or disengaged from the output element
interface
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surface so that the gear block 162 can smoothly disengage (i.e., pull and/or
drop away)
from the output element 150.
Gear blocks 162 can be arranged so that they extend outwardly, for example,
the
interface surface 163 (e.g., a plurality of projections or teeth 166), which
correspond to a
complementary interface surface 154 (e.g., projections or gear teeth)
configured on an
interface surface 153 of the output element 150, extending outwardly from a
center guide
or central axis 106 or, the interface surface 163 can extend inwardly towards
a central
axis 106. Gear blocks 162 can also include a set of cam followers 194 that may
allow for
a traversing of a pathway of the cam element 130. The cam follower(s) 194 can
maintain
contact with a pathway or groove formed in the planar surface of the cam
element 130. It
is understood that the interface between the gear block 162 and the output
element
interface surface 153 of the output element 150 of the present invention
comprises not
only the preferred gear teeth as depicted, but also any complementary
arrangement such
as pins and holes or even friction fit surfaces
With reference now to Fig. 10C, a side elevation view of the output element
150,
gear blocks 162, torque levers 199 in the central aperture 132 is shown. A
shaft and/or
other rotatable device can be passed through the central aperture 132 attached
to the
output element and/or cam element (not illustrated). The cam followers 194 can
be
coupled to the gear blocks 162, as well as the torque levers 199. The cam
followers 194
can follow specific paths for both the torque levers and the gear blocks
generating forces
to move them through their various positions going from a path along the outer
path of
the cam element or an inner path for the gear blocks.
The gear block(s) illustrated 162 are shown in various positions starting with
the
top most gear block 162A is shown in a transitioning/repositioning position
128 where it
is fully disengaged from the interface surface of the output element 150 and
the interface
surface of the gear block 162A is fully disengaged. (Please note that the
illustrated
spacing of the gear block teeth is exaggerated to better illustrate the
different bias
configurations at issue). Moving to gear block 162B is shown in a reversed
tension or
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negative bias configuration 127. There can also be a position such as one that
gear block
162C and/or 162D when they are in a neutral bias configuration. Gear block
162E is
illustrated in a positively biased or engaged configuration 126, which can
result in a
rotation of the output element 150. Gear block 162F is illustrated also in a
positively
biased or engaged configuration 126. Gear block 162G is also illustrated as
one in a
neutral bias configuration. There can be three engagement positions for a gear
block to
be in: an engaged or positive bias position 126, a reversed tension or
negative bias
position 127, and/or a neutral bias or balanced position 125. Additionally, a
gear block
can be in a transitioning/repositioning position 128, which allows for the
gear block 162
to disengage and/or move away from the output element 150 to return to one of
the
engagement positions.
Moreover, it should be understood that the, annular or closed loop cyclical
movement of each gear block and cam element may be specifically programmed or
designed to vary the bias configurations during a single cycle to enhance the
effectiveness of the gear block assembly. Additionally, the amount or strength
of bias,
whether positive, negative, or balanced can be calibrated and varied
throughout the cycle.
For example, in one embodiment, when a gear block first engages the interface
surface of
the output element, the gear block is designed to engage with a neutral bias
to maximize
the efficiency of the engagement process, then quickly transition to a
positive bias to
maximize power transfer, then slightly before disengagement a return to a
neutral bias to
assist with an efficient disengagement prior to the
transitioning/repositioning The
negative bias configuration could be programmed into the cycle to minimize
backlash.
As the cam followers coupled to the gear block follow the first or second
pathway
of the cam element, they enable the gear block to move in a radial direction
or what can
be referred to as an up or down motion. An associated pivoting of the torque
lever allows
for the rotation or angular movement of the gear block in what can be referred
to as a left
or right movement. These movements can be corresponded or calculated together
to
generate a cyclical, annular or closed loop path for the gear block that may
have a
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generally rectangular, elliptical, circular, square, conical, oval, ovoid,
truncated circular
pattern, or any combination thereof, design specified pattern of movement. In
at least
one embodiment of the present disclosure, torque lever and/or gear block are
coupled
together in a way that allows for a pivot point of the gear block and torque
lever as
caused by the traversing of the path by the cam followers to create the
movement of the
gear block. In at least one example, the angular movement of the gear block
places a
torque upon the output element 150.
With reference to Figs. 9A, 9B, 10A, 10B, and 10C, by varying the radius of
each
pathway or groove 136, 137 on the cam element 130, torque lever(s) 199 drive
their
respective gear block(s) 162 through a two-dimensional circuit in response to
rotation of
the cam element 130. In general, the two-dimensional circuit 139 includes
urging the
gear block 162 to engage the output element 150 and move or rotate the output
element
150 a specified distance prior to disengaging from the output element 150, and
returning
back the same specified distance to again reengage the output element 150 once
again
and repeat the process. It is understood that the two-dimensional circuit 139
depicted in
the drawings is not to scale and is somewhat exaggerated to illustrate the
general
principal of the invention. For example, the distance A-B would typically be
much
smaller than depicted. The travel path or circuit 139 of each gear block 162
is controlled
by adjusting the size and configuration of the torque lever(s) 199, socket
189, gear
block(s) 162, and/or altering the pathways or grooves 136, 137 formed in the
cam
element 130
When adapted to a gearbox mechanism 120, a plurality of gear block assemblies
160 are configured about the central axis 106 of the cam element 130. The cam
element
130, in at least one version, may be coupled to a power source (not
illustrated) by an
output device (not illustrated). As the cam element 130 rotates, the cam
follower(s) 194
of the respective torque lever(s) 199 and/or gear block(s) 162 of each gear
block
assembly 160 maintain contact with a particular pathway or groove 136, 137
formed in
the planar surface 135 of the cam element 130. The variance of distance from
the center
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of rotation of the different pathways or grooves 136, 137 of the cam element
130 causes
the torque lever(s) 199, and/or socket 189 pivotally attached to a gear
block(s) 162 to
work in concert to move their respective gear block(s) 162 through a
predetermined
circuit of movement 139. This predetermined circuit of movement 139 of the
gear block
160 can be precisely calibrated to meet specific engineering requirements. For
example,
the torque ratio and speed reduction may be regulated and controlled by
adjusting the
circuit of movement 139 of each gear block assembly 160.
Numerous embodiments of gearbox mechanisms are possible using the gear block
assembly 160 of the present invention. All embodiments of gearbox mechanisms
constructed in accordance with the present invention feature a plurality of
gear block
assemblies 160 configured about the central axis 106 of the cam element 130
and may
comprise either an odd or even number of gear block assemblies 160. At least
two, and
preferably three or more, gear block assemblies are required for a gearbox
mechanism of
the present invention. The movement of the gear block assemblies 160 typically
moves
in a rotational series to one another.
However, in a preferred embodiment of the present invention wherein the
plurality of gear block assemblies comprises four or more even-number gear
block
assemblies 160, the gear block assemblies 160 configured on opposing sides of
the cam
element 130 engage and disengage in unison from the secondary or output
element 150.
For example, an embodiment of the gearbox mechanism 120 may feature four gear
block
assemblies 160. Similarly, another embodiment of the gearbox mechanism 120 may
feature six gear block assemblies 160. This is accomplished by ensuring that
the
individual pathways or grooves formed in the planar surface of the cam element
are in
phase with one another along the planer surface of the cam element.
With reference now to Fig. 11, an illustration of a third embodiment of a
gearbox
mechanism 220 of the present invention is depicted. The gearbox mechanism 220,
in at
least one version, can include a cam element 230, a main body 240, and output
element
250, and a plurality of simplified gear block assemblies 260. In at least one
example, the
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output element 250 is retained within the main body 240 by a retainer 212 (or
retainer
ring) via fasteners and/or couplers. The gear block assemblies 260 can be
placed within
the main body 240, and interfacing with the output element 250 and cam element
230. In
some examples, the cam element 230 interfaces with an input hub and/or ball
bearing
assembly 216 (can also include a set of ball bearings, roller bearings, or
ball bearing ring)
through a friction or geometrical fit. A central axis 206 can traverse the
retainer 212,
output element 250, the main body 240, the gear block assemblies 260, the cam
element
230, the input hub 214, and/or the ball bearing assembly 216.
The simplified gear block assemblies 260 can include a torque lever 299, a
gear
block 262, a first cam follower 294A, and a second cam follower 294B. The cam
followers 294A/294B follow pathways (not illustrated) in the cam element 230
to
generate forces on the torque lever 299, and/or the gear block(s) 262
generating a
pivoting motion for both the torque lever 299 and the gear block(s) 262 In at
least one
version, the pivoting motion can be generally square pivot path for the gear
block(s) 262.
While in other versions, the pivot path of the gear block(s) 262 will
generally be oval or
circular.
The gearbox mechanism 220 can be coupled to an input or rotating device (not
illustrated) such as an electric motor, internal combustion engine, or any
conventional
power source that can be adapted to generate rotative power. The input or
rotating device
(not illustrated) may be rotatively coupled through means of gears, chains,
belts, or
magnetic fields. An output device (not illustrated) may be coupled to the
output element
250.
In at least one version, a central aperture 232 that has a central axis 206
traversing
through it may be a part of the gearbox mechanism 220. The gearbox mechanism
220 is
configured about the central axis 206 and can include a main body 240 that is
stationary
with respect to the cam element 230, output element 250, and/or cam-actuated
gear block
assemblies 260. In at least one example, spacer element(s) (not illustrated)
may also be
used to ensure that movement of the output element 250, cam element 230,
and/or cam-
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actuated gear block assemblies 260 are not impeded by the main body 240 and/or
retainer(s) 212, 214. The cam-actuated gear block assemblies 260 can be evenly
spaced
about the circumference of the output element 250. Each gear block assembly
260
includes a gear block 262, a torque lever 299, and at least one cam follower
294, which
connect the gear block 262 to the planer surface of the cam element 230. The
torque
lever 299, and/or gear block 262 can interact to be pivotally attached, and
correspond to
the interaction and/or engagement of the cam follower(s) 294 with the cam
element 230.
With reference now to Fig. 12A, an exploded view of the main body 240, output
element 250, and retainer 212 is shown. In a preferred embodiment, the main
body 240
serves as a housing for the gear block assemblies (not illustrated), and the
cam element
(not illustrated). The main body 240 can be coupled on the cam side 241 to an
input hub,
rotating device, a retainer, a plate, or other protective or securing devices
via a fastener or
coupling aperture 245. On the output side 243, the main body 240 can be
coupled to a
retainer 212 via retainer fastener or coupling aperture 245
The retainer 212 can also interface with the output element 250 and/or the
output
element outer circumferential surface 251, through a retainer inner
circumferential
surface 257 in at least one version, the output element 250 can have an output
element
lip 259 that may support and/or engage, the retainer 212 and/or retainer inner
circumferential surface 257. A portion of the retainer 212 can interface with
the output
element 250, while the remaining amount of the retainer can interface with the
main body
240. A fastener (not illustrated) can couple, fasten, and/or pass through a
retainer
fastener aperture 259 for fastening and/or coupling of the retainer 212 and
the main body
240.
The output element 250, in at least one version, can include a roller track
261 (or
ball bearing track) to allow and/or assist the output element 250 in rotation.
The rotation
of the output element 250 can result with the gear block(s) 262 engage with
the output
element interface surface 253. In at least one example, the rotation of the
output element
250 may also be controlled through a reverse or tension engagement
negative bias
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configuration) of gear block(s) 262 that are not in a driving or positive bias
rotational
engagement in order to reduce and/or eliminate backlash.
With reference now to Fig. 12B, a perspective view of a main body 240 is
shown.
The main body 240, in at least one version, can provide a housing for the gear
assemblies
(not illustrated). The gear block assemblies (not illustrated) can rest and/or
be supported
by the main body retaining surface 267. The gear block(s) (not illustrated)
may also be
retained and/or supported by the main body gear block interface surface 269.
The torque
lever(s) (not illustrated) may be supported and/or retained by the main body
torque lever
interface surface, and/or the main body torque lever void 277 as defined by
the main
body 240. A torque lever post (not illustrated) can be configured to be
retained and/or
supported by the main body torque lever void 277 to allow for a pivoting
motion of the
torque lever (not illustrated) to occur. The pivoting motion of the torque
lever (not
illustrated) can also coincide with a pivoting motion of the gear block (not
illustrated)
that allows for the interfacing, engaging, and/or rotating of an output
element (not
illustrated).
in at least one version, the main body 240 can also have a spacer (not
illustrated)
for the gear assemblies that can be secured to the main body 240 through a
spacer
aperture 279 defined by the main body 240. The spacer aperture 279 may be
surrounded
by the main body spacer interface surface 287. A cam interface surface 289 can
support
a cam element (not illustrated) as it engages with the gear assemblies (not
illustrated), a
rotatable or rotating device, and/or an input device. The main body 240 can be
coupled
on the cam side 241 to an input hub, rotating device, a retainer, a plate, or
other
protective or securing devices via a fastener or coupling aperture 244. The
input hub,
rotating device, a retainer, a plate, or other protective or securing devices,
in at least one
example, can be utilized to secure and/or support a cam element (not
illustrated).
With reference now to Fig. 12C, an exploded perspective view of a main body
240, and gear block assemblies 260. The output element 250 may rest and/or be
supported by the main body 240, and have a ball bearing assembly 207 (could
also
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include a set of ball bearings, roller bearings, or ball bearing ring) that
can be coaxial
with the guide of a cam element (not illustrated) to allow the cam element
freedom of
movement. The gear block 262 can have a gear block post 264 that may interact
with a
torque lever aperture 297 to provide a pivot point for the gear block 262
and/or torque
lever 299. The torque lever 299 may also have a torque lever post 288 that
interacts
and/or engages with a main body torque lever void 277 and/or a gear block
opening 211
to provide a pivot point for the torque lever 299 and/or gear block 262. A cam
follower
294 can also be rotatively coupled to the gear block post 264, and a cam
follower 294B
can be rotatively coupled to a cam follower post 286 of the torque lever 299.
The torque
lever 299, the gear block 262, and cam follower(s) 294A, 294B can be in at
least one
version, a cam actuated gear block assembly 260. In at least one example, a
spacer 246
may also be added to provide support and/or secure the torque lever 299 and/or
gear
block 262.
With reference now to Fig. 13, a perspective view of a cam element 230 is
depicted. The cam element 230 can have at least one plane 215A along the
central axis
206. In at least one version, the cam element 230 can have two planes
215A/215B.
While in other versions, the cam element 230 may have three planes
215A/215B/215C.
The cam element 230 can have a cam element guide 216 that allows for an
interaction of
the cam element 230 with an output element guide and/or ball bearing assembly
(or set of
ball bearings) (not illustrated). The cam element guide 216 can be coaxial
with the
output element guide and/or ball bearing assembly (or set of ball bearings)
(not
illustrated) allowing for a centering along the central axis 206 via the cam
element central
aperture 232. The output element guide and/or ball bearing assembly (or set of
ball
bearings) (not illustrated) can interface with a cam element guide
circumferential surface
217 along the outside of the cam element guide 216.
In at least one example, the first plane 215A may correspond and/or include a
first
pathway 236. The first pathway 236 can allow for the transversal of a cam
follower (not
illustrated) to generate a pivot or pivoting force on a torque lever and/or
gear block (not
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illustrated). As the cam follower (not illustrated) traverses the first
pathway 236 the
pathway can change in direction to move a torque lever and/or gear block (not
illustrated)
coupled to the cam follower. Similarly, the second plane 215B may correspond
and/or
include a second pathway 237. The second pathway 237 can allow for the
transversal of
a cam follower (not illustrated) to generate a pivot or pivoting force on a
torque lever
and/or gear block (not illustrated). As the cam follower (not illustrated)
traverses the
second pathway 237, the pathway can change in direction to move a torque lever
and/or
gear block (not illustrated) coupled to the cam follower.
The gear block assemblies (not illustrated) can rest and/or be supported by a
cam
element support surface 218. A vertical or depth surface 219 of the cam
element support
surface 218 may also, in at least one example, provide a surface for the gear
block
assemblies to interface with and/or engage with. A cam element spacer 221 may
also be
included and/or coupled to the cam element guide 216. The cam element spacer
221
may, in some examples, be in a third plane 215C of the cam element 230.
With reference now to Fig. 14, a perspective view of gear block assemblies 260
interfacing with an output element 250. The gear block assemblies 260 can
include a
gear block 262, a torque lever 299, a first cam follower 294A, and/or a second
cam
follower 294B. In at least one version the first cam follower 294A is coupled
to the gear
block 262, and the second cam follower 294B is coupled to the torque lever
299. As the
cam followers 294A/294B traverse the first and second pathways 236/237 they
generate
radial and angular movements of the torque lever 299 and/or the gear block
262. These
longitudinal and latitudinal movements of the torque lever 299 and/or gear
block 262
allow for and/or generate the pivot movements of the torque lever 299, and/or
gear block
262. In at least one example, a spacer 246 can be utilized to support and/or
engage the
torque lever 299.
The torque lever pivot post 288 and the gear block pivot void 297 interact to
generate forces that cause the gear block 262 to engage and/or disengage from
the output
element 250. The movement of a gear block 262, in at least one example, is a
cyclical,
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annular or closed loop movement that may have a generally rectangular,
elliptical,
circular, square, conical, oval, ovoid, truncated circular pattern, or any
combination
thereof, design specified pattern of movement.
For example, a gear block interface surface 263 can engage and/or disengage
from an output element interface surface The gear block 262 will move in a
cyclical
manner as a result of the pivot movements of the torque lever 299 and cam
followers
294A/294B. In at least one version, the gear block can have four positions. A
first
position 228 (or transitioning position) allows for the gear block to traverse
or move to a
new position to begin a new rotation of the output element 250. The second
position 226
(or engaged or positive bias movement position) allows for the gear block to
generate a
rotational or pulling force 228 on the output element 250. The third position
225 (or
neutral or balanced position) may allow the gear block 262 to be in a position
to engage,
rotate, or disengage from the output element interface surface with no forces
generated on
the output element. The fourth position 227 (i.e., reverse tension or negative
bias
configuration) allows for a tension to be placed on the output element 250 to
assist in the
prevention and/or elimination of backlash of the output element 250.
The cam element guide 216 can be interfaced with the output element 250
through a rotational support, ball bearing assembly, and/or set of ball
bearings (not
illustrated) that can be placed between the cam element guide circumferential
surface 217
and the output element circumferential surface 251.
As shown in the embodiment depicted in the Figures, the plurality of cam-
actuated gear block assemblies 260 transfer power from an input or rotating
device (not
illustrated) to an output element 250. In a preferred embodiment, each gear
block
assembly 260 includes a gear block 262 having an interface surface 263 (e.g.,
a plurality
of projections or teeth 266) which correspond to a complementary output
element
interface surface 254 (e.g., projections or gear teeth) configured on an outer
circumferential surface 251 of the output element 250. The present invention
comprises
not only the preferred gear teeth as depicted, but also any complementary
arrangement
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such as pins and holes or even friction fit surfaces.
While the output element 250 is depicted as a single circular ring, it is
understood
that the output element 250 may comprise two circular rings held apart by
spacer
elements (not illustrated). The output element 250 includes apertures or holes
258 for
attaching to an output shaft or power takeoff (not illustrated) In addition,
it is
understood that the inner circumference 251 of the output element 250 may also
comprise a surface to interface with some other gear train mechanism.
In addition, it is understood that the gear block 262 may include a
divider/alignment block (not illustrated) dividing the interface surface 263
into two
separate sections. The variant of the gear block 262 featuring the alignment
block (not
illustrated) is particularly suitable to embodiments which feature output
elements 250
comprised of circular rings.
The gear blocks 262 of the present invention are specifically designed to
enable a
greater surface area (e.g., greater number of gear teeth) to engage the output
element 250
at any given time, thereby spreading the stresses associated therein across a
greater area.
By dramatically increasing the contact area between the gear block 262 and the
output
element 250 at any given time the mechanical stress level is significantly
decreased. In
addition, the gear block 262 assemblies 260 of the present invention reduce
backlash to
zero and even preloaded conditions to create a tight connection between the
power source
and/or the powered device (not illustrated). This is an extremely desirable
feature
especially for high vibration applications. Moreover, because the stresses
associated with
engagement of the gear block 262 against the output element 250 are
distributed across a
greater area, the gear block 262 may be manufactured of lighter-weight
materials, which
are typically less expensive and easier to manufacture, with no degradation in
reliability.
For example, per Hertz Contact Theory a typical stress result for spur gears
are in
the range from 450MPa to 600MPa. High wade steels are the best fitted
materials for
handling such high stress levels Other materials like low grade steel or
aluminum will
deform under the similar conditions. However, by distributing the stresses
across a large
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areas of contact in accordance with the gearbox mechanism of the present
invention, the
levels of stress under the similar conditions can be reduced to about 20MPa.
These low
stress levels allow the gearbox mechanism of the present invention to be
manufactured
using low grade steels, aluminums or even plastics for the same application.
By reducing
its weight and size, the gearbox mechanism of the present invention is
adaptable to a
broad range of applications that were previously impractical because of weight
and space
limitations.
The cam element 230 can be coupled to an input device, power source, or other
rotating device (not illustrated) by means of an shaft, gears, belts, magnetic
fields,
friction fit, or other means of coupling. Power generated by an input device,
power
source, or other rotating device (not illustrated) can be transferred to a
shaft, gears, belts,
magnetic fields, friction fit, or other means of coupling, which causes the
cam element
230 to rotate about the central axis 206. The cam assembly 230 includes along
its planar
surface a plurality of unique pathways or grooves which each interface with
the cam
follower(s) 294 of a gear block assembly 260 so that as the cam element 230
rotates, the
movement of the gear block 262 is controlled in two dimensions in accordance
with a
certain design parameter. By varying the radius of the pathway or grooves on
the cam
element 230 the gear block assemblies 260 drive respective gear block(s) 262
through a
two-dimensional circuit in response to rotation of the cam element 230.
Broadly
speaking, the two-dimensional circuit includes urging the gear block 262 to
engage the
output element 250 and move or rotate the output element 250 a specified
distance prior
to disengaging from the output element 250, and returning back the specified
distance to
again reengage the output element 250 once again and repeat the process. The
travel path
or circuit of each gear block 262 is controlled by adjusting the size, height,
length and
configuration of the torque lever(s) 299, gear block(s) 262, and/or cam
follower(s) 294
and altering the pathways or grooves formed in the cam element 230.
For example, the pivotal connections may further include torsional spring
elements (not shown) which bias the torque lever 299, and/or gear block 262 so
that the
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cam follower 294 maintains contact with the surface of its respective pathway
or groove
236, 237 formed in the planar surface 235 of the cam element 230 throughout
the rotation
cycle of the cam element 230. Alternatively or in addition, a ring spring
connecting all of
the gear blocks 262 in a gear train may be used as a biasing mechanism in
accordance
with the present invention.
The gear block assemblies 260 are biased and/or secured so that each cam
follower 294 maintains contact with the surface of its respective pathway or
groove
formed in the cam element 230 throughout the rotation cycle of the cam element
230.
For example, cam follower 294A maintains contact with the surface of a first
pathway
236, and cam follow 294B maintains contact with the surface of a second
pathway 237.
Each pathway has a unique circumference, the radius of which varies over the
course of
the pathway.
The first pathway 236 has a first radius ri at one part of its circuit that is
greater
than a second radius r2 at another part of its circuit. This creates a unique,
undulating
path for each pathway as the cam element 230 rotates. While the cam element
230
depicted in the Figures, appears to be a single disc or unit having a
plurality of pathways
or grooves formed in the planar surface 235 of the cam element 230, it is
understood that
the cam element 230 may also comprise a plurality of separate discs, each
having a
unique pathway formed in its planar or circumferential surface, which are
mechanically
coupled to one another to assemble a single cam assembly 230.
With reference to Figs. 12A, 12B, 12C, 13, and 14, by varying the radius of
each
pathway or groove 236, 237 on the cam element 230, torque lever(s) 299 drive
their
respective gear block(s) 262 through a two-dimensional circuit in response to
rotation of
the cam element 230. In general, the two-dimensional circuit 239 includes
urging the
gear block 262 to engage the output element 250 and move or rotate the output
element
250 a specified distance prior to disengaging form the output element 250, and
returning
back the same specified distance to again reengage the output element 250 once
again
and repeat the process. It is understood that the two-dimensional circuit 239
depicted in
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the drawings is not to scale and is somewhat exaggerated to illustrate the
general
principal of the invention. For example, the distance A-B would typically be
much
smaller than depicted. The travel path or circuit 239 of each gear block 262
is controlled
by adjusting the size and configuration of the torque lever(s) 299, gear
block(s) 262,
and/or altering the pathways or grooves 236, 237 formed in the cam element
230.
When adapted to a gearbox mechanism 220, a plurality of gear block assemblies
260 are configured about the central axis 206 of the cam element 230. The cam
element
230, in at least one version, may be coupled to a power source (not
illustrated) by an
output device (not illustrated). As the cam element 230 rotates, the cam
follower(s) 294
of the respective torque lever(s) 299 and/or gear block(s) 262 of each gear
block
assembly 260 maintain contact with a particular pathway or groove 236, 237
formed in
the planar surface 235 of the cam element 230. The variance of distance from
the center
of rotation of the different pathways or grooves 236, 237 of the cam element
230 causes
the torque lever(s) 299 pivotally attached to a cam follower(s) 194 to work in
concert to
move their respective gear block(s) 262 through a predetermined circuit of
movement
239. This predetermined circuit of movement 239 of the gear block 260 can be
precisely
calibrated to meet specific engineering requirements. For example, the torque
ratio and
speed reduction may be regulated and controlled by adjusting the circuit of
movement
239 of each gear block assembly 260.
Numerous embodiments of gearbox mechanisms are possible using the gear block
assembly 260 of the present invention. All embodiments of gearbox mechanisms
constructed in accordance with the present invention feature a plurality of
gear block
assemblies 260 configured about the central axis 206 of the cam element 230
and may
comprise either an odd or even number of gear block assemblies 260. At least
two, and
preferably three gear block assemblies are required for a gearbox mechanism of
the
present invention. The movement of the gear block assemblies 260 typically
moves in a
rotational series to one another.
However, in a preferred embodiment of the present invention wherein the
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plurality of gear block assemblies comprises four or more even-number gear
block
assemblies 260, the gear block assemblies 260 configured on opposing sides of
the cam
element 230 engage and disengage in unison from the secondary or output
element 250.
For example, an embodiment of the gearbox mechanism 220 may feature four gear
block
assemblies 260. Similarly, another embodiment of the gearbox mechanism 220 may
feature six gear block assemblies 260. This is accomplished by ensuring that
the
individual pathways or grooves formed in the planar surface of the cam element
are in
phase with one another along the planer surface of the cam element.
It will now be evident to those skilled in the art that there has been
described
herein an improved gearbox mechanism. Although the invention hereof has been
described by way of a preferred embodiment, it will be evident that other
adaptations and
modifications can be employed without departing from the spirit and scope
thereof. The
terms and expressions employed herein have been used as terms of description
and not of
limitation; and thus, there is no intent of excluding equivalents, but on the
contrary it is
intended to cover any and all equivalents that may be employed without
departing from
the spirit and scope of the invention.
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