1. xxx
Roller Gearing and Transmission Technology Pál Bogár sincroll - drive technologies ltd London
xxx

2. Agenda - 45mins The Innovative Idea - what new do we do
xxx
Agenda - 45mins
The Innovative Idea what new do we do
Realisation of the Idea how do we do it
Design Examples what variety can we do
Concept Prototype Tests - facts and proofs so far
Benefits and Advantages - why should it be used
Potential Applications - where could it be used
Running Application Projects - who got interested so far
The Sincroll Company - our business, skills and facilities
xxx

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

4. Realisation of the Idea
xxx
Realisation of the Idea
More like a ball screw than a conventional toothed-wheel gear
Forces transmit via “single” contact points between rollers and grooves
lines of contact points determine the lines of the grooves and the shape of the wheels
cross-sectional shape of the grooves is irrelevant
lines of grooves are key to ensure proper forces for pure rolling motion
Hertzian stress is well contained
curvatures of rollers and grooves are similar near the contact point
xxx

5. Realisation of the Idea (cont’d)
xxx
Realisation of the Idea (cont’d)
Complex physics
G: roller (ball)
P1, P2: contact points between the balls and the wheels
gp: path travelled by the ball’s centre when in coupling
g1, g2: paths travelled by the contact points
u, v: various velocity vectors
w1, w2: angular velocity vectors of the two wheels
xxx

6. Design Examples The technology is …
xxx
Design Examples
The technology is …
universally applicable to any gearing problem
any shaft angles
crossing or non-crossing axes
internal or external coupling
planetary systems and worm gears
linear drives and gear racks
highly flexible and rich in design
for any given gearing problem, provides a variety of solutions
highly optimisable and customisable
very different from conventional
it is more like a generalised ball screw or roller bearing
xxx 6

7. non-intersecting axes axes angle = 90o gearing ratio = 1:1
xxx
non-intersecting axes
axes angle = 90o
gearing ratio = 1:1
ball diameter = 4mm
contact factor = 8
Page 7
xxx

8. intersecting axes axes angle = 90o gearing ratio = 11:15
xxx
intersecting axes
axes angle = 90o
gearing ratio = 11:15
ball diameter = 4mm
contact factor = 9
Page 8
xxx

9. parallel axes axes angle = 0o gearing ratio = 12:23
xxx
parallel axes
axes angle = 0o
gearing ratio = 12:23
ball diameter = 4mm
contact factor = 8
Page 9
xxx

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

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

12. parallel axes gear rack axes angle = 45o gearing ratio = n/a
xxx
parallel axes gear rack
axes angle = 45o
gearing ratio = n/a
ball diameter = 4mm
contact factor = 16
Page 12
xxx

13. perpendicular axes gear rack axes angle = 90o gearing ratio = n/a
xxx
perpendicular axes gear rack
axes angle = 90o
gearing ratio = n/a
ball diameter = 4mm
contact factor = 10
Page 13
xxx

14. internal coupling non-intersecting axes axes angle = 45o
xxx
internal coupling non-intersecting axes
axes angle = 45o
gearing ratio = 1:2
ball diameter = 5mm
contact factor = 7
Page 14
xxx

15. micro-rollers non-intersecting axes axes angle = 45o
xxx
micro-rollers non-intersecting axes
axes angle = 45o
gearing ratio = 1:5
ball diameter = 0mm
contact factor = 8
Page 15
xxx 15

16. Concept Prototype Tests
xxx
Concept Prototype Tests
The prototype tested was the 1:10 non-intersecting axes, 45o setup
Made of steel with nitriding finish of grooves surfaces
Test lab at the Budapest University of Technology
Tests supervised by the Department of Machine and Product Design
Tests performed: All this was done:
Basic checks of operations With and without back-lash
Kinematics and noise checks For both directions of rotation
Static power efficiency For both directions of load
Dynamic power efficiency For various angular velocities
Movement precision
Reliability
xxx

17. non-intersecting axes T E S T P R O T O T Y P E axes angle = 45o
xxx
non-intersecting axes T E S T P R O T O T Y P E
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19
Page 17
xxx

18. non-intersecting axes T E S T P R O T O T Y P E axes angle = 45o
xxx
non-intersecting axes T E S T P R O T O T Y P E
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19
Page 18
xxx 18

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

20. xxx
The Test Rig
xxx

21. Test Data for Movement Precision
xxx
Test Data for Movement Precision
xxx

22. Summary of Test Results
xxx
Summary of Test Results
Basic operations, kinematics, noise and reliability
no particular issues, performance was quite good in all respect
All tests were insensitive (in terms of statistical significance) to
changing direction of rotation
changing the direction of the load
and whether the back-lash was eliminated or not
Static efficiency at least 98% - this was independent of
roller recycling device being in place or not
back-lash has been eliminated or not (surprise!)
Dynamic efficiency at least 94%
groove surfaces were sub-optimal as a result of nitriding
we will re-test again soon with polished groove finish and improved roller recycling device
xxx

23. Summary of Test Results (cont’d)
xxx
Summary of Test Results (cont’d)
Movement precision showed a periodic structure where the periodicity was the same as the period of revolutions of the larger wheel in the gear. This shows there was a manufacturing error in the larger wheel.
the error was about +/- 0.2 degrees – looks like a normal amount of inaccuracy and should not be a cause for alarm
we want to retest with a higher precision electronics to see if anything else besides the larger wheel has an effect on precision
xxx

24. parallel axes A L U M I N I U M P R O T O T Y P E
xxx
parallel axes A L U M I N I U M P R O T O T Y P E
axes angle = 0o ( n o t t e s t e d )
gearing ratio = 26:23
ball diameter = 4mm
contact factor = 8
Page 24
xxx 24

25. parallel axes A L U M I N I U M P R O T O T Y P E
xxx
parallel axes A L U M I N I U M P R O T O T Y P E
axes angle = 0o ( n o t t e s t e d )
gearing ratio = 26:23
ball diameter = 4mm
contact factor = 8
Page 25
xxx 25

26. Benefits and Advantages
xxx
Benefits and Advantages
Power efficiency close to 100%
due to pure rolling motion done by the rollers
sliding friction is practically eliminated
Contact factor up to 20 or more
load distributes over many rollers
Back-lash eliminated
easy to eliminate back-lash by forcing the wheels together
efficiency loss is in-significant
… and implications of these
xxx

27. Implied Advantages (Expected)
xxx
Implied Advantages (Expected)
High power efficiency
No sliding friction
Lower energy losses
Lower starting torque
Smaller motor needed
Friendlier to the environment – a green technology
Lower operating costs
Reduced heating up
Reduced abrasion
Less cooling and lubrication needed
Less wear and deterioration
Longer lifetime
Less vibration and noise
High contactor factor
Smaller size
Higher power density
Smoother and steadier movements
Precise movements
Lower noise
Greater reliability
No back-lash
Precise movements
Less vibrations and resonances
Longer lifetime
xxx

28. Potential Applications
xxx
Potential Applications
Applicable in all areas of mechanical gearing and power transmission
Including any / high or low:
torque o ratio o precision o rpm o size
For example:
High-power drives
due to low operating costs, small size and good reliability
All vehicles
due especially to high efficiency, high power density, special shape and long lifetime
Material handling machines
due especially to smaller actuating torque and reliability
Machine tools
due to eliminated back-lash
alternative to ball-screw drives
Wind power generators
due to high energy efficiency, high gear-up ratio, no back-lash
Standard gear families
especially worm gears and bevel gears due to high efficiency and compact size, respectively
xxx 28

29. Running Application Projects
xxx
Running Application Projects
Car transmission, 5 fwd+1 back
Parallel axes, complex setup
Car rear axle hypoid gears
Right-angle
Intersecting axes
Non-intersecting axes
Twin-wheel
Car parts
Window lifter
Engine starter
Truck rear axle hypoid gears
Same as car hypoid gears
Railway traction drives
Also parallel axes
Wind turbines
Yaw and pitch drives
Main gearbox
Machine tools
Turning tables
Aviation
Flight control drives/actuators
General industrial
Worm gears
Parallel-shaft gears
Planetary gears
Right-angle “bevel” gears
Linear actuators
Precision drives
Plastic gears
Miniature gears
xxx 29

30. The Sincroll Company Our primary business
xxx
The Sincroll Company
Our primary business
of the new roller gear technology
research and development
commercialisation and transfer
Our design and development skills
twenty years of experience in
scientific research
computer aided design and simulations
applications design and development, evaluation and testing
Our management skills
corporate management
entrepreneurial and start-up management
xxx 30

31. The Sincroll Company (cont’d)
xxx
The Sincroll Company (cont’d)
Access to machining facilities
manufacture of high-quality prototypes
build test equipment and perform basic tests
produce on a relatively small scale, pilot runs
Access to suppliers
local market knowledge
supplier contacts, networks and relationships
twenty years of experience, track record
Wide range of services
basic R&D, theoretical and experimental work
specifications and analysis, advisory and design
prototype and applications manufacture and testing
production advisory and outsourcing
technology licensing
xxx 31