1. Roller Gearing and Power Transmission Mechanism
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Roller Gearing and Power Transmission Mechanism
Pál Bogár
Sincroll Drive Technologies 1
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2. Agenda The Innovative Idea - what new we do
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Agenda
The Innovative Idea - what new we do
Realisation of the Idea - how we do it
Example Designs - what it can be used for
Benefits and Advantages - why we do it / how good it can get
Prototype Tests - how much we achieved so far
Potential Applications - what business potential we foresee
The Sincroll Company - who we are: business, skills, facilities
Potential for Collaboration - what Nissan and us can do together 2
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3. The Innovative Idea Brand new technology
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The Innovative Idea
Brand new technology
- 4 months in the market
Trivial problem – non-trivial solution
Rollers connect the wheels
wheels do not connect directly
(there are no “teeth”)
Rollers roll along grooves on both wheels simultaneously
rigid coupling between the wheels
Rollers do pure rolling motion without sliding
ensured by the shape of the grooves 3
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4. Realisation of the Idea
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Realisation of the Idea
Force and torque are transmitted through the contact points between the rollers and the grooves
Properly selected line of contact points i.e. the curve of the grooves ensure proper forces acting and thus pure rolling motion
The ensemble of grooves determines the shape of the wheel 4
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5. Realisation of the Idea - continued
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Realisation of the Idea - continued
Complex physics
G: the roller (ball)
P1, P2: contact points between the balls and the wheels
gp: path travelled by the ball’s centre when in coupling
g1, g2: paths travelled by the contact points
u, v: various velocity vectors
w1, w2: angular velocity vectors of the two wheels 5
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6. non-intersecting axes axes angle = 90o gearing ratio = 1:1
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non-intersecting axes
axes angle = 90o
gearing ratio = 1:1
ball diameter = 4mm
contact factor = 8 6
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7. intersecting axes axes angle = 90o gearing ratio = 11:15
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intersecting axes
axes angle = 90o
gearing ratio = 11:15
ball diameter = 4mm
contact factor = 9 7
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8. parallel axes axes angle = 0o gearing ratio = 12:23
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parallel axes
axes angle = 0o
gearing ratio = 12:23
ball diameter = 4mm
contact factor = 8 8
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9. direction of rotation = same gearing ratio = 1:5 ball diameter = 4mm
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parallel axes
direction of rotation = same
gearing ratio = 1:5
ball diameter = 4mm
contact factor = 9 9
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10. direction of rotation = opposite gearing ratio = 23:25
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parallel axes
direction of rotation = opposite
gearing ratio = 23:25
ball diameter = 4mm
contact factor = 19 10
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11. non-intersecting axes axes angle = 45o gearing ratio = 1:2
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:2
ball diameter = 4mm
contact factor = 8 11
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12. non-intersecting axes axes angle = 45o gearing ratio = 1:2
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:2
ball diameter = 4mm
contact factor = 8 12
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13. non-intersecting axes axes angle = 50o gearing ratio = 13:25
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non-intersecting axes
axes angle = 50o
gearing ratio = 13:25
ball diameter = 4mm
contact factor = 18 13
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14. parallel axes gear rack axes angle = 45o gearing ratio = n/a
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parallel axes gear rack
axes angle = 45o
gearing ratio = n/a
ball diameter = 4mm
contact factor = 16 14
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15. perpendicular axes gear rack axes angle = 90o gearing ratio = n/a
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perpendicular axes gear rack
axes angle = 90o
gearing ratio = n/a
ball diameter = 4mm
contact factor = 10 15
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16. internal coupling non-intersecting axes axes angle = 45o
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internal coupling non-intersecting axes
axes angle = 45o
gearing ratio = 1:2
ball diameter = 5mm
contact factor = 7 16
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17. micro-rollers non-intersecting axes axes angle = 45o
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micro-rollers non-intersecting axes
axes angle = 45o
gearing ratio = 1:5
ball diameter = 0mm
contact factor = 8 17
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18. worm gear axes angle = 90o gearing ratio = 1:50 ball diameter = 4mm
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worm gear
axes angle = 90o
gearing ratio = 1:50
ball diameter = 4mm
contact factor = n/a 18
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19. planetary gear system axes angle = collinear gearing ratio = 1:300
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planetary gear system
axes angle = collinear
gearing ratio = 1:300
ball diameter = 4mm
contact factor = 8 19
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20. Main Advantages Three main advantages – plus their implications …
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Main Advantages
Three main advantages – plus their implications …
Power efficiency close to 100%
due to pure rolling motion done by the rollers
sliding friction is practically eliminated
Contact factor up to 20 or more
load distributes over many rollers
Back-lash free
easy to eliminate back-lash by forcing the wheels together
compromise in performance i.e. efficiency in-significant 20
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21. Implied Advantages High power efficiency High contactor factor
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Implied Advantages
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
Special shape (e.g. very thin) - more flexibly adjustable
Higher power density
Smoother and steadier movements
Precise movements
Lower noise
Greater reliability
No back-lash
Precise movements
Less vibrations and resonances
Longer lifetime 21
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22. Other Selected Features
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Other Selected Features
Flexibility in design
more control parameters for the designer
a richer and more adjustable system
one gear problem but many solutions
New framework – new intuition
conventional gear design intuition may not work here
this is more like a generalised ball screw or roller bearing
Lot of potential for further R&D advances in the future
e.g. optimisation of roller movement, parallel grooves, non-ball rollers, micro roller “liquid” etc.
a lot of applications need to be developed 22
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23. Other Selected Features - continued
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Other Selected Features - continued
Performance determined on the “micro” level at the contact of the rollers and the grooves
performance relatively insensitive to overall gear geometry
e.g. can change gearing ratio without changing the wheel diameters directly
can also change direction of rotation without adding extra wheels
Hertz stress benign
curvature of balls and grooves are similar and are the same sign
point-like contact expands into a surface-like contact and Hertz stress drops
yet frictional losses do not increase much because of low relative velocities of the (now sliding) contact surfaces 23
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Prototype Tests
Prototype tested was 1:10 ratio, non-intersecting, 45o axes
Made of steel with nitriding finish of grooves surfaces
Made by Sincroll
Test lab was at the Budapest University of Technology
Tests supervised by the Department of Machine and Product Design
Tests performed: All this was done:
Basic checks of operations With and without back-lash
Kinematics and noise checks For both directions of rotation
Static power efficiency For both directions of load
Dynamic power efficiency For various angular velocities
Movement precision 24
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25. non-intersecting axes T E S T P R O T O T Y P E axes angle = 45o
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non-intersecting axes T E S T P R O T O T Y P E
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19 25
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26. non-intersecting axes axes angle = 45o gearing ratio = 1:10
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19 26
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27. non-intersecting axes axes angle = 45o gearing ratio = 1:10
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19 27
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28. non-intersecting axes axes angle = 45o gearing ratio = 1:10
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19 28
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29. non-intersecting axes axes angle = 45o gearing ratio = 1:10
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non-intersecting axes
axes angle = 45o
gearing ratio = 1:10
ball diameter = 4mm
contact factor = 19 29
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The Test Rig 30
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31. Test Data for Movement Precision
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Test Data for Movement Precision 31
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32. Summary of Test Results
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Summary of Test Results
Basic operations, kinematics, noise and reliability
no particular issues, performance was quite good in all respect
All tests were insensitive (in terms of statistical significance) to
changing direction of rotation
changing the direction of the load
and whether the back-lash was eliminated or not
Static efficiency at least 98% - this was independent of
roller recycling device being in place or not
back-lash has been eliminated or not (surprise!) 32
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33. Summary of Test Results
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Summary of Test Results
Dynamic efficiency
first measurement 92%
after improving the surface quality of the roller recycling channel the efficiency went up to 94%
groove surfaces were sub-optimal as a result of nitriding
we will re-test again soon with polished groove finish and improved roller recycling device
Movement precision showed a periodic structure that where the periodicity was the same as the period of revolutions of the larger wheel in the gear. This shows there was a manufacturing error in the larger wheel.
the error was about +/- 0.2 degrees – looks like a normal amount of inaccuracy and should not be a cause for alarm
we want to retest with a higher precision electronics to see if anything else besides the larger wheel has an effect on precision 33
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34. parallel axes A L U M I N I U M P R O T O T Y P E axes angle = 0o
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parallel axes A L U M I N I U M P R O T O T Y P E
axes angle = 0o
gearing ratio = 26:23
ball diameter = 4mm
contact factor = 8 34
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35. parallel axes axes angle = 0o gearing ratio = 26:23
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parallel axes
axes angle = 0o
gearing ratio = 26:23
ball diameter = 4mm
contact factor = 8 35
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36. Potential Applications
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Potential Applications
High-power drives
due to low operating costs, small size and great reliability
All Vehicles
due especially to high efficiency and high power density
Material handling machines
due especially to smaller starting torque
Machine tools
due to no back-lash
an alternative to ball-screw drives
Wind power generators
high energy efficiency, high gear-up ratio and backlash-free adjustments
Standard gear and transmission families 36
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37. Applicable Industries
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Applicable Industries
Cement, stone and ore industries
Grinding machines, rolling mills, presses, separators, mixers, elevators etc
Chemical and environmental industries
Agitators, mixers, pumps and compressors, cooling towers, dryers, turbines, aerators and thickeners in sewage treatment etc.
Electric power generation
Wind, gas, coal, oil, water and nuclear power generators etc.
Food and agri industries
Cutters, feeders, mixers, harvesters, combines, sewage treatment machinery etc.
Machine tools industries
Table movers, rotators, dividers, gear racks, spindle drives etc. 37
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38. Applicable Industries - continued
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Applicable Industries - continued
Materials handling machines
Various kind of cranes, lifts, hoisters, elevators, escalators, excavators, conveyors, ropeways, factory assembly lines etc.
Mining industries
Excavators, conveyors, lifters, hoisters etc.
Paper, packaging and printing machines
Cutters, feeders, dryers etc.
Plastics and rubber industries
Extruders etc.
Steel and iron industries
Conveyors, elevators, metal working machinery etc. 38
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39. Applicable Industries - continued
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Applicable Industries - continued
Sugar industries
Cutters, feeders, shredders, mills etc.
Textile industries
Cutters, feeders, dryers, spinning machines etc.
Vehicles
Cars, motorbikes, bicycles: gearboxes, steering gears, differential gears etc.
Trucks and special purpose vehicles: gearboxes, steering gears, differential gears etc.
Railway vehicles such as trams, locomotives, regional railways, metro-underground etc.
Ships and boats: gearboxes, generators, dredger drives etc.
Airplanes, fixed and rotating wings
Wood and forestry industries
Special purpose vehicles, cranes, conveyors etc. 39
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40. The Sincroll Company Our primary business is This includes
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The Sincroll Company
Our primary business is
research and development
commercialisation
technology transfer of the new roller gear technology
This includes
continued independent work same as what we have been doing thus far
as well as new collaborations with partners via e.g. license agreements
Our skills and tens of years of experience are in design and development including
theoretical research and computer design and simulation
applications design and development, evaluation, lab experiments and testing 40
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41. The Sincroll Company - continued
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The Sincroll Company - continued
Our management skills come from years of scientific research, corporate and entrepreneurial experiences
We also have direct access to limited but high-quality machining facilities
we manufacture high-quality prototypes and perform basic tests
we also do production on a relatively small scale (secondary business)
In this way we can offer a wide range of services to our customers and our partners
starting from basic R&D, theoretical and experimental work
all the way up to prototype and equipment manufacture and pilot and small scale production 41
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42. Potential for Collaboration
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Potential for Collaboration
Looking for a partner is a new idea
we came to the market four months ago only
Following about five years of intensive R&D
We believe the technology is mature enough now to be successfully applied in commercial applications
We need partners to help us to find the best applications that we can develop with the ultimate target of a commercial product in the focus
We also need partners to contribute in the partnership with production capacity and skills as well as market knowledge, sales and marketing networks and customer relationships 42
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43. Potential for Collaboration – continued
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Potential for Collaboration – continued
In return we provide the technology through e.g. a licence agreement as well as our R&D and pilot production services in order to progress the developments of the technology further 43
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44. THANK YOU 44