Roller Gearing and Power Transmission Mechanism Pl Bogr

Roller Gearing and Power Transmission Mechanism Pál Bogár Sincroll Drive Technologies 1

Agenda • The Innovative Idea • Realisation of the Idea • Example Designs - what new we do • Benefits and Advantages • Prototype Tests • Potential Applications - why we do it / how good it can get • The Sincroll Company • Potential for Collaboration - who we are: business, skills, facilities - how we do it - what it can be used for - how much we achieved so far - what business potential we foresee - what Nissan and us can do together 2

The Innovative Idea Brand new technology Trivial problem – non-trivial solution - 4 months in the market • 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

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

Realisation of the Idea - continued Complex physics G: the roller (ball) P 1, P 2: contact points between the balls and the wheels gp: path travelled by the ball’s centre when in coupling g 1, g 2: paths travelled by the contact points u, v: various velocity vectors w 1, w 2: angular velocity vectors of the two wheels 5

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

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

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

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

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

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

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

non-intersecting axes angle = 50 o gearing ratio = 13: 25 ball diameter = 4 mm contact factor = 18 13

parallel axes gear rack axes angle = 45 o gearing ratio = n/a ball diameter = 4 mm contact factor = 16 14

perpendicular axes gear rack axes angle = 90 o gearing ratio = n/a ball diameter = 4 mm contact factor = 10 15

internal coupling non-intersecting axes angle = 45 o gearing ratio = 1: 2 ball diameter = 5 mm contact factor = 7 16

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

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

planetary gear system axes angle = collinear gearing ratio = 1: 300 ball diameter = 4 mm contact factor = 8 19

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

Implied Advantages High power efficiency High contactor factor No back-lash • • • • 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 • • • Smaller size Special shape (e. g. very thin) - more flexibly adjustable Higher power density Smoother and steadier movements Precise movements Lower noise Greater reliability • Precise movements Less vibrations and resonances Longer lifetime 21

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

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

Prototype Tests • • • Prototype tested was 1: 10 ratio, non-intersecting, 45 o 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: – – – Basic checks of operations Kinematics and noise checks Static power efficiency Dynamic power efficiency Movement precision All this was done: - With and without back-lash For both directions of rotation For both directions of load For various angular velocities 24

non-intersecting axes angle = 45 o gearing ratio = 1: 10 ball diameter = 4 mm contact factor = 19 TEST PROTOTYPE 25

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

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

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

non-intersecting axes angle = 45 o gearing ratio = 1: 10 ball diameter = 4 mm contact factor = 19 29

The Test Rig 30

Test Data for Movement Precision 0. 3 Error in Degrees 0. 2 0. 1 0. 0 -0. 1 -0. 2 -0. 3 0 10 20 29 Number of Revolutions of the Smaller Wheel 39 49 31

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

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

parallel axes ALUMINIUM axes angle = 0 o gearing ratio = 26: 23 ball diameter = 4 mm contact factor = 8 PROTOTYPE 34

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

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

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

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

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

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

The Sincroll Company - continued • Our management skills come from 10 -20 years of scientific research, corporate and entrepreneurial experiences • We also have direct access to limited but high-quality machining facilities – we manufacture high-quality prototypes and perform basic tests – we also do production on a relatively small scale (secondary business) • In this way we can offer a wide range of services to our customers and our partners – starting from basic R&D, theoretical and experimental work – all the way up to prototype and equipment manufacture and pilot and small scale production 41

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

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

THANK YOU 44