U.S. patent application number 12/526770 was filed with the patent office on 2010-04-15 for continuously variable transmissions and methods therefor.
This patent application is currently assigned to FALLBROOK TECHNOLOGIES INC.. Invention is credited to Jeremy Carter, David Kieke, Charles Lohr, Brad Pohl.
Application Number | 20100093479 12/526770 |
Document ID | / |
Family ID | 39524756 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100093479 |
Kind Code |
A1 |
Carter; Jeremy ; et
al. |
April 15, 2010 |
CONTINUOUSLY VARIABLE TRANSMISSIONS AND METHODS THEREFOR
Abstract
Inventive embodiments are directed to components, subassemblies,
systems, and/or methods for continuously variable transmissions
(CVT) having a variator provided with a plurality of tilting,
traction planets and traction rings. In one embodiment, a variator
is coupled to a rangebox to provide multiple operating modes. In
another embodiment, a hydraulic system is configured to control the
transmission ratio of the variator and the rangebox. Various
inventive shift-cam-and-sun subassemblies can be used to facilitate
shifting of the transmission ratio of a CVT. Embodiments of a
transmission housing and bell housing are adapted to house
components of a CVT and, in some embodiments, to cooperate with
other components of the CVT to support operation and/or
functionality of the CVT. Various related devices include
embodiments of, for example, a pivot arm, a control feedback
mechanism, axial force generation and management mechanisms, a
control valve integral with an input shaft, a pivot pin hub, and a
rotatable carrier configured to support planet-pivot arm
assemblies. FIG. 72 shows a torque-split ball-type rolling traction
CVT with a ball-type rolling traction variator (1200) and planetary
gearset (1400) which is followed by a rangebox (1600).
Inventors: |
Carter; Jeremy; (Austin,
TX) ; Lohr; Charles; (Austin, TX) ; Pohl;
Brad; (Leander, TX) ; Kieke; David; (Austin,
TX) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET, FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Assignee: |
FALLBROOK TECHNOLOGIES INC.
San Diego
CA
|
Family ID: |
39524756 |
Appl. No.: |
12/526770 |
Filed: |
February 7, 2008 |
PCT Filed: |
February 7, 2008 |
PCT NO: |
PCT/US08/53347 |
371 Date: |
August 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60889512 |
Feb 12, 2007 |
|
|
|
Current U.S.
Class: |
475/159 ; 476/38;
476/8 |
Current CPC
Class: |
F16H 37/084 20130101;
F16H 15/503 20130101; F16H 2037/0886 20130101; F16H 15/28
20130101 |
Class at
Publication: |
475/159 ; 476/8;
476/38 |
International
Class: |
F16H 37/08 20060101
F16H037/08; F16H 15/28 20060101 F16H015/28; F16H 57/04 20100101
F16H057/04 |
Claims
1. A drive comprising: a prime mover; and a transmission coupled to
the prime mover, wherein the transmission comprises: a continuously
variable unit (CVU); an input interface coupled to the prime mover
and to the CVU; an output interface coupled to the CVU; and a
parallel branch for mechanical power transmission, said parallel
branch coupled to the input interface and to the output
interface.
2. The drive of claim 1, wherein the CVU comprises a plurality of
spherical traction rollers.
3. The drive of claim 2, further comprising a lubrication system
operably coupled to the CVU, the lubrication system configured to
provide a lubricant to the spherical traction rollers.
4. The drive of claim 2, wherein the transmission further comprises
a rangebox coupled to the output interface.
5. The drive of claim 4, wherein the output interface comprises a
combining device.
6. The drive of claim 5, wherein the combining device comprises a
planetary gearset.
7.-14. (canceled)
15. A transmission comprising: a plurality of traction rollers; a
carrier assembly operably coupled to the traction rollers; an input
element configured to transfer torque to the traction rollers, the
input element comprising: a load cam having bidirectional load cam
ramps; a traction ring having bidirectional load cam ramps; an
output element configured to transfer torque from the traction
rollers; a shifter assembly configured to adjust an axis of
rotation of the traction rollers; a hydraulic system operably
coupled to the shifter assembly; and a lubrication system
configured to provide lubricant to at least the traction
rollers.
16. The transmission of claim 15, wherein the hydraulic system
comprises at least one hydraulic piston.
17. The transmission of claim 16, wherein the shifter assembly
comprises at least one shift cam, and wherein the at least one
hydraulic piston is operationally coupled to the at least one shift
cam.
18. (canceled)
19. The transmission of claim 15, wherein the output element
comprises a load cam.
20. The transmission of claim 19, wherein the load cam comprises
bidirectional ramps.
21.-39. (canceled)
40. A transmission comprising: a plurality of spherical traction
rollers; a carrier assembly for supporting the traction rollers; an
input element for transferring torque to the traction rollers; an
output element for transferring torque from the traction rollers;
an axial force generator for applying a clamping force to the
spherical rollers, input element, and output element; a shifter
assembly for adjusting an axis of rotation of the spherical
traction rollers; a hydraulic system for actuating the shifter
assembly; and a lubrication system for providing lubricant to at
least the spherical traction rollers.
41.-43. (canceled)
44. The transmission of claim 40, wherein the output element
comprises a load cam.
45. The transmission of claim 44, wherein the load cam comprises
bidirectional ramps.
46.-50. (canceled)
51. The transmission of claim 40, further comprising an input
interface coupled to the input element.
52. The transmission of claim 51, further comprising an output
interface coupled to the output element.
53. The transmission of claim 52, further comprising a parallel
branch coupled to the input interface and to the output
interface.
54.-103. (canceled)
104. A center manifold for a continuously variable unit (CVU), the
center manifold comprising: a base plate having a plurality of
channels and ports for receiving and distributing control fluid and
lubricant; and a cover plate adapted to couple to the base plate,
the cover plate having a plurality of channels and ports for
receiving and distributing control fluid and lubricant.
105. The center manifold of claim 104, further comprising a
plurality of recess for clearing a plurality of traction planets of
the CVU.
106. The center manifold of claim 104, further comprising at least
one structure for locating the center manifold in a housing of the
CVU.
107.-217. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of, and herby
incorporates by reference herein in its entirety, U.S. Provisional
Application 60/889,512, filed on Feb. 14, 2007.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The disclosed invention relates generally to mechanical
power modulation and transmission. More specifically, the invention
concerns continuously variable units and transmissions,
subassemblies, components, and methods for use therewith.
[0004] 2. Description of the Related Art
[0005] In the relevant technology various types of continuously
variable transmissions (CVT) are known. The particular type of CVT
which pertains to the present disclosure is typically known as a
ball-type rolling traction CVT. Although ball-type rolling traction
CVTs have gained some acceptance in certain industrial
applications, the technology has generally been unable to overcome
technical and economic hurdles to gain a wider adoption across
multiple fields of use.
[0006] The inventive embodiments disclosed here address many of the
challenges that have prevented ball-type rolling traction CVTs from
gaining wider acceptance in the marketplace. In particular, though
certainly not limited in scope of applicability, the inventive
embodiments disclosed here provide mechanisms and methods for
employing ball-type continuously variable units and/or continuously
variable transmissions in automotive applications.
SUMMARY OF INVENTION
[0007] The systems and methods herein described have several
features, no single one of which is solely responsible for its
desirable attributes. Without limiting the scope as expressed by
the claims that follow, its more prominent features will now be
discussed briefly. After considering this discussion, and
particularly after reading the section entitled "Detailed
Description of Certain Inventive Embodiments" one will understand
how the features of the system and methods provide several
advantages over traditional systems and methods.
[0008] One aspect of the invention relates to a drive having a
prime mover and a transmission coupled to the prime mover. In one
embodiment the transmission has a continuously variable unit (CVU),
an input interface coupled to the prime mover and to the CVU, and
an output interface coupled to the CVU. The drive also has a
parallel branch for mechanical power transmission. The parallel
branch can be coupled to the input interface and to the output
interface.
[0009] Another aspect of the invention addresses a transmission
having a main shaft, an input load cam, an input traction ring, and
a first set of load cam rollers positioned between the input load
cam and the input traction ring. In one embodiment, the
transmission has a number of traction planets in contact with the
input traction ring, and the transmission has a traction sun in
contact with the traction planets. In some embodiments, the
transmission has an output traction ring in contact with the
traction planets, an output load cam, and a second number of load
cam rollers positioned between the output traction ring and the
output load cam. In one embodiment, the transmission has a
planetary gearset that has a sun gear, a ring gear, and a carrier.
The output load cam is coupled to the ring gear, and the main shaft
is coupled to the sun gear. The transmission can also have a
transfer shaft coupled to the planetary gear set carrier.
[0010] One more aspect of the invention concerns a transmission
including a number of traction rollers, a carrier assembly operably
coupled to the traction rollers, and an input element configured to
transfer torque to the traction rollers. The input element includes
a load cam and a traction ring that each has bidirectional load cam
ramps. In one embodiment, the transmission includes an output
element configured to transfer torque from the traction rollers.
The transmission also includes a shifter assembly configured to
adjust an axis of rotation of the traction rollers. In some
embodiments, the transmission includes a hydraulic system operably
coupled to the shifter assembly, and the transmission includes a
lubrication system configured to provide lubricant to at least the
traction rollers.
[0011] Yet another aspect of the invention involves a drive having
a torque converter, a main shaft coupled to the torque converter,
an input load cam coupled to the main shaft, and an input traction
ring operationally coupled to the input load cam. The drive also
includes a number of traction planets adapted to receive torque
from the input traction ring. In one embodiment, the drive includes
an output traction ring adapted to receive torque from the traction
planets and an output load cam operationally coupled to the output
traction ring. The drive also includes a planetary gearset coupled
to the output load cam and to the main shaft.
[0012] One aspect of the invention concerns a transmission having a
number of spherical traction rollers, a carrier assembly for
supporting the traction rollers, an input element for transferring
torque to the traction rollers, and an output element for
transferring torque from the traction rollers. In one embodiment,
the transmission includes an axial force generator for applying a
clamping force to the spherical rollers, input element, and output
element. The transmission includes a shifter assembly for adjusting
an axis of rotation of the spherical traction rollers. In one
embodiment, the transmission includes a hydraulic system for
actuating the shifter assembly, and the transmission includes a
lubrication system for providing lubricant to at least the
spherical traction rollers.
[0013] Another aspect of the invention relates to a continuously
variable unit (CVU) having a rotatable main shaft, an input load
cam coupled to the main shaft, an input traction ring operationally
coupled to the input load cam, and a number of traction planets in
contact with the input traction ring. In one embodiment, the CVU
includes an output traction ring in contact with the traction
planets and an output load cam operationally coupled to the output
traction ring. The CVU also includes a traction sun in contact with
the traction planets. A number of planet axles define the axes of
rotation for the traction planets. The CVU includes at least one
shift lever for each planet axle. The CVU also includes at least
one shift cam operationally coupled to the shift levers and at
least one stator configured to axially and radially support the
planet axles and the shift levers. The CVU includes at least one
control piston configured to actuate an axial movement of the at
least one shift cam, and the CVU can include a center manifold
configured to support the at least one stator. The center manifold
is also configured to provide control fluid and lubricant to the
CVU.
[0014] Yet one more aspect of the invention addresses a
continuously variable unit (CVU) having a number of traction
planets arranged angularly about a longitudinal axis of the CVU.
The CVU includes a traction sun in contact with the traction
planets and a number of planet axles coupled to the traction
planets. The planet axles define the axes of rotation for the
traction planets. The CVU includes a number of shift levers. At
least one shift lever is coupled to each planet axle. The CVU
includes a shift cam operably coupled to the shift levers, and the
CVU has a stator configured to axially and radially support the
planet axles and the shift levers. The CVU also includes at least
one control piston configured to actuate an axial movement of the
shift cam and a center manifold configured to support the stator.
The center manifold is adapted to provide a control fluid and a
lubricant to the CVU.
[0015] In another aspect, the invention concerns a continuously
variable unit (CVU) having an input element configured to receive a
power input, a number of traction members coupled to the input
element, a carrier assembly adapted to facilitate support of the
traction members, and a load-cam-and-traction-ring subassembly
configured to generate axial force. The CVU includes a shifter
assembly operably coupled to the traction members and an output
element configured to receive power from the traction members. In
one embodiment, the CVU includes a hydraulic system configured to
be in fluid communication with the shifter assembly.
[0016] Another aspect of the invention relates to a shifting
mechanism for a rolling traction transmission. The shifting
mechanism includes a traction sun, a number of shift cams, and a
number of control pistons operationally coupled to the shift cams.
In one embodiment, the traction sun is placed between the shift
cams.
[0017] One aspect of the invention relates to a control piston for
a shifting mechanism of a continuously variable unit (CVU). The
control piston includes a generally cylindrical body having a
central bore adapted to engage a piston tube. In one embodiment,
the control piston includes a piston face configured to interface
with control fluid and a surface configured to facilitate sensing
of an axial position of the control piston. Another aspect of the
invention relates to a control piston a control piston tube having
a generally cylindrical tube with a through central bore. The
control piston tube includes a surface adapted to couple to a
control piston, and the control piston tube has a surface adapted
to coupled to a shift cam.
[0018] Another aspect of the invention addresses a shift cam for a
shifting mechanism of a continuously variable unit (CVU). The shift
cam includes a central bore, a shift cam profile, and a shift cam
extension. In some embodiments, the shift cam profile is
substantially defined by the data points shown in FIG. 41. In other
embodiments, the shift cam has an angled face adapted to allow
lubricant flow. In yet other embodiments, the central bore of the
shift cam is adapted to couple to a control piston tube.
[0019] One more aspect of the invention concerns a piston tube for
use in a rolling traction transmission. The piston tube includes a
substantially annular cylindrical body having a center bore, a
first face located on the outer circumference of the annular
cylindrical body, and a second face located on the outer
circumference of the annular cylindrical body. The first face is
configured to receive a shift cam of the transmission. The second
face is configured to receive a control piston of the transmission.
The piston tube also includes an orifice located on the outer
circumference of the annular cylindrical body. The orifice is
adapted to provide a lubricant to the transmission.
[0020] Yet another aspect of the invention involves a
stator-manifold assembly having a center manifold and at least one
stator coupled to the center manifold so that the center manifold
provides, and the stator receives, control fluid and lubricant. In
some embodiments, the stator-manifold assembly includes at least
one oil galley in fluid communication with the at least one
stator.
[0021] One aspect of the invention concerns a center manifold for a
continuously variable unit (CVU). The center manifold includes a
base plate having a number of channels and ports for receiving and
distributing control fluid and lubricant. In one embodiment, the
center manifold includes a cover plate adapted to couple to the
base plate. The cover plate has a number of channels and ports for
receiving and distributing control fluid and lubricant.
[0022] Another aspect of the invention relates to a base plate for
a center manifold of a continuously variable unit (CVU). The base
plate includes a number of ports and channels for receiving and
distributing fluid, and a number of recesses for clearing one or
more traction planets of the CVU. In one embodiment, the base plate
includes one or more structures for facilitating the locating and
fastening of the base plate to a housing of the CVU. The base plate
also includes a number of channels for receiving and housing sensor
cables.
[0023] Yet one more aspect of the invention addresses a stator for
a continuously variable unit (CVU). The stator includes a number of
extensions adapted to facilitate the coupling of the stator to a
manifold. The extensions comprise one or more channels for
receiving and distributing fluid. The stator includes a tubular
body configured to form a chamber for receiving a control fluid and
a control piston. The stator also includes an extension configured
to deliver lubricant to an oil galley.
[0024] In another aspect, the invention concerns a cover plate for
continuously variable unit (CVU). The cover plate includes a
substantially circular shaped body. The circular shaped body has a
first side face, a second side face, and a cut-out pattern
configured to substantially surround an array of
planet-and-shift-lever subassemblies of the CVU. The cover plate
includes a number of lubricant channels arranged on the first side
face. The cover plate also includes a number of lubricant spray
ports positioned to be in fluid communication with the lubricant
channels.
[0025] Another aspect of the invention relates to an oil galley for
a continuously variable unit (CVU). The oil galley includes a
central bore having an annular recess for receiving fluid. In one
embodiment, the oil galley has a number of radial channels
extending substantially radially from the annular recess toward an
outer perimeter of the oil galley. The radial channels are spaced
angularly about the central bore. The oil galley also includes a
number of axial channels that extend substantially axially from
each of the radial channels.
[0026] One aspect of the invention relates to a transmission
housing having one or more structures for retaining and locating a
center manifold. The transmission housing includes a number of
ports for delivering and receiving fluids to internal components of
the transmission. In one embodiment, the transmission housing
includes a number of ports for receiving a number of sensors. The
transmission housing also includes one or more passages for
receiving one or more cam dowels configured to cooperate with
structures of the transmission housing and/or the center manifold
for retaining and locating the center manifold.
[0027] Another aspect of the invention addresses a main shaft for a
continuously variable transmission (CVT). The main shaft includes
an elongated body having a first end portion, a central portion,
and a second end portion. The main shaft includes a set of torque
converter engagement splines formed on the first end portion. A
first engagement extension extends from the torque converter
engagement splines. The main shaft includes a set of combining
device engagement splines formed on the second end portion. A
second engagement extension extends from the second end portion. In
one embodiment, the main shaft includes an axial reaction flange
located on the second end portion.
[0028] One more aspect of the invention concerns a main shaft for a
continuously variable transmission (CVT). The main shaft includes
an elongated body having a first end portion, a central portion,
and a second end portion. In one embodiment, the main shaft
includes a number of input load cam engagement splines formed on
the central portion and an axial reaction flange located on the
second end portion.
[0029] Yet another aspect of the invention involves a traction ring
for use in a continuously variable transmission. The traction ring
includes a substantially annular ring having a front face and a
back face. In one embodiment, the traction ring includes a contact
surface formed on the front face. The traction also includes a
groove formed on the back face.
[0030] One aspect of the invention concerns a load cam for use in a
continuously variable transmission (CVT). The load cam includes a
bowl shaped body having a perimeter edge portion and a hub portion.
The hub portion has a central bore. The load cam includes a
cylindrically shaped flange that is concentric with the hub
portion. In one embodiment, the load cam includes a number of ribs
radially extending from the hub portion to the perimeter edge
portion. The ribs intersect the flange. The load cam also includes
a number of bi-directional ramps formed on a face of the perimeter
edge portion.
[0031] Another aspect of the invention relates to an input load cam
shroud for use in a continuously variable transmission. The input
load cam shroud includes a bowl shaped body having a central
opening. In one embodiment, the input load cam includes several
flanges formed about the perimeter of the bowl shaped body. The
flanges form a number of shoulders that are adapted to engage a
number of mating features of a load cam of the CVT.
[0032] Yet one more aspect of the invention addresses an input load
cam assembly for use in a continuously variable transmission. The
input load cam assembly includes a load cam and a load cam shroud.
The load cam has a bowl shaped body with a perimeter edge portion
and a hub portion having a central bore. The load cam includes a
cylindrically shaped flange concentric with the hub portion and a
number of ribs extending from the hub portion to the perimeter edge
portion. The ribs intersect the flange. The load cam also includes
a number of bi-directional ramps formed on a face of the perimeter
edge portion. The load cam shroud includes a bowl shaped body
having a central opening. The load cam shroud also includes a
number of flanges formed about the perimeter of the bowl shaped
body. The flanges form a plurality of shoulders adapted to engage a
plurality of mating features of a load cam shroud of the CVT.
[0033] In another aspect, the invention concerns a load cam for use
in a continuously variable transmission. The load cam includes a
substantially bowl shaped body having a hub portion and a perimeter
edge portion. The perimeter edge portion has a front face and a
rear face. The load cam includes a number of fins arranged
angularly around the front face of the perimeter edge portion. The
load cam also includes a number of bi-directional ramps formed on a
rear face of the perimeter edge portion.
[0034] Another aspect of the invention relates to an axial lock nut
for use in a continuously variable transmission (CVT). The axial
lock nut includes a substantially cylindrical body that has a
threaded central bore, an extension portion, and a polygon-shaped
outer periphery portion. A number of notches are formed on the
outer periphery portion. The notches are configured to couple to a
dowel pin of the CVT. The axial lock nut also includes an anti-rock
piloting surface formed on the central bore.
[0035] One aspect of the invention relates to a bearing support
adapter for use in a continuously variable transmission (CVT). The
bearing support adapter includes a substantially cylindrical body
having a first face, a second face, and a central bore. In one
embodiment, the bearing support adapter has a flange extending
radially from the first face. The flange is configured to react
axial force. The bearing support adapter also includes a bearing
support surface located on the outer circumference of the
cylindrical body and a shoulder arranged on the central bore in
proximity to the first face. In one embodiment, the bearing support
adapter has a thrust bearing recess formed on the second face.
[0036] Another aspect of the invention addresses a continuously
variable transmission having a main shaft, a number of spherical
planets, a first load-cam-and-traction-ring subassembly, a second
load-cam-and-traction-ring subassembly, and a bearing support
adapter. The main shaft is arranged along a longitudinal axis of
the transmission and adapted to receive a power input. The planets
are arranged angularly about the longitudinal axis of the
transmission. The first load-cam-and-traction-ring subassembly is
operably coupled to the main shaft and to the spherical planets.
The second load-cam-and-traction-ring subassembly is operably
coupled to the spherical planets. The bearing support adapter is
coupled to the main shaft and configured to support a bearing
coupled to the second load-cam-and-traction-ring subassembly.
[0037] One more aspect of the invention concerns a
shift-cam-and-sun subassembly for a continuously variable
transmission (CVT). The shift-cam-and-sun subassembly includes a
traction sun, a shift cam operably coupled to the traction sun, and
a piston tube coupled to the shift cam. The piston tube is coaxial
with the traction sun. The shift-cam-and-sun subassembly also
includes a control piston coupled to the piston tube. The control
piston is coaxial with the traction sun.
[0038] Yet another aspect of the invention involves a traction sun
for a continuously variable transmission (CVT). The traction sun
includes a generally cylindrical body having a central bore. A
first recess is formed on the central bore, and is configured to
receive a bearing. A central shoulder is formed on the central
bore, and is in proximity to the first recess. The traction sun
also includes an exterior edge face formed on the outer
circumference of the cylindrical body. The exterior edge face
configured to be a rolling contact surface for number of traction
planets of the CVT.
[0039] One aspect of the invention concerns a shift cam for a
continuously variable transmission (CVT). The shift cam includes a
substantially disc-shaped body having a front face, a rear face,
and a central bore. In one embodiment, the shift cam has an
extension surface extending from the central bore. The shift cam
has a reference surface formed on the rear face. The shift cam also
has a shift cam profile formed on the front face. A set of
coordinates define the shape of the shift cam profile. The
coordinates are based on the reference surface and include those of
the data table shown in FIG. 41.
[0040] Another aspect of the invention relates to a cam dowel
having a substantially cylindrical body with a central bore, a
first end portion, and a second end portion. The cam dowel includes
a cam wedge formed on the first end portion. The cam dowel also
includes a substantially flat face formed on the second end
portion.
[0041] Yet one more aspect of the invention addresses a combining
device for a continuously variable transmission (CVT). The
combining device includes a transfer shaft, a hub, a number of
planet gears, a planet gear carrier, and a sun gear. The transfer
shaft is an elongated body with a first end, a second end, and a
central bore. The hub is operably coupled to the transfer shaft and
is coaxial with the transfer shaft. The planet gears are operably
coupled to the hub. The planet gear carrier is configured to
support the planet gears. In one embodiment of the combining
device, the sun gear is coupled to the planet gears. The sun gear
has a central bore configured to couple to a main axle of the
CVT.
[0042] In another aspect, the invention concerns a combining device
for use in a continuously variable transmission (CVT). The
combining device includes a hub configured to support a planetary
gear set. In one embodiment, the combining device has a first power
input portion operably coupled to the hub. The hub has a second
power input portion. The combining device also has a power output
portion operably coupled to the hub.
[0043] Another aspect of the invention relates to a continuously
variable transmission having a rotatable main shaft arranged along
the longitudinal axis of the transmission. In one embodiment, the
transmission includes a variator having a number of traction
planets arranged angularly about the longitudinal axis of the
transmission. The transmission includes a combining device operably
coupled to the variator and to the main shaft. The transmission
also includes a rangebox operably coupled to the combining
device.
[0044] One aspect of the invention relates to a rangebox for use in
a continuously variable transmission (CVT). The rangebox includes a
power input portion configured to receive power from a transfer
shaft of the CVT, and an output shaft arranged along the
longitudinal axis of the rangebox. The output shaft is configured
to transfer power out of the rangebox. The rangebox includes a
high-and-low mode subassembly configured to receive power from the
power input portion. The high-and-low mode subassembly is arranged
along the longitudinal axis of the range box and coaxial with the
output shaft. The rangebox includes a reverse mode subassembly
configured to receive power from the power input portion. The
reverse mode subassembly is operably coupled to the output shaft.
The rangebox also includes an overrun clutch operably coupled to
the high-and-low mode subassembly and arranged between the forward
clutch and the power input portion.
[0045] Another aspect of the invention addresses a planet axle for
supporting rotation of a traction roller and facilitating a tilting
of the axis of rotation. The planet axle includes a generally
cylindrical body having a through bore along a longitudinal axis of
the cylindrical body. In one embodiment, the planet axle also
includes one or more axle capturing features for engagement of a
transverse axle.
[0046] One more aspect of the invention concerns a shift lever for
a continuously variable transmission (CVT). The shift lever has an
elongated body with a first end portion and a second end portion.
The shift lever includes a first bore formed on the first end
portion. The first bore is configured to receive a planet axle of
the CVT. In one embodiment, the shift lever has a second bore
formed on the first end portion. The second bore intersects the
first bore in a substantially perpendicular location. The second
bore is configured to receive a shift guide roller axle of the CVT.
The shift lever also has an axle receiving passage formed on the
second end. The axle receiving passage is configured to receive a
shift cam roller axle of the CVT.
[0047] Yet another aspect of the invention involves a
planet-and-shift-lever mechanism for use in a continuously variable
transmission. The planet-and-shift-lever mechanism includes a
spherical planet having a central bore, a planet axle placed in the
central bore, and a first shift lever coupled to a first end of the
planet axle. In one embodiment, the planet-and-shift-lever
mechanism has a second shift lever coupled to a second end of the
planet axle and a first skew roller coupled to the first end of the
planet axle. The planet-and-shift-lever mechanism also has a second
skew roller coupled to the second end of the planet axle, a first
shift cam roller coupled to the first shift lever, and a second
shift cam roller coupled to the second shift lever.
BRIEF DESCRIPTION OF THE FIGURES
[0048] FIG. 1 is a high-level block diagram showing an embodiment
of a drive apparatus 100 that includes an inventive continuously
variable transmission and continuously variable unit.
[0049] FIG. 2 is a schematic diagram of one embodiment of
continuously variable transmission and continuously variable unit
in accordance with certain inventive teachings of the
disclosure.
[0050] FIG. 3A is a cross-sectional view of one embodiment of a
continuously variable transmission employing a continuously
variable unit.
[0051] FIG. 3B is a partially exploded view of the continuously
variable transmission of FIG. 3A.
[0052] FIG. 4 is a partial cross-section of certain components of a
continuously variable unit (CVU).
[0053] FIG. 5 is a perspective view of a shaft that can be used
with the CVU of FIG. 4.
[0054] FIG. 6 is a cross-sectional view of the shaft of FIG. 5.
[0055] FIG. 7 is a partial cross-section of certain components of
the CVU of FIG. 4.
[0056] FIG. 8 is a perspective view of a traction ring that can be
used with the CVU of FIG. 4.
[0057] FIG. 9 is a cross-sectional view of the traction ring of
FIG. 8.
[0058] FIG. 10 is a perspective view of a load cam and shroud
assembly that can be used with the CVU of FIG. 4.
[0059] FIG. 11 is a perspective view of the load cam and shroud
assembly of FIG. 10.
[0060] FIG. 12 is a partially exploded view of the load cam and
shroud assembly of FIG. 10.
[0061] FIG. 13 is a perspective view of a load cam that can be used
with the CVU of FIG. 4.
[0062] FIG. 14 is a cross-sectional view of the load cam of FIG.
13.
[0063] FIG. 15 is a perspective view of a lock nut that can be used
with the CVU of FIG. 4.
[0064] FIG. 16 is a cross-sectional view of the lock nut of FIG.
15.
[0065] FIG. 17 is a perspective view of yet another load cam that
can be used with the CVU of FIG. 4.
[0066] FIG. 18 is yet another perspective of the load cam of FIG.
17.
[0067] FIG. 19 is a cross-sectional view of the load cam of FIG.
17.
[0068] FIG. 20 is a partial cross-section of certain components of
the CVU of FIG. 4.
[0069] FIG. 21 is a perspective view of yet another load cam that
can be used with the CVU of FIG. 4.
[0070] FIG. 22 is a cross-sectional view of the load cam of FIG.
21.
[0071] FIG. 23 is another perspective view of the load cam of FIG.
21.
[0072] FIG. 24 is a perspective view of a shroud that can be used
with the CVU of FIG. 4.
[0073] FIG. 25 is a perspective view of a bearing support adapter
that can be used with the CVU of FIG. 4.
[0074] FIG. 26 is a cross-sectional view of the bearing support
adapter of FIG. 25.
[0075] FIG. 27 is a perspective view of yet another load cam that
can be used with the CVU of FIG. 4.
[0076] FIG. 28 is another perspective view of the load cam of FIG.
27.
[0077] FIG. 29 is a cross-sectional view of the load cam of FIG.
27.
[0078] FIG. 30 is a partial cross-sectional view of certain
components of the CVU of FIG. 4.
[0079] FIG. 31 is a perspective view of a planet-and-shift-lever
subassembly that can be used with the CVU of FIG. 4.
[0080] FIG. 32 is a cross-sectional view of certain components of
the planet-and-shift-lever subassembly of FIG. 31.
[0081] FIG. 33 is an exploded view of the
planet-and-shift-lever-subassembly of FIG. 32.
[0082] FIG. 34 is a perspective view of a planet axle that can be
used with the CVU of FIG. 4.
[0083] FIG. 35 is a cross-sectional view of the planet axle of FIG.
34.
[0084] FIG. 36 is a perspective view of a shift-cam-and-sun
subassembly that can be used with the CVU of FIG. 4.
[0085] FIG. 37 is a cross-sectional view of certain components of
the shift-cam-and-sun subassembly of FIG. 36.
[0086] FIG. 38 is an explode view of certain components of the
shift-cam-and-sun subassembly of FIG. 37.
[0087] FIG. 39 is a cross-sectional view of a sun that can be used
with the CVU of FIG. 4.
[0088] FIG. 40 is a cross-sectional view of a shift cam that can be
used with the CVU of FIG. 4.
[0089] FIG. 40A is a detail view A of the shift cam of FIG. 40.
[0090] FIG. 41 is a data table with data points specifying a
suitable profile for the shift cam of FIG. 40.
[0091] FIG. 42 is a cross-sectional view of a control piston that
can be used with the CVU of FIG. 4.
[0092] FIG. 43 is a perspective view of a piston tube that can be
used with the CVU of FIG. 4.
[0093] FIG. 44 is a partial, cross-sectional view of certain
components of the CVU of FIG. 4.
[0094] FIG. 45 is a perspective view of a stator-manifold
subassembly that can be used with the CVU of FIG. 4.
[0095] FIG. 46 is a cross-sectional view of certain components of
the stator-manifold of FIG. 45.
[0096] FIG. 47 is a perspective view of a center manifold that can
be used with the stator-manifold of FIG. 45.
[0097] FIG. 48 is a second perspective view of the center manifold
of FIG. 47.
[0098] FIG. 49 is a perspective view of a base plate that can be
used with the center manifold of FIG. 47.
[0099] FIG. 50 is a second perspective view of the base plate of
FIG. 49.
[0100] FIG. 51A and FIG. 51B are perspective views of a cam dowel
that can be used with the CVU of FIG. 4 and the stator-manifold
subassembly of FIG. 45.
[0101] FIG. 52 is a plan view of a cover plate that can be used
with the center manifold of FIG. 47.
[0102] FIG. 53 is a perspective view of the cover plate of FIG.
52.
[0103] FIG. 54 is a perspective view of a stator that can be used
with the CVU of FIG. 4.
[0104] FIG. 55 is a second perspective view of the stator of FIG.
54.
[0105] FIG. 56 is a cross-sectional view of the stator of FIG.
54.
[0106] FIG. 57 is yet another cross-sectional view of the stator of
FIG. 54.
[0107] FIG. 58 is yet another cross-sectional view of the stator of
FIG. 54.
[0108] FIG. 59 is side view of the stator of FIG. 54.
[0109] FIG. 60 is a perspective view of an oil galley that can be
used with the CVU of FIG. 4.
[0110] FIG. 61 is a second perspective view of the oil galley of
FIG. 60.
[0111] FIG. 62 is a cross-sectional view of the oil galley of FIG.
60.
[0112] FIG. 63 is a partial, cross-sectional view of certain
components of the CVU of FIG. 4.
[0113] FIG. 64 is a yet another cross-sectional view of certain
components of the CVU of FIG. 4.
[0114] FIG. 65 is a perspective view of a bell housing and certain
components of an input interface that can be used with
transmissions of FIGS. 1, 2, and 3A.
[0115] FIG. 66 is a cross-sectional, partial perspective view of
the bell housing of FIG. 65.
[0116] FIG. 67 is a partially explode view of certain components of
the bell housing and input interface of FIG. 65.
[0117] FIG. 68 is a perspective view of a combining device that can
be use with the transmission o FIG. 3A.
[0118] FIG. 69 is a side view of the combining device of FIG.
68.
[0119] FIG. 70 is a cross-sectional view of the combining device of
FIG. 68.
[0120] FIG. 71 is a partially exploded view of certain components
of the combining device of FIG. 67.
[0121] FIG. 72 is a schematic diagram of a continuously variable
unit adapted to cooperate with a rangebox.
[0122] FIG. 73 is a perspective view of one embodiment of a range
box that can be used with the CVU of FIG. 4 and/or the transmission
of FIG. 3A.
[0123] FIG. 74 is a cross-sectional view of the rangebox of FIG.
73.
[0124] FIG. 75 is a perspective view of a rear housing that can be
used with the transmission of FIG. 3A.
[0125] FIG. 76 is a cross-sectional, perspective view of certain
components and features of the rear housing of FIG. 75.
[0126] FIG. 77 is a plan view of the bottom side of the rear
housing of FIG. 75.
DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS
[0127] Certain inventive embodiments will now be described with
reference to the accompanying figures, wherein like numerals refer
to like elements throughout. The terminology used in the
description presented herein is not intended to be interpreted in
any limited or restrictive manner simply because it is being
utilized in conjunction with a detailed description of certain
specific embodiments of the invention. Furthermore, embodiments of
the invention may include several novel features, no single one of
which is solely responsible for its desirable attributes or which
is essential to practicing the inventions herein described. The
CVT/IVT embodiments described here are generally related to
transmissions and variators disclosed in U.S. Patent Application
60/890,438, the entire disclosure of which is hereby incorporated
herein by reference.
[0128] As used here, the terms "operationally connected,"
"operationally coupled", "operationally linked", "operably
connected", "operably coupled", "operably linked," and like terms,
refer to a relationship (mechanical, linkage, coupling, etc.)
between elements whereby operation of one element results in a
corresponding, following, or simultaneous operation or actuation of
a second element. It is noted that in using said terms to describe
inventive embodiments, specific structures or mechanisms that link
or couple the elements are typically described. However, unless
otherwise specifically stated, when one of said terms is used, the
term indicates that the actual linkage or coupling may take a
variety of forms, which in certain instances will be obvious to a
person of ordinary skill in the relevant technology.
[0129] For description purposes, the term "radial" is used here to
indicate a direction or position that is perpendicular relative to
a longitudinal axis of a transmission or variator. The term "axial"
as used here refers to a direction or position along an axis that
is parallel to a main or longitudinal axis of a transmission or
variator. For clarity and conciseness, at times similar components
labeled similarly (for example, control piston 582A and control
piston 582B) will be referred to collectively by a single label
(for example, control pistons 582).
[0130] FIG. 1 is a high-level block diagram showing an embodiment
of a drive apparatus 100, which is referred to herein as the drive
100. In some embodiments, the drive 100 includes a transmission 101
operationally coupled between a prime mover 102 and a load 114. The
prime mover 102 delivers power to the transmission 101, and the
transmission 101 delivers power to the load 114. The prime mover
102 can be one or more of any number of power generating devices,
and the load 114 can be one or more of any number of driven devices
or components. Examples of the prime mover 102 include, but are not
limited to, engines, motors and the like. Examples of loads
include, but are not limited to, drivetrain differential
assemblies, power take-off assemblies, generator assemblies, pump
assemblies, and the like.
[0131] In one embodiment, the transmission 101 includes an input
interface 104, a variator 106, a parallel branch 108 (for example,
a fixed ratio branch), an output interface 110, and a rangebox 112.
The input interface 104 is operationally coupled to the prime mover
102. The variator 106 and the parallel branch 108 can be
operationally coupled in parallel between the input interface 104
and the output interface 110. The rangebox 112 is operationally
coupled between the output interface 110 and the load 114.
[0132] The input interface 104 can be configured for receiving
power from the prime mover 102 and transferring such power to the
variator 106 and the parallel branch 108 in a distributed manner.
The output interface 110 can be configured for combining power
(that is, torque applied at a given rotational speed) from the
variator 106 and the parallel branch 108 and transferring such
combined power to the rangebox 112. It is disclosed herein that
neither the input interface 104 nor the output interface 110 is
necessarily limited to a particular respective physical and/or
operational configuration. Accordingly, the input interface 104 may
include any gearing or coupling structure suitable for providing
such distributed power transfer and distribution functionality, and
the output interface 110 may include any gearing or coupling
structure suitable for providing such combined power transfer
functionality. Examples of the input interface 104 include, but are
not limited to, a torque converter assembly, a hydraulic clutch
coupling, a manually actuated clutch assembly, a
computer-controlled clutch assembly, a magnetorheological clutch
coupling, and the like.
[0133] The parallel branch 108 can be configured for enabling power
distributed thereto from the input interface 104 to be directly
transferred to the output interface 110 without any selective
variation (that is, adjustment) of rotational speed and/or
rotational direction associated with that power. However, in other
embodiments, the parallel branch 108 can be configured to modulate
power in discrete (that is, stepped) or continuously variable
modes. The variator 106 can be configured for enabling power
distributed thereto from the input interface 104 to be transferred
to the output interface 110 in a manner whereby torque and/or
rotational speed associated with that power is selectively variable
(that is, selectively adjustable). Accordingly, a torque split unit
in accordance with one embodiment of the present invention
comprises the variator 106 and the parallel branch 108 and provides
for two power paths between the input interface 104 and the output
interface 110. A first one of the power paths extends through the
variator 106 and a second one of the power paths extends through
the parallel branch 108. As will be discussed below in greater
detail, power distribution between the two power paths is dependent
upon a selectively variable ratio of an input power specification
of the variator 106 (for example, input torque and input rotational
shaft speed) with respect to an output power specification of the
variator 106 (for example, output torque and output rotational
shaft speed). One reason for implementing a split torque unit is to
increase a torque capacity of the transmission 101. For example,
during a duty cycle that requires a high torque output, it is
desirable to route a majority of such high torque through the
parallel branch 108 thereby precluding torque carrying components
of the variator 106 from having to experience long periods of high
torque application. Preferably, but not necessarily, a transmission
in accordance with the present invention is of a split torque type.
However, it is disclosed herein that the parallel branch 108 may,
in some embodiment of the present invention, be omitted such that
power is transferred between the input interface 104 and the output
interface 110 solely through the variator 106.
[0134] The rangebox 112 provides various gear selection and clutch
engagement functionalities. Examples of such gear selection
functionality include, but are not limited to, selective engagement
of available rangebox gear ratios and selective engagement of
various load drive directions. Examples of such clutch engagement
functionality include, but are not limited to, passive
implementation of various clutch engagement operations and active
implementation of various clutch engagement operations.
[0135] Referring to FIG. 2 now, one embodiment of the transmission
101 will be described. As shown in FIGS. 1 and 2, the input
interface 104 can serve as a torque interface for receiving an
applied input torque at a given rotational speed or range of
rotational speeds from the prime mover 102. Through the input
interface 104, the applied input torque is delivered to the
variator 106 and the parallel branch 108 in a distributed manner.
Torque is distributed dependent upon a torque ratio setting of the
variator 1200.
[0136] As discussed above, the parallel branch 108 can be
configured to receive power from the input interface 104 and to
distribute that power directly to the output interface 110 without
any selective variation of rotational speed and/or rotational
direction associated with that power. In one embodiment, the
parallel branch 108 includes a shaft rotatably coupled between the
input interface 104 and the output interface 110 for transferring
power from the input interface 104 and the output interface 110
without any selective variation of rotational speed and/or
rotational direction associated with that power.
[0137] As shown in FIG. 2, in one embodiment the variator 106 can
include traction members 202, an input element 204, a shifter
assembly 206, an axial force generator (AFG) 208, a carrier
assembly 210, a hydraulic system 212, a lubrication system 214, and
an output element 216. The input element 204, the shifter assembly
206, the axial force generator 208, the carrier assembly 210, the
lubrication system 214, and the output element 216 are
operationally coupled to the traction members 202. The hydraulic
system 212 is operationally connected to the shifter assembly 206
and is configured for adjusting a torque ratio setting of the
variator 106. The input element 204 is operationally coupled to the
input interface 104 for receiving power from the input interface
104. Power is transmitted from input element 204 to the output
element 216 through the traction members 202. Power is output from
the variator 106 through the output element 216, being delivered to
the output interface 110.
[0138] The carrier assembly 210 provides for physical placement and
support of the traction members 202. The shifter assembly 206
provides functionality for selectively manipulating the traction
members 202, thereby enabling a ratio of input torque exerted on
the input element 204 to output torque exerted on the output
element 216 (that is, the torque ratio) to be selectively varied in
a continuous, or stepless, manner. In doing so, the shifter
assembly 206 enables the amount of torque transferred jointly by
the variator 106 and the parallel branch 108 between the input
interface 104 and the output interface 110 to be selectively
varied. The hydraulic system 212 can be configured for
hydraulically controlling the shifter assembly 206 to vary the
torque ratio. The lubrication system 214 can be configured to
deliver a lubricant to, among other things, mechanical interfaces
between traction members 202, the input element 204, and the output
element 216. In one embodiment, the lubrication system 214 is
adapted to provide lubricant to the rangebox 112. The axial force
generator 208 can be configured for exerting a force (for example,
clamping force, axial force, etc.) to keep the input element 204
and the output element 216 in sufficient contact with the traction
members 202, thereby limiting slippage at points of contact
therebetween. In some embodiments, the axial force generator 208
can cooperate with, or be at least partly operationally coupled
with the hydraulic system 212.
[0139] Still referring to FIG. 2, in one embodiment, the rangebox
112 includes a first rangebox structure 220 configured for varying
a gear range, a second rangebox structure 222 configured for
adjusting a load drive direction, and a third rangebox structure
224 configured to protect against load overrun conditions. The
first rangebox structure 220 preferably facilitates selective
adjustment between a rangebox high gear ratio (for example,
relatively low torque output exerted at a relatively high
rotational speed) and a rangebox low gear ratio (for example,
relatively high torque output exerted at a relatively low
rotational speed), which increases the overall gear ratio range of
the transmission 101. The second rangebox structure 222 can be
configured to facilitate selective adjustment between a first
rotary drive direction (for example, corresponding to driving the
load 114 in a forward operational direction) and a second rotary
drive direction (for example, corresponding to driving the load 114
in a reverse operational direction). The third rangebox structure
224 is adapted to facilitate mechanical slippage in the case where
the load 114 attempts to back drive the prime mover 102 through the
transmission 101.
[0140] Passing to FIGS. 3A and 3B now, various aspects of a
transmission 600 will now be discussed. In one embodiment, the
transmission 600 can include a torque converter subassembly 800, a
main shaft 1000, a variator 1200, a combining device 1400, a
rangebox 1600, and a transmission housing 1800. The transmission
housing 1800 can include a bell housing 1810 (that is, a first
housing portion) and a rear housing 1820 (that is, a second housing
portion) separably connected to the bell housing 1810. In the
embodiment illustrated, the torque converter subassembly 800, the
main shaft 1000, the variator 1200, the combining device 1400, and
the rangebox 1600 are operably mounted on or within the
transmission housing 1800 in an axially aligned manner. Thus, it is
disclosed herein that the transmission housing 1800 is configured
for housing and supporting various subassemblies and/or components
of the transmission 600. In other embodiments, any one of the
torque converter subassembly 800, the variator 1200, the combining
device 1400, and the rangebox 1600 can be arranged in a parallel
shaft configuration relative to the other components.
[0141] In some embodiments, the variator 1200 and the main shaft
1000 can be operably coupled between a power output portion of the
torque converter subassembly 800 and power input portions of the
combining device 1400. In operation, the torque converter
subassembly 800 transfers power to the variator 1200 through the
main shaft 1000. The variator 1200 supplies power to a first power
input portion 1410 of the combining device 1400. The main shaft
1000 supplies power to a second power input portion 1405 of the
combining device 1400. Power from the variator 1200 and the main
shaft 1000 can be supplied to the combining device 1400 in a
selectively variable ratio (for example, power from the variator
1200 in relation to power from the main shaft 1000) and can be
combined by the combining device 1400. The combining device 1400
delivers the combined power to the rangebox 1600 via a power output
portion 1401 of the combining device 1400. The power output portion
1401 can include a carrier of planetary gear set and/or a transfer
shaft.
[0142] In one embodiment, the variator 1200 mounts on the main
shaft 1000. In one configuration, the variator 1200 and the main
shaft 1000 form a torque split unit. More specifically, the ratio
of torque transferred to the combining device 1400 through the
variator 1200 or through the main shaft 1000 is selectively
variable dependent upon a torque ratio setting of the variator
1200. To this end, the variator 1200 transfers power to the
combining device 1400 in a manner whereby the torque and/or the
rotational speed associated with that power is selectively and
continuously variable (that is, adjustable). Thus, the variator
1200 can be configured for receiving power of a first specification
(for example, first torque and first rotational shaft speed) and
outputting power of a second specification (for example, second
torque and second rotational shaft speed).
[0143] The torque converter subassembly 800 is one embodiment of an
input interface 104, for example, thereby providing the
functionality of transferring power from a prime mover attached to
the torque converter subassembly 800 to the variator 1200 via, for
example, the main shaft 1000. In other embodiments, a different
type of input interface such as, for example, a manually controlled
clutch subassembly, a computer controlled clutch assembly, or a
flywheel can be implemented in place of the torque converter
subassembly 800. The combining device 1400 is an embodiment of an
output interface, thereby providing the functionality of combining
power received from the variator 1200 and the main shaft 1000 and
transferring such power to the rangebox 1600. In one embodiment,
the rangebox 1600 receives power from the combining device 1400 and
outputs power in conjunction with providing one or more of the
various gear selection and clutch engagement functionalities
discussed above in reference to FIGS. 1 and 2. As is discussed
further below, the rangebox 1600 in combination with the variator
1200 enables the transmission 600 to operate in multiple modes
(that is, a multi-mode transmission).
[0144] Referring to FIGS. 3A and 4, in one embodiment, the variator
1200 can include an input load-cam-and-traction-ring subassembly
2000A, an output load-cam-and-traction-ring subassembly 2000B, an
array of planet-and-shift-lever subassemblies 2100, a
shift-cam-and-sun subassembly 2200, and a stator-manifold
subassembly 2300. In one embodiment, the shift-cam-and-sun
subassembly 2200 is supported by the stator-manifold subassembly
2300. The shift-cam-and-sun subassembly 2200 is supported in a
manner enabling the shift-cam-and-sun subassembly 2200 to be
translated along a longitudinal axis LA1 of the main shaft 1000.
The planet-and-shift-lever subassemblies 2100 are arrayed angularly
around the main shaft 1000, and are supported jointly by the
shift-cam-and-sun subassembly 2200 and the stator-manifold
subassembly 2300. Each one of the planet-and-shift-lever
subassemblies 2100 is supported in a manner that facilitates
synchronous rotation of all the planet-and-shift-lever
subassemblies 2100 about a respective reference axis TA1 extending
through a planet 2102 of each one of the planet-and-shift-lever
subassemblies 2100. Through such synchronous rotation, all of the
planet-and-shift-lever subassemblies 2100 are in the same relative
rotational position at a given point in time. The axis TA1 (see
FIG. 4) associated with each one of the planet-and-shift-lever
subassemblies 2100 extends through a center point of the respective
planet 2102 substantially perpendicular to a radial reference axis
RA1 extending from the longitudinal axis LA1 through the center
point of the respective planet 2102.
[0145] In some embodiments, the main shaft 1000 includes a first
end portion 1005, a central portion 1010 and a second end portion
1015. The first end portion 1005 couples to a power output portion
805 of the torque converter assembly 800 (for example, an output
hub of a converter turbine) in a manner precluding relative
rotation of the main shaft 1000 with respect to the power output
portion 805. The central portion 1010 of the main shaft 1000
couples to the input load-cam-and-traction-ring subassembly 2000A
in a manner precluding relative rotation of the main shaft 1000
with respect to the input load-cam-and-traction-ring subassembly
2000A. The second end portion 1015 of the main shaft 1000 couples
to the first power input portion 1405 of the combining device 1400
in a manner precluding relative rotation of the main shaft 1000
with respect to the first power input portion 1405. The output
load-cam-and-traction-ring subassembly 2000B of the variator 1200
couples to a second power input portion 1410 of the combining
device 1400 in a manner precluding relative rotation of the output
load-cam-and-traction-ring subassembly 2000B with respect to the
second power input portion 1410. Thus, the main shaft 1000 is
suitably configured for transferring power from the torque
converter subassembly 800 (a) directly to the combining device
1400, and (b) to the combining device 1400 through the variator
1200.
[0146] Each of the planets 2102 is located by the input
load-cam-and-traction-ring subassembly 2000A, the output
load-cam-and-traction-ring subassembly 2000B, and the
shift-cam-and-sun subassembly 2200. The main shaft 1000 can be
configured to exert torque on the input load-cam-and-traction-ring
subassembly 2000A. Through traction at a respective input traction
interface TI1 between the input load-cam-and-traction-ring
subassembly 2000A and each planet 2102, torque is exerted by the
input load-cam-and-traction-ring subassembly 2000A on the planets
2102, thereby causing each planet 2102 to rotate about a respective
planet axle 2104 (see FIG. 4). The input traction interface TI1 is
defined, as used here, at a region of contact between the input
load-cam-and-traction-ring subassembly 2000A and the respective
planet 2102.
[0147] Through traction at a respective output traction interface
TI2 between the input load-cam-and-traction-ring subassembly 2000B
and each planet 2102, torque is exerted by the planets 2102 on the
output load-cam-and-traction-ring subassembly 2000B, thereby
causing the output load-cam-and-traction-ring subassembly 2000B to
rotate about the main shaft 1000. The output traction interface TI2
is defined, as used here, at a region of contact between the output
load-cam-and-traction-ring subassembly 2000B and the respective
planet 2102. As shown in FIG. 3A, the output
load-cam-and-traction-ring subassembly 2000B can be coupled to the
combining device 1400. Accordingly, torque can be transferred from
the main shaft 1000 to the combining device 1400 through the
variator 1200.
[0148] As discussed above in reference to FIGS. 3A and 3B, the
ratio of torque transferred to the combining device 1400 through
the variator 1200 or through the main shaft 1000 can be selectively
variable dependent upon the torque ratio of the variator 1200. The
torque ratio refers to a relative position of the input traction
interface TI1 and the output traction interface TI2, relative to
the axis LA2, for a given tilt of the planet-and-shift-lever
subassemblies 2100. When the tangential surface velocity of the
planets 2102 at the input traction interface TI1 is the same as the
tangential surface velocity of the planets 2102 at the output
traction interface TI2, the torque ratio is substantially equal to
1 and there is no corresponding torque multiplication. Through
tilting of the planet-and-shift-lever subassemblies 2100, the ratio
of the tangential surface velocity of the planets 2102 at the input
traction interface TI1 to that of the tangential surface velocity
of the planets 2102 at the output traction interface TI2 is
selectively adjustable. As discussed further below, the
shift-cam-and-sun subassembly can be configured such that
translation of the shift-cam-and-sun subassembly 2200 causes such
tilt of the planet-and-shift-lever subassemblies 2100. The
direction of tilt of the planet-and-shift-lever subassemblies 2100
from the position corresponding to the torque ratio of 1 dictates
whether the torque multiplication is greater than 1 (that is,
torque output is greater than torque input) or less than 1 (that
is, torque input is greater than torque output).
[0149] As depicted in FIGS. 3A and 4, the input traction interface
TI1 and the output traction interface TI2 are angularly equidistant
relative to a radial reference axis RA1 extending through the
tangential reference axis TA1. As a result, the torque ratio is 1
when a longitudinal axis LA2 of each planet 2102 is parallel with
the longitudinal axis LA1 of the main shaft 1000. Such an
equidistant configuration provides for a balanced adjustment range
such that full adjustment of the planet-and-shift-lever
subassemblies 2100 in a first adjustment direction results in the
same absolute torque multiplication value as full adjustment in a
second direction. In other embodiments, the input traction
interface TI1 and the output traction interface TI2 may be
non-equidistant from the reference axis TA1 when the torque ratio
is 1.0 and the longitudinal axis LA2 is parallel with the
longitudinal axis LA1. Such a non-equidistant configuration
provides for biasing of the adjustment range such that full
adjustment of the planet-and-shift-lever subassemblies 2100 in the
first adjustment direction results in a different absolute torque
multiplication value than full adjustment in the second adjustment
direction.
[0150] Referring now to FIGS. 3A and 4-6, in one embodiment the
variator 1200 can be axially constrained on the main shaft 1000
between an axial reaction flange 1020 of the main shaft 1000 and an
axial lock nut 1305 (FIG. 4). The axial lock nut 1305 includes a
threaded bore configured for mating with a corresponding threaded
portion 1025 of the main shaft 1000. The axial reaction flange 1020
can be fixedly attached to the main shaft 1000 adjacent the second
end portion 1015 of the main shaft 1000. The threaded portion 1025
can be an integral component of the main shaft 1000, adjacent to
the central portion 1010 of the main shaft 1000. In one embodiment,
the main shaft 1000 includes an anti-rock piloting surface 1028
configured for engaging a mating anti-rock piloting surface of the
axial lock nut 1305 for limiting rocking of the axial lock nut 1305
with respect to the main shaft 1000.
[0151] A first engagement extension 1030 at the first end portion
1005 of the main shaft 1000 can be configured for engaging or
supporting a bearing assembly 810 (FIG. 3A) that interfaces with
certain components of the torque converter subassembly 800 or other
support member. A second engagement extension 1035 at the second
end portion 1015 of the main shaft 1000 can be configured for
engaging or supporting a bearing assembly 1415 (FIG. 3A) that
interfaces with certain components of the combining device 1400. In
some embodiments, the bearing assemblies 810, 1415 include each
only a bushing or a bearing component. In other embodiments, the
bearing assemblies 810, 1415 each include a bushing or a bearing
component and a seal component configured to engage a mating
surface of the respective engagement extension 1030, 1035.
[0152] Referring to FIGS. 5 and 6, the first end portion 1005 of
the main shaft 1000 can include torque converter engaging splines
1040 configured to couple to mating splines of the power output hub
of the torque converter assembly 800. The central portion 1010 of
the main shaft 1000 includes input load cam engaging splines 1045
configured to couple to mating splines of the
input-load-and-traction-ring subassembly 2000A (that is, a power
input portion) of the variator 1200. The second end portion 1015 of
the main shaft 1000 can include combining device engaging splines
1050 configured to couple to mating splines of the first power
input portion 1405 of the combining device 1400. Thus, the main
shaft 1000 can be configured for transferring power from the torque
converter subassembly 800 directly to the combining device 1400,
and to the combining device 1400 through the variator 1200. A
splined coupling is one example of a coupling suitable for
precluding relative rotation of the main shaft 1000 with respect to
the power output portion of the torque converter subassembly 800,
the power input portion of the variator 1200, and the first power
input portion 1405 of the combining device 1400. However, other
couplings can be used. A key and mating engagement coupling is
another example of a suitable coupling.
[0153] In one embodiment, the main shaft 1000 can include a first
channel 1055 (FIGS. 3A, 4 and 6) for facilitating flow of a
transmission fluid from the power output portion 805 of the torque
converter subassembly 800 to an interface between the main shaft
1000 a transmission oil pump 806 (FIG. 3A) of the torque converter
subassembly 800. The main shaft 1000 can include a second channel
1060 for enabling flow of lubricant to the variator 1200 and/or to
the combining device 1400.
[0154] Referring now to FIGS. 7-14, in one embodiment the input
load-cam-and-traction-ring subassembly 2000A can include an input
load cam 2005A, an input traction ring 2010A, a plurality of input
load cam rollers 2015A (FIG. 7), and an input load cam shroud
2020A. In one embodiment, the input load cam 2005A is in splined
engagement with the main shaft 1000, thereby facilitating the
transfer of torque from the main shaft 1000 to the input load cam
2005A. The input load cam 2005A can be configured to transfer
torque to an input traction ring 2010A via the plurality of input
load cam rollers 2015A. The input load cam rollers 2015A are
engaged between the input load cam 2005A and the input traction
ring 2010A. The input traction ring 2010A can be positioned between
the input load cam rollers 2015A and the planets 2102. Torque
applied to the input load cam 2005A by the main shaft 1000 is
transferred from the input load cam 2005A to the input traction
ring 2010A through the load cam rollers 2015A.
[0155] In one embodiment, the input load cam 2005A can include a
generally bowl-shaped body 2052A (see FIGS. 10-11) having a hub
portion 2054A and a perimeter edge portion 2056A. In one
embodiment, the hub portion 2054A includes a central bore 2058A
having internal splines configured for mating with the input load
cam engaging splines 1045 (FIG. 5) of the main shaft 1000, thereby
supporting the input load cam 2005A and enabling power to be
transferred from the main shaft 1000 to the variator 1200.
[0156] In one embodiment, a set of bi-directional ramps 2060A can
be provided in a rear face 2062A of the perimeter edge portion
2056A. The ramps 2060A can be configured for receiving one of the
input load cam rollers 2015A (FIG. 7) and cooperates with the
respective input load cam roller 2015A for applying an axial force
and a tangential force on the input traction ring 2010A. In other
embodiments, a cam roller retainer (not shown) can be provided to
receive and support the input load cam rollers 2015. Through such
cooperation, rotation of the input load cam 2005A causes the input
load cam rollers 2015A to urge the input traction ring 2010A into
compressive engagement with the planets 2102 and to urge the input
traction ring 2010A into rotation about the longitudinal axis LA1
of the main shaft 1000, thereby providing for torque transfer from
the input load cam 2005A to the planets 2102 via the input traction
ring 2010A.
[0157] Referencing FIGS. 8 and 9, in one embodiment, the input
traction ring 2010A has a generally annular ring shape with a front
face 2061A and a back face 2063A. The input traction ring 2010A
includes a contact surface 2065A that engages the planets 2102 (one
shown in FIG. 7). The input traction interface TI1 is the region of
contact between the contact surface 2065A of the input traction
ring 2010A and each one of the planets 2102 (one shown in FIG. 7).
Through traction at each input traction interface TI1 torque
imparted to the input traction ring 2010A by the input load cam
2005A is transferred to the planets 2102, thereby causing each
planet 2102 to rotate about the respective planet axle 2104.
Preferably, but not necessarily, traction at each input traction
interface TI1 is provided through an elastohydrodynamic layer
formed by a traction fluid. The contact surface 2065A is generally
angled relative to the front face 2061A, such that the profile of
the contact surface 2065A mates efficiently with a curvature of
each planet 2102. The angle of inclination between the front face
2061A and the contact surface 2065A can be between about 5 degrees
and 75 degrees, more preferably between about 15 degrees and 65
degrees, even more preferably between about 30 degrees and 55
degrees, and most preferably between about 35 degrees and 50
degrees.
[0158] The back face 2063A can include a radiused groove 2067A
configured for receiving the load cam rollers 2015A to facilitate
torque transfer from the input load cam 2005A to the input traction
ring 2010A. It is disclosed herein that an input traction ring can
include the set of bi-directional ramps, and an input load cam can
include the radiused groove. In other embodiments, the input
traction ring and the input load cam both have ramps.
[0159] Referring to FIGS. 12-14, in some embodiments, radially
extending ribs 2064A can be attached to a front face 2066A of the
body 2052A, extending generally from the perimeter edge portion
2056A to the hub portion 2054A. A cylindrically shaped flange 2068A
extends from the front face 2066A. The cylindrically shaped flange
2068A intersects the radially extending ribs 2064A. The radially
extending ribs 2064A and the cylindrically shaped flange 2068A
jointly and individually enhance stiffness of the bowl-shaped body
2052A and serve as cooling fins for dissipating heat. Furthermore,
in some embodiments, the radially extending ribs 2064A can be used
to facilitate the sensing of rotational speed of the input load cam
2005A.
[0160] Referencing FIGS. 11, 12, and 14, a recess 2070A in a front
face 2071A of the hub portion 2054A is configured for receiving an
anti-rocking device 2072A (FIG. 12) such as, for example, a
bushing, a bearing or a sleeve, which serves to limit rocking of
the input load cam 2005A with respect to the main shaft 1000. A
preloading spring recess 2076A and a thrust bearing recess 2078A
are provided in a rear face 2079A of the hub portion 2054A. The
preload spring recess 2076A is configured for receiving a
preloading spring 2083A (FIG. 7), and the thrust bearing recess
2078A is configured for receiving a thrust bearing 2085A (FIG. 7).
Jointly, such a preloading spring and thrust bearing arrangement
serves to exert a reactive preload force between the input load cam
assembly 2000A, the stator-manifold subassembly 2300 and the output
load cam assembly 2000B when the preloading spring 2083A is
compressed. Examples of the preloading spring 2083A include, but
are not limited to, a Bellville washer, a wavy washer, a helical
compression spring and other suitably configured spring members.
Examples of the thrust bearing 2085A include, but are not limited
to, a roller thrust bearing, a thrust bushing, and other devices
suitably configured for carrying a thrust load.
[0161] Referring now to FIGS. 7, 12, 14, 15 and 16, a plurality of
dowel pin holes 2069A (FIGS. 12 and 14) in the front face 2071A can
be configured for receiving one or more dowel pins (not shown) to
facilitate coupling of the axial lock nut 1305 (FIGS. 7, 15 and 16)
to the input load cam 2005A for preventing unintentional loosening
of the axial lock nut 1305. As shown in FIGS. 15 and 16, the axial
lock nut 1305 can have a threaded bore 1306 configured for engaging
the corresponding threaded portion 1025 of the main shaft 1000. In
on embodiment, the axial lock nut 1305 can be provided with a
polygonal-shaped (for example, hexagonal) outer periphery portion
1307 configured to engage a tool for manipulating the axial lock
nut 1305. A plurality of notches 1309 (for example, dowel engaging
features) can be provided in the outer periphery portion 1307 for
engaging dowels (not shown) received within one of the dowel pin
holes 2069A. Such engagement facilitates selective angular
positioning and constraining of the axial lock nut 1305 with
respect to the load input cam 2005A, which is useful for preventing
unintentional loosening of the axial lock nut 1305. A
circumferential groove 1311 exposed at an exterior surface 1312 of
the axial lock nut 1305 can be configured to receive a retaining
device (not shown) such as, for example, a snap ring to retain the
one or more dowels within respective ones of the dowel pin holes
2069A. When engaged within the circumferential groove 1311, the
retaining device prevents the dowels from unintentionally backing
out of the respective dowel pin holes 2069A. An extension portion
1313 of the axial lock nut 1305 includes an anti-rock piloting
surface 1315 (that is, a reaction surface) that engages the mating
anti-rock piloting surface 1028 (FIG. 5) of the main shaft 1000 for
limiting rocking of the axial lock nut 1305 with respect to the
main shaft 1000.
[0162] As shown in FIGS. 7 and 10-14, the input load cam shroud
2020A includes a bowl-shaped body 2082A having perimeter flanges
2084A. The input load cam shroud 2020A is mountable over the front
face 2066A of the input load cam 2005A. When so mounted, each one
of the perimeter flanges 2084A can be positioned between a
respective adjacent pair of the radially extending ribs 2064A, and
the hub portion 2054A is exposed within a central opening 2086A of
the body 2082A. The radially extending ribs 2064A can include a
recessed portions 2088A (FIG. 12) that receives a shoulder 2090A
(FIG. 12) extending between adjacent ones of the perimeter flanges
2084A. The input load cam shroud 2020A can be mounted on the input
load cam 2005A to, among other things, reduce the potential for the
radially extending ribs 2064A to generate unwanted fluid dynamics
(for example, air and/or lubricant drag).
[0163] FIGS. 17-19 show an alternative embodiment of an input load
cam, which is referred to herein as the input load cam 3005A. The
input load cam 3005A is suitably configured for being used in place
of the input load cam 2005A discussed above with reference to FIGS.
4 and 13-14. The input load cam 3005A includes a generally
bowl-shaped body 3052A having a hub portion 3054A and a perimeter
edge portion 3056A. In some embodiments, the body 3052A has a
conical shape. The hub portion 3054A can include a central bore
3058A having splines configured to mate with splines of the central
portion 1010 of the main shaft 1000 (FIG. 4), thereby facilitating
power transfer from the main shaft 1000 to the variator 1200. A set
of bi-directional ramps 3060A can be provided in a rear face 3062A
of the perimeter edge portion 3056A. The ramps 3060A can be
configured for receiving the input load cam rollers 2015A (FIG. 7)
and to cooperate with the input load cam rollers 2015A for applying
an axial force and a tangential force on the input traction ring
2010A. Through such cooperation, the ramps 3060A facilitate torque
transfer from the input load cam 3005A to the input traction ring
2010A.
[0164] Radial fins 3064A can be attached to a front face 3066A of
the body 3052A, extending outwardly from the perimeter edge portion
3056A. The radial fins 3064A serve, among other things, as cooling
fins for dissipating heat. Furthermore, the radial fins 3064A can
be used for facilitating the sensing of the rotational speed of the
input load cam 3005A. The input load cam shroud 2020A of FIGS.
10-12 is compatible with the input load cam 3005A. The input load
cam shroud 2020A can be mounted on the input load cam 3005A;
however, in some embodiments, the input load cam shroud 2020A is
not used.
[0165] A recess 3070A (FIGS. 11, 12 and 14) in a front face 3071A
of the hub portion 3054A can be configured for receiving an
anti-rock device such as, for example, the anti-rock device 3072A
shown in FIG. 12. A preloading spring recess 3076A and a thrust
bearing recess 3078A are provided in a rear face 3079A of the hub
portion 3054A. The preloading spring recess 3076A is configured for
receiving the preloading spring 2083A (FIG. 7), and the thrust
bearing recess 3078A is configured for receiving the thrust bearing
2085A (FIG. 7). Jointly, such a preloading spring and thrust
bearing arrangement serves to, among other things, exert a reactive
preload force between the input load cam assembly 2000A, the
stator-manifold subassembly 2300, and the output load cam assembly
2000B. A plurality of dowel pin holes 3069A (FIGS. 18 and 19) in
the front face 3071A can be configured for receiving dowel pins
(not shown) to facilitate coupling of the axial lock nut 1305
(FIGS. 7, 15 and 16) to the input load cam 3005A for preventing
unintentional loosening of the axial lock nut 1305.
[0166] Referring now to FIGS. 20-26 the output
load-cam-and-traction-ring subassembly 2000B can include an output
load cam 2005B, an output traction ring 2010B, a plurality of
output load cam rollers 2015B (FIG. 20), an output load cam shroud
2020B, an output load cam bearing assembly 2022B, and a bearing
support adapter 2024B. The output load cam 2005B can be mounted on
the main shaft 1000 through use of the output load cam bearing
assembly 2022B and the bearing support adapter 2024B. As shown in
FIG. 20, the output load cam bearing assembly 2022B fits between
the output load cam 2005B and the bearing support adapter 2024B. In
one embodiment, the output load cam bearing assembly 2022B can be
axially constrained by corresponding structural features of the
output load cam 2005B and the bearing support adapter 2024B.
[0167] Referencing FIGS. 25-26, in one embodiment, the bearing
support adapter 2024B can include a central bore 2025B configured
for engaging a mating surface 1065 (FIGS. 5 and 20) of the main
shaft 1000. The bearing support adapter can include a shoulder
2026B configured to abut against the axial reaction flange 1020 of
the main shaft 1000 to react axial loads that arise in the variator
1200. The shoulder 2026B is accessible through a first face 2016B
of the bearing support adapter 2024B. The bearing adapter 2024B can
be mounted on the main shaft 1000 by, for example, an interference
fit, press fit, or close tolerance clearance fit with the mating
support surface 1065 of the main shaft 1000. A flange 2027B of the
bearing support adapter 2024B can be adapted to react axial loads
from the output load cam bearing assembly 2022B. In one embodiment,
the bearing support adapter 2024B can include a piloting surface
2029B that pilots on, or alternatively provides clearance with
respect to, the axial reaction flange 1020. The bearing support
adapter 2024B can include a recess 2077B for receiving and
supporting a spring 2087B (see FIG. 20). The spring 2087B can be a
Bellville spring for providing preloading.
[0168] A bearing support surface 2028B of the bearing support
adapter 2024B can be configured to support the output load cam
bearing assembly 2022B. The bearing support adapter 2024B can
include a preloading spring recess 2076B and a thrust bearing
recess 2078B, which are both accessible through a second face 2018B
of the bearing support adapter 2024B. The preloading spring recess
2076B is configured for receiving a preloading spring 2083B (FIG.
20), and the thrust bearing recess 2078B is configured for
receiving a thrust bearing 2085B (FIG. 20). Jointly, such a
preloading spring and thrust bearing arrangement serves to exert a
reactive preload force between the input load cam assembly 2000A,
the stator-manifold subassembly 2300, and the output load cam
assembly 2000B, when the preloading spring 2083B is compressed.
Examples of the preloading spring 2083B include, but are not
limited to, a Bellville washer, a wavy washer, a helical
compression spring, and other suitably configured spring members.
Examples of the thrust bearing 2085B include, but are not limited
to, a roller thrust bearing, a thrust bushing, and other devices
suitably configured for carrying a thrust load. In some
embodiments, the thrust bearing recess 2078B receives a bearing
race adapted to cooperate with a needle bearing, which couples to a
bearing race 4243 that is integral with, or positioned adjacent to,
the stator 4200 (see FIG. 56).
[0169] In one embodiment, the output load cam 2005B is coupled to
the output traction ring 2010B via the output load cam rollers
2015B, which can be positioned between the output load cam 2005B
and the output traction ring 2010B. The output traction ring 2010B
is placed between the output load cam rollers 2015B and the planets
2102. Torque exerted on the output traction ring 2010B by the
planets 2102 is transferred from the output traction ring 2010B to
the output load cam 2005B through the load cam rollers 2015B.
[0170] In some embodiments, the output load cam 2005B can include a
generally bowl-shaped body 2052B having a hub portion 2054B and a
perimeter edge portion 2056B. The hub portion 2054B includes a
central bore 2058B having splines 2059B configured to mate with
splines of the second power input portion 1410 of the combining
device 1400 (FIG. 3A), thereby facilitating power transfer from the
variator 1200 to the combining device 1400. The hub portion 2054B
can also include a bearing recess 2057B configured for receiving an
outer race of the output load cam bearing assembly 2022B (FIG.
20).
[0171] A set of bi-directional ramps 2060B is provided in a rear
face 2062B of the perimeter edge portion 2056B. The ramps 2060B can
be configured for receiving the output load cam rollers 2015B (FIG.
20) and for cooperating with the output load cam rollers 2015B for,
among other things, applying an axial force on the output traction
ring 2010B. Through such cooperation, rotation of the output
traction ring 2010B causes the output load cam rollers 2015B to
urge the output traction ring 2010B into compressive engagement
with the planets 2102 and to urge the output load cam 2005B into
rotation about the longitudinal axis LA1 of the main shaft 1000,
thereby providing for torque transfer from the planets 2102 to the
output load cam 2005B. Radially extending ribs 2064B can be
attached to a front face 2066B of the body 2052B, extending
generally from the perimeter edge portion 2056B to the hub portion
2054B. The radially extending ribs 2064B enhance stiffness of the
body 2052B and serve as cooling fins for dissipating heat, among
other things. Furthermore, the radially extending ribs 2064 can be
used for facilitating the sensing of rotational speed of the output
load cam 2005B. In some embodiments, the output load cam 2005B can
include a hub portion 2054B configured to engage the second power
input portion 1405 of the combining device 1400 in a manner
precluding relative rotation of the output load cam 2005B with
respect to the second power input portion 1405. In this manner, the
interface between the output load cam 2005B and the second power
input portion 1405 enables power transfer from the variator 1200 to
the combining device 1400.
[0172] As shown in FIGS. 20 and 24, in one embodiment, the output
load cam shroud 2020B can include a bowl-shaped body 2082B having
perimeter flanges 2084B. The output load cam shroud 2020B is
mountable over the front face 2066B of the output load cam 2005B.
When so mounted, each one of the perimeter flanges 2084B is
positioned between a respective adjacent pair of the radially
extending ribs 2064B, and the hub portion 2054B of the output load
cam 2005B is exposed within a central opening 2086B of the body
2082B. The radially extending ribs 2064B can include a recessed
portions 2088B (FIG. 24) that receive shoulders 2090B extending
between adjacent ones of the perimeter flanges 2084B. The shroud
2020B can be mounted on the output load cam 2005B to, among other
things, reduce the potential for the radially extending ribs 2064B
to generate undesired fluid dynamics.
[0173] FIGS. 27-29 show an alternative embodiment of an output load
cam, which is referred to herein as the output load cam 3005B. The
output load cam 3005B is suitably configured for being used in
place of the output load cam 2005B discussed above in reference to
FIGS. 4 and 20-23. In one embodiment, the output load cam 3005B
includes a generally bowl-shaped body 3052B having a hub portion
3054B and a perimeter edge portion 3056B. The hub portion 3054B
includes a central passage 3058B having splines 3059B configured to
mate external splines of the second power input portion 1405 of the
combining device 1400, thereby facilitating power transfer from the
variator 1200 to the combining device 1400. In one embodiment, the
hub portion 3054B can also include a bearing recess 3057B
configured for receiving an outer race of the output load cam
bearing assembly 2022B (FIG. 20). In some embodiments, a set of
bi-directional ramps 3060B can be provided in a rear face 3062B of
the perimeter edge portion 3056B. The ramps 3060B can be configured
for receiving the output load cam rollers 2015B (FIG. 20) and to
cooperate with the output load cam rollers 2015B for applying an
axial force on the output traction ring 2010B and the output load
cam 3005B. Through such cooperation, the ramps 3060B enable torque
transfer from the output traction ring 2010B to the output load cam
3005B. In some embodiments, radial fins 3064B are attached to a
front face 3066B of the body 3052B, extending outwardly from the
perimeter edge portion 3056B. The radial fins 3064B serve as
cooling fins for dissipating heat. Furthermore, the radial fins
3064B can be used for facilitating the sensing of rotational speed
of the output load cam 3005B. The shroud 2020B of FIG. 24 is
compatible with the output load cam 3005B. The shroud 2020B can be
mounted on the output load cam 3005B to, among other things, reduce
the potential for the radial fins 3064B to generate undesirable
fluid dynamics.
[0174] Referring now to FIGS. 30-33, in one embodiment, each one of
the planet-and-shift-lever subassemblies 2100 includes a planet
2102 rotatably mounted on a planet axle 2104, which can be
positioned on a planet central bore 2103. Spaced apart planet
bearings 2108, an inner spacer 2110, and outer spacers 2112 can
mount coaxially on the planet axle 2104. In some embodiment, the
inner spacer 2110 is positioned between the planet bearings 2108,
and each one of the planet bearings 2108 is positioned between a
respective one of the outer spacers 2112 and the inner spacer 2110.
Accordingly, each planet 2102 is rotatably mounted on a respective
planet axle 2104 in a load-bearing and rotatable manner. It is
disclosed herein that the present invention is not limited to a
particular planet bearing and spacer arrangement for rotatably
mounting each planet 2102 on the respective planet axle 2104. For
example, in some embodiments, a planet bearing and spacer
arrangement using more than two or less two planet bearings and
more than two or less spacers (that is, inner position and/or outer
position) can be implemented.
[0175] Planet axle shift levers 2106 ("shift levers 2106") can be
fixedly attached to opposing end portions 2107 of the planet axle
2104 such that the planet 2102 is positioned between the shift
levers 2106. The planet axle 2104 extends through a planet axle
bore 2111 (see FIGS. 32 and 33) of each shift lever 2106. In one
embodiment, the opposing end portions 2107 include a skew roller
shoulders 2109 on which skew rollers 2122 mount. Each skew roller
2122 can be held in place by a washer 2124 and a clip ring 2126,
which clip ring 2126 can be engaged within a groove in the skew
roller shoulder 2109. It is disclosed herein that, in some
embodiments, a shift lever 2106 can include one or more features
(not shown) such as, for example, a recess, a channel, etc., for
providing clearance with other components of the variator 1200.
[0176] As shown in FIGS. 30-33, in some embodiments, a shift guide
roller axle 2116 can be engaged within a shift guide roller axle
bore 2117 (FIG. 33) of each shift lever 2106 and within a
corresponding axle capturing feature 2119 (FIGS. 32 and 33) of the
planet axle 2104. In one embodiment, the shift guide roller axle
bore 2117 intersects and is generally perpendicular to the planet
axle bore 2111. The shift guide roller axle bore 2117 is adjacent
to a first end portion 2121 of the shift lever 2106. Examples of
the axle capturing feature 2119 include, but are not limited to, a
feature generally characterized as a notch, a cut out, a channel, a
seat, or the like. The shift guide roller axle 2116 and the
corresponding axle capturing feature 2119 can be configured for
limiting (for example, substantially precluding) radial
displacement of the shift guide roller axle 2116 with respect to
the engaged axle capturing feature 2119. Thus, such mating
configuration of the shift guide roller axle 2116 and the
corresponding axle capturing feature 2119 limits displacement of
the shift lever 2106 along the longitudinal axis LA2 of the planet
axle 2104 when the shift guide roller axle 2116 is mounted on the
planet axle 2104 with the shift guide roller axle 2116 engaged
within the shift guide roller axle bore 2117 and the corresponding
axle capturing feature 2119 (FIGS. 32 and 33). Shift guide rollers
2114 can be mounted on opposing end portions of each shift guide
roller axle 2116. Each shift guide roller axle 2116 can be secured
in place by, for example, washers 2118 and clip rings 2120, which
clip rings 2120 can be engaged within a groove 2191 of the shift
guide roller axle 2116. In other embodiments, the shift guide
roller axle 2116 can be secured by, for example, an interference
fit, press fit, etc.
[0177] At a second end portion 2125 of each shift levers 2106, a
roller receiving channel 2129 is provided. A shift cam roller 2128
is positioned in the roller receiving channel 2129. A shift cam
roller axle 2130 extends through the shift cam roller 2128 and into
engagement with axle receiving passages 2131 (FIG. 33). The shift
cam roller axle 2130 can be secured in place through an
interference fit with the respective axle receiving passages 2131.
In other embodiments, securing means such as a clip and groove
arrangement can be implemented.
[0178] Referring to FIGS. 32-35, in one embodiment, the planet axle
2104 can have a through central bore 2134 and transverse channels
2142 in a substantially cylindrical body 2132. The transverse
channels 2142, among other things, enable fluid communication
between the central bore 2134 and the space external of the planet
axle 2104, thereby allowing for lubrication of the bearings 2108.
The skew roller shoulders 2109, which are provided for receiving
the skew rollers 2122, are defined by a reduction in diameter of
the cylindrical body 2132. Grooves 2140 are provided in the skew
roller shoulders 2109 for receiving the clip rings 2126 that
constrain the skew rollers 2122 (FIG. 32). It is disclosed herein
that, in other embodiments, the cylindrical body 2132 has a
generally uniform diameter from over its entire length, such that
reduction in diameter defining the skew roller shoulders 2109 is
omitted and the skew rollers 2122 are corresponding configured for
mating with uniform diameter of the cylindrical body 2132.
[0179] Referring to FIGS. 30 and 37-43, in one embodiment, the
shift-cam-and-sun subassembly 2200 can include sun 2202, bearings
2204, shift cams 2206, control pistons 2208, piston tube 2210, shim
2212, inner seals 2214, and outer seals 2216. As shown in FIGS. 30,
37 and 38, in some embodiments, the control pistons 2208 are
coupled to the shift cams 2206 through the piston tube 2210. The
control pistons 2208 and the shift cams 2206 can be mounted on the
piston tube 2210 by, for example, a press-fit interface. The sun
2202 can be operationally coupled to the shift cams 2206 through
the bearings 2204. The bearings 2204 can be configured to transfer
axial and radial loads between the sun 2202 and the shift cams
2206. The sun 2202 and the shift cams 2206 can be configured to
receive the bearings 2204. The inventive embodiments are not
limited to bearings of a particular type. For example, an angular
contact bearing is a suitable bearing type for the bearings
2204.
[0180] In one embodiment, the shim 2212 is positioned between the
shift cams 2206 for setting a desired axial clearance between the
sun 2202 and the shift cams 2206. Such clearance facilitates
relative rotation between the shift cams 2206 and the sun 2202
without allowing contact between adjacent surfaces. In other
embodiments, a plurality of shims can be used for achieving the
desired clearance between the sun 2202 and the shift cams 2206. In
still other embodiments, the shim 2212 can be omitted and the shift
cams 2206 and/or sun 2202 can be manufactured in a manner to
achieve suitable clearance between the sun 2202 and the shift cams
2206.
[0181] As shown in FIGS. 37-39, in one embodiment, the sun 2202 can
have a body 2218 having a generally cylindrical outer diameter and
internal recesses 2222 for receiving the bearings 2204. As shown,
the sun 2202 can have a central shoulder 2220 that facilitates
axial constraint of the bearings 2204, thereby limiting an
insertion depth of each one of the bearings 2204 within the
respective one of the recesses 2222. The inventive embodiments are
not limited to particular ways for positioning the bearings 2204
with respect to the body 2218. For example, in other embodiments, a
bearing 2204 has an outer race with an integral positioning flange
that engages an exterior edge face 2223 of the sun 2202. In still
other embodiments, the recesses 2222 have a tapered face and each
one of the bearings 2204 has an outer race with a tapered exterior
surface that engages the tapered face of the respective one of the
recesses 2222. In still other embodiments, a discrete spacer can be
used to facilitate proper spacing between the bearings 2204. In yet
other embodiments, the outer races of the bearings 2204 can be
formed integral with the sun 2202, and/or the inner races of the
bearing 2204 can be formed integral with the shift cam extensions
2206.
[0182] As shown in FIGS. 37, 38, 40 and 40A, in one embodiment, the
shift cam 2206 can include a shift cam profile 2224, which are
adapted to guide the motion of the shift cam rollers 2128. One
embodiment of data points defining a shape of the shift cam profile
2224 is shown in the table of FIG. 41. The X-dimension refers to an
axial distance between a reference surface 2225 and the shift cam
profile 2224. The Y-dimension refers to a radial distance between a
longitudinal centerline axis of a central bore 2228 of the shift
cam 2206 and the shift cam profile 2224. In some embodiments, the
shift cam 2206 includes a shift cam extension 2226 having an
exterior face 2227 configured to receive a respective one of the
bearings 2204, and having an interior face 2229 configured to
engage an exterior face 2252 of the piston tube 2210. Preferably,
but not necessarily, the shift cam extension 2226 includes a
lubrication flow enhancing feature 2232 such as, for example a
cut-out or notch. In one embodiment, a rear face 2230 of the shift
cam 2206 opposite to the shift cam profile 2224 is configured to be
slightly angled relative to the reference surface 2225 for, among
other things, promoting the flow of lubricant in the general area
of the bearings 2204 and to maintain a desired clearance between
the rear face 2230 of the shift cam 2206 and the exterior surfaces
2223 (FIG. 39) of the sun 2202.
[0183] As shown in FIGS. 37, 38 and 42, in one embodiment, a
control piston 2208 has a central bore 2249 configured for engaging
an exterior face 2254 (FIGS. 37 and 38) of the piston tube 2210. In
some embodiments, the control piston 2208 has an internal recess
2250 and an external neck 2248 each configured for receiving and
supporting the inner seal 2214 and the outer seal 2216,
respectively. The control piston 2208 has a piston face 2240 on
which control fluid pressure exerts force. In one embodiment, the
control piston 2208 includes a number of recesses 2242, wherein a
recess 2242 can be configured to provide clearance for the second
end portion 2125 (FIG. 33) of a respective shift lever 2106. Side
faces 2244 of the recess 2242 can be configured to substantially
constrain movement of the second end portion 2125 of the shift
lever 2106, thereby limiting rotation of the respective shift lever
2106 about the longitudinal axis LA1 of the variator 1200. In some
embodiments, the contoured shape of the recess 2242 can be used as
a detectable proximity surface that facilitates the determination
of a relative position of the control piston 2208 with respect to
the longitudinal axis LA1. An anti-rotation feature 2246 (for
example, a groove, pin, seat slot, etc.) can be provided in an
exterior face of the control piston 2208 for engaging a mating anti
rotation feature of an adjacent variator component to limit
rotation of the control piston 2208 about the longitudinal axis
LA1.
[0184] As shown in FIGS. 38 and 43, in one embodiment, the piston
tube 2210 can include exterior faces 2252, 2254 and a central bore
2256. The faces 2252 can be configured to receive the shift cams
2206, and the faces 2254 can be configured to receive the control
pistons 2208. The outside diameter of the faces 2254 is nominally
the same as each other, and the outside diameter of the faces 2252
are nominally the same as each other. In one embodiment, the
outside diameter of the faces 2252 is slightly smaller than the
outside diameter of the faces 2252, which precludes having to press
fit the shift cams 2206 over the respective outer engagement
surface 2252 prior to press fitting it onto the respective inner
engagement surface 2254. As is discussed further below, the central
bore 2256 can be configured to receive mating portions of a stator
4200A, 4200B (see FIG. 44) therein. Preferably, but not
necessarily, the piston tube 2210 has a shim receiving recess 2260
(for example, a circumferential groove) for receiving a portion of
the shim 2212 (FIG. 38) and has an orifice 2259 for allowing
passage of lubricant. Preferably, but not necessarily, the orifice
2259 is exposed within the shim receiving recess 2260.
[0185] Referring now to FIGS. 44-46, in one embodiment, the
stator-manifold subassembly 2300 includes a center manifold 4000, a
first stator 4200A, a second stator 4200B, a first oil galley 4400A
and a second oil galley 4400B. The first stator 4200A attaches to a
first side face 4005 of the center manifold 4000, and the second
stator 4200B attaches to a second side face 4010 of the center
manifold 4000. The first oil galley 4400A mounts on the first
stator 4200A, and the second oil galley 4400B mounts on the second
stator 4200B. As used here, the terms "oil", "lubricant",
"lubricating fluid," and "traction fluid" are generally
interchangeable. Where appropriate, it will be clear by the context
that the fluid, or condition, refers to lubrication rather than
traction.
[0186] In one embodiment, the center manifold 4000 is configured
for, among other things, facilitating the stator-manifold
subassembly 2300 being fixedly mounted to the transmission housing
1800 of the transmission 600 (FIG. 3A), supporting the stators
4200A, 4200B, distributing control fluid and traction fluid to the
variator 1200 (FIGS. 3A and 44), and housing and supporting various
sensors. Examples of such sensors include, but are not limited to,
sensors for sensing lubricant temperature, pressure, and viscosity.
In some embodiments, a sensor is provided for sensing the position
of the shift lever subassembly 2100 relative to a surface on the
stator 4200.
[0187] The stators 4200A, 4200B can be configured for, among other
things, supporting the planet-and-shift-lever subassemblies 2100,
supporting the shift-cam-and-sun subassembly 2200, and
communicating control and traction fluids. As discussed below, the
planet-and-shift-lever subassemblies 2100 are each movably
supported jointly by the stators 4200A, 4200B and the
shift-cam-and-sun subassembly 2200. The shift-cam-and-sun
subassembly 2200 cooperates with the stators 4200A, 4200B for
facilitating control of movement of the planet-and-shift-lever
subassemblies 2100. The oil galleys 4400A, 4400B are configured for
spraying (that is, delivering) lubricant onto portions of the
planet-and-shift-lever subassemblies 2100, the shift-cam-and-sun
subassembly 2200, and other components of the variator 1200.
[0188] Referring now to FIGS. 44-53, the center manifold 4000
includes a base plate 4015 and a cover plate 4020. The base plate
4015 includes a first side face 4016A and a second side face 4016B,
and the cover plate 4020 includes a first side face 4021A and a
second side face 4021B. In one embodiment, the plates 4015, 4020
are generally circularly shaped when viewed in a direction
perpendicular to a respective side face. In some embodiments, the
plates 4015, 4020 each has a cut-out pattern 4025 configured to
generally surround the array of planet-and-shift-lever
subassemblies 2100 (FIG. 44). The plates 4015, 4020 attach to each
other in a side-by-side configuration as shown in FIGS. 44-48 with
the cut-out pattern of the base plate 4015 being aligned with the
cut-out pattern of the cover plate 4020. The second side face 4016B
of the base plate 4015 abuts the first side face 4021A of the cover
plate 4020 when the plates 4015, 4020 are placed in the
side-by-side configuration.
[0189] A first sensor cable groove 4027 and a second sensor cable
groove 4029 can be provided in the first side face 4016A of the
base plate 4015. Example sensors corresponding to such sensor
cables include, but are not limited to, a gamma sensor, a fluid
temperature sensor, and a speed measuring device sensor. The base
plate 4015 includes bolt holes 4030 (FIGS. 47, 49 and 50), and the
cover plate 4020 includes bolt holes 4031 (FIGS. 48, 52 and 53),
which bolt holes 4030, 4031 are configured to receive bolts (not
shown) for securing the plates 4015, 4020 in the side-by-side
configuration. As shown, in one embodiment, the bolt holes 4030 are
counterbored, and the bolt holes 4031 include threads for having a
threaded portion of the respective bolt engaged therewith. In other
embodiments, the bolt holes 4030, 4031 can have different
configurations that still provide for securing the plates 4015,
4020 in the side-by-side configuration.
[0190] As shown in FIGS. 47-49, 52 and 53, the plates 4015, 4020
preferably, but not necessarily, each include dowel pin holes 4035.
The dowel pin holes 4035 of the base plate 4015 and the dowel pin
holes 4035 of the cover plate 4020 are located in the same relative
positions with respect to the cut-out pattern 4025. The dowel pin
holes 4035 can be located radially in line with lubricant ports
4089, 4087 of the respective plate 4015, 4020. Thus, engagement of
dowel pins (not shown) within the dowel pin holes 4035 facilitates
and simplifies proper alignment of the base plate 4015 with the
cover plate 4020.
[0191] In one embodiment, the base plate 4015 includes a footing
4040 (see FIGS. 45-46 and 49-50) configured for cooperating with
the transmission housing 1800 (FIG. 3A) to provide torque reaction
at the footing 4040, thereby limiting movement of the base plate
4015 with respect to the transmission housing 1800. Bolt holes 4043
receive bolts (not shown) for fastening the base plate 4015 to the
transmission housing 1800. In some embodiments, the base plate 4015
includes locating pads 4045 that engage a mating structure (for
example, a conformingly shaped recess, protruding ridge, etc.) of
the transmission housing 1800. The locating pads 4045 facilitate
locating the base plate 4015 in the transmission housing 1800.
[0192] As shown in FIGS. 45, 47, and 49, in some embodiments,
opposing ones of the locating pads 4045 include a cam wedge base
4050 that cooperates with a corresponding cam dowel 4055 (see FIGS.
45 and 51A-51B) for fixedly engaging (for example, pressing) the
base plate 4015 and/or the cover plate 4020 against one or more
mating features of the transmission housing 1800. The cam wedge
base 4050 is a generally flat surface that is angled with respect
to the first side face 4016A of the base plate 4015. Through such
engagement, the center manifold 4000 can be positioned and,
additionally, torque reaction can be provided adjacent one or more
of the locating pads 4045 for limiting movement of the base plate
4015 with respect to the transmission housing 1800.
[0193] As best shown in FIGS. 47-48 and 51A-51B, a cam dowel 4055
includes a generally cylindrical shaped cam body 4057 having a
first end portion 4065 and a second end portion 4067. The first end
portion 4065 includes a cam wedge 4069 and the second end portion
4067 has a generally flat face 4070 (that is, extending generally
perpendicular to a longitudinal reference axis of the cam body
4057). The cam wedge 4069 includes a face that is skewed with
respect to the longitudinal reference axis of the cam body 4057.
Preferably, but not necessarily, the face of the cam wedge 4069 is
generally flat. Preferably, but not necessarily, a threaded bore
4072 extends from the flat face 4070 at least partially toward the
second end portion 4067. In use, for example, the cam dowel 4055
resides within a threaded passage in a wall of the transmission
housing 1800, with the cam wedge 4069 extending from within the
threaded passage into engagement with the cam wedge base 4050. The
cam dowel 4055 can be forced against the cam wedge base 4050 using,
for example, a setscrew engaged within the threaded passage within
the wall of the transmission housing 1800. Through such forced
engagement between the tapered faces of the cam wedge 4069 and the
cam wedge base 4050, the center manifold 4000 bears against a
mating feature of the transmission housing 1800, thereby limiting
movement of the center manifold 4000 with respect to the
transmission housing 1800. The threaded bore 4072 provides for
engagement with a threaded extractor device for facilitating
removal of the cam dowel 4055 from a passage of the transmission
housing 1800.
[0194] In one embodiment, the plates 4015, 4020 are configured for
routing lubricant and control fluid to the stators 4200A, 4200B. It
is disclosed herein that the lubricant and the control fluid can be
the same fluid used for different purposes (that is, lubricant and
control). It is further disclosed herein that the lubricant and the
control fluid can be the same as the transmission fluid discussed
above in reference to FIG. 3A, which is advantageous in that it
obviates the need to segregate such fluids.
[0195] Referring to FIGS. 47-53, in some embodiments, the base
plate 4015 can include lubricant flow passages (not shown) that
extend between a respective lubricant inlet port 4076 and a
respective lubricant outlet port 4084, thereby facilitating
lubricant flow between corresponding lubricant inlet ports 4076 and
lubricant outlet ports 4084. In one embodiment, the lubricant inlet
ports 4076 receive lubricant from a lubrication fluid pump
apparatus (not shown) of the transmission 600 or a standalone
lubrication fluid pump apparatus. In some embodiments, the base
plate 4015 can include a first control fluid passage (not shown)
that extends between a first control fluid inlet port 4078 and a
first control fluid outlet port 4091 to allow flow of control fluid
between the first control fluid inlet port 4078 and the first
control fluid outlet port 4091. The base plate 4015 can also
include a second control flow passage (not shown) that extends
between a second control fluid inlet port 4080 and a second control
fluid outlet port 4092 to allow flow of control fluid between the
second control fluid inlet port 4080 and the second control fluid
outlet port 4092.
[0196] In one embodiment, each lubricant inlet port 4076, the first
control fluid inlet port 4078, and the second control fluid inlet
port 4080 are located in a bottom edge face 4082 of the footing
4040, as shown in FIG. 50. The control fluid outlet ports 4091,
4092 are in fluid communication with corresponding control fluid
passages (not shown) that extend between the side faces 4016A,
4016B of the base plate 4015. A first control fluid port 4093 of
the cover plate 4020 (FIGS. 52 and 53) aligns with the first
control fluid outlet port 4091 of the base plate 4015, and a second
fluid control port 4094 of the cover plate 4020 aligns with the
second control fluid outlet port 4092 of the base plate 4015 when
the plates 4015, 4020 are positioned in the side-by-side
configuration.
[0197] In one embodiment, the center manifold 4000 can be
configured so that lubricant flows from the lubricant inlet ports
4076 to the respective lubricant outlet ports 4084 and then into a
lubricant distribution channel 4085 (FIG. 52) in the first side
face 4021A of the cover plate 4020. The lubricant distribution
channel 4085 extends at least partially around a perimeter region
of the cover plate 4020. Branch lubricant channels 4086 extend
between the lubricant distribution channel 4085 and lubricant ports
4087 and/or between the lubricant distribution channel 4085 and a
respective lubricant spray port 4088. The lubricant ports 4087
communicate with fluid passages (not shown) that extend between the
side faces 4021A, 4021B of the cover plate 4020. The lubricant
ports 4087 align with lubricant ports 4089 when the plates 4015,
4020 are positioned in the side-by-side configuration, thereby
enabling the first stator 4200A to receive lubricant from the
lubricant ports 4089, and the second stator 4200B to receive
lubricant from the lubricant ports 4087.
[0198] A spray of lubricant can be provided from the lubricant
spray ports 4088 of the cover plate 4020, which can be directed at,
for example, the output traction interface TI2 (FIG. 44) between
the output traction ring 2010B and the planets 2102 (one shown in
FIG. 44). Similarly, the base plate 4015 can include lubricant
spray ports 4090 (see FIG. 49) that each aligns with the lubricant
distribution channel 4085 and/or a respective one of the branch
lubricant channels 4086, thereby facilitating the provision of a
spray of lubricant from the lubricant spray ports 4090, which can
be directed at, for example, the input traction interface TI1 (FIG.
44) between the input traction ring 2010A and the planets 2102 (one
shown in FIG. 44).
[0199] In one embodiment, the control fluid passages (not shown)
extending between the control fluid inlet ports 4078, 4080 and the
respective control fluid outlet ports 4091, 4092 allow independent
and selective communication of control fluid with a control fluid
pump apparatus (not shown) of the transmission 600 or stand alone
apparatus. Through such independent and selective communication, a
pressure differential between the control fluid passages can be
produced. As discussed further below, selective control of this
pressure differential facilitates selective adjustment of a
position of the shift-cam-and-sun subassembly 2200 (FIG. 44) with
respect to the longitudinal axis LA1 of the main shaft 1000.
[0200] As shown in FIGS. 45 and 46, the stators 4200A, 4200B are
preferably, but not necessarily, essentially identical in
construction and will both sometimes be referred to herein
generically as the stator 4200. Referring to FIGS. 45, 46 and
54-59, in one embodiment, the stator 4200 can include a number of
shift lever guide flanges 4202, a plurality of stator extensions
4204, and a control piston receiver 4206. In one embodiment, the
shift lever guide flanges 4202 attach to the control piston
receiver 4206 in a radially extending and uniformly angularly
spaced manner. A planet axle passage 4208 extends between each
adjacent pair of shift lever guide flanges 4202. The stator
extensions 4204 extend axially from a first side face 4210 of each
shift lever guide flange 4202. The control piston receiver 4206
extends axially from a second side face 4212 of each shift lever
guide flange 4202. Preferably, but not necessarily, the shift lever
guide flanges 4202, the stator extensions 4204, the control piston
receiver 4206A, and the planet axle passages 4208 are uniformly
spaced and angularly arranged around a longitudinal axis LA3 of the
control piston receiver 4206 whereby the stator 4200 is generally
circularly shaped and symmetrical with respect to the longitudinal
axis LA3. A center manifold engagement face 4213 (FIG. 55) of each
one of the stator extensions 4204 is substantially flat and extends
substantially perpendicular to the longitudinal axis LA3.
[0201] In some embodiments, the control piston receiver 4206
includes a receiver neck 4214, a receiver end face 4216, and a
control piston engaging member 4218. The control piston engaging
member 4218 is generally a cylindrically shaped tubular body having
an exterior surface 4222 and an interior surface 4224. The interior
surface 4224 defines a central bore 4225 of the control piston
engaging member 4216, which receives the main shaft 1000. A
circumferential seal groove 4227 (FIGS. 46 and 56-58) can be
provided in the interior surface 4224 for receiving a seal (not
shown) that engages a mating surface of the main shaft 1000. A
control piston receiving chamber 4220 is defined between the
receiver neck 4214, the receiver end face 4216, and the control
piston engaging member 4218. The exterior surface 4222 of the
control piston engaging member 4218 and an interior surface 4226 of
the receiver neck 4214 extend substantially parallel to each other
and serve as control piston support surfaces. The control piston
receiving chamber 4220 is configured for receiving one of the
control pistons 2208 (FIG. 36-38). The exterior surface 4222 of the
control piston engaging member 4218 is configured (for example, has
a sufficient smoothness and straightness) for forming a sealed
interface with the inner seal 2214 of the control piston 2208, and
the interior surface 4226 of the receiver neck 4214 is configured
for forming a sealed interface with the outer seal 2216 of the
control piston 2208. A longitudinal axis of the control piston
engaging member 4218 extends coincidentally with the longitudinal
axis LA3 of the control piston receiver 4206. The surfaces 4222,
4226 are concentric about the longitudinal axis LA3.
[0202] As best shown in FIGS. 54 and 55, a skew roller reaction
surface 4228 and a shift guide roller reaction surface 4230 are
provided at opposing edges of each shift lever guide flange 4202.
The skew roller reaction surface 4228 is substantially flat and the
shift guide roller reaction surface 4230 is contoured. Examples of
such contour include, but are not limited to, semi-circular,
parabolic, elliptical and angularly tapered. In one embodiment, the
contour is circular and the center of its radius of curvature is
coincident with the center of tilt of the planet 2102. Adjacent
skew roller reaction surfaces 4228 of adjacent shift lever guide
flanges 4202 extend substantially parallel to each other and
adjacent shift guide roller reaction surfaces 4230 of adjacent
shift lever guide flanges 4202 are substantially aligned.
[0203] As shown in FIGS. 54-57, in one embodiment, a control fluid
communicating bolt hole 4232 can be provided in one of the stator
extensions 4204. In addition to serving as a bolt hole for
receiving a bolt that secures the stator 4200 to the center
manifold 4000 (that is, a stator securing bolt), the control fluid
communicating bolt hole 4232 can be configured to serve as a
channel for fluid communication with the control piston receiving
chamber 4220. In some embodiments, a lubricant communicating bolt
hole 4234 can be provided in a number of other stator extensions
4204. In addition to serving as a bolt hole for receiving a bolt
that secures the stator 4200 to the center manifold 4000, the
lubricant communicating bolt hole 4234 can be configured to serve
as a channel for providing lubricant to a planet/shift lever
lubricant jet 4236 in the stator extension 4204, to an oil galley
feeding port 4238 in the receiver neck 4214, and/or an output load
cam assembly bearing lubricant jet 4240 in the receiver end face
4216.
[0204] As best shown in FIG. 56, in one embodiment, the control
fluid communicating bolt hole 4232 has a stepped profile such that
a first portion of the control fluid communicating bolt hole 4232,
which is exposed at the second side face 4212 of the respective
shift lever guide flange 4202, has a relatively close clearance fit
with the stator securing bolt and a second portion of the control
fluid communicating bolt hole 4232, which is exposed at the center
manifold engagement face 4213 of the stator extension 4204, has an
oversize clearance fit with the stator securing bolt. In this
manner, the flow of control fluid past the stator securing bolt in
the second portion of the control fluid communicating bolt hole
4232 is essentially unrestricted. Drill holes 4242 that extend
between the second portion of the control fluid communicating bolt
hole 4232 and the control piston receiving chamber 4220 in an
intersecting manner form a control fluid channel between the
control fluid communicating bolt hole 4232 and the control piston
receiving chamber 4220. The openings of the drill holes 4242
exposed at the extension 4204, exterior surface of the receiver
neck 4214, and at the exterior surface of the receiver end face
4216 are plugged to prevent control fluid discharge therefrom.
[0205] In some embodiments, a lubricant communicating bolt hole
4234 has a stepped profile such that a first portion of the
lubricant communicating bolt hole 4234, which is exposed at the
second side face 4212 of the respective shift lever guide flange
4202, has a relatively close clearance fit with the stator securing
bolt and a second portion of the lubricant communicating bolt hole
4234, which is exposed at the center manifold engagement face 4213
of the stator extension 4204, has an oversize clearance fit with
the stator securing bolt. In this manner, the lubricant flow past
the stator securing bolt in the second portion of the lubricant
communicating bolt hole 4234 is essentially unrestricted. Drill
holes 4244 that extend in an intersecting manner between the second
portion of the lubricant communicating bolt hole 4234 and the oil
galley feeding port 4238, and/or the bearing lubricant jet 4240,
form a lubricant channel between the lubricant communicating bolt
hole 4234 and such ports and/or jets. The opening of the drill
holes 4244 exposed at an exterior surface of the stator extensions
4204 can be plugged to prevent unintentional and/or undesirable
lubricant discharge therefrom. For example, if the stator 4200 does
not provide the output load cam bearing assembly 2022B (FIG. 20)
with a dedicated supply of lubricant, the drill hole forming the
output load cam assembly bearing lubricant jet 4240 is plugged.
[0206] In one embodiment, a drill hole 4246 (FIGS. 55, 57 and 59)
extending through one of the shift lever guide flanges 4202 and the
receiver neck 4214 forms a passage that can be used for routing
wires and/or housing a sensor (not shown) such as, for example, a
proximity sensor which cooperates with a contoured recess 2242 of
the control piston 2208 for allowing a determination of the axial
position of the control piston 2208. The drill hole 4246 can be
drilled from the outer diameter of the shift lever guide flange
4202 through the receiver neck 4214 into the control piston
receiving chamber 4220. Similarly, a set screw hole 4248 can be
formed in the receiver neck 4214 (for example, through one of the
shift lever guide flanges 4202) for receiving an anti-rotation
member (not shown) such as, for example, a set screw. The
anti-rotation member cooperates with the groove 2246 (FIG. 38) of a
respective control piston 2208 for precluding rotation of the
respective control piston 2208 within the control piston receiving
chamber 4220.
[0207] As shown in FIG. 55, the stator 4200 can include dowel pin
holes 4250 for facilitating proper positioning of the stator 4200
with the center manifold 4000. In one embodiment, the dowel pin
holes 4250 are located radially in line with the respective
lubricant communicating bolt hole 4234 of the stator 4200. The
radial position of each dowel pin hole 4250 is substantially the
same as the radial position of each dowel pin hole 4305 of the
center manifold 4000. Accordingly, dowel pins (not shown) of
suitable length engaged with the dowel pin holes 4035 are coupled
with corresponding dowel pin holes 4250, thereby facilitating
proper alignment of the stator 4200 with the center manifold 4000.
Furthermore, such a dowel pin hole arrangement enables positioning
of the stator 4200 for aligning the control fluid communicating
bolt hole 4232 of the stator 4200 with either one of the control
fluid ports 4091, 4092 of the base plate 4015 or with either one of
the control fluid ports 4093, 4094 of the cover plate 4020,
depending on which one of the plates 4015, 4020 the stator 4200 is
engaged with. In this manner, for example, the first stator 4200A
aligns with the first control fluid port 4091 of the base plate
4015, and the second stator 4200B aligns with the second control
fluid port 4093 of the cover plate 4020, thereby allowing for
communication of control fluid with the stators 4200A, 4200B.
[0208] Referring back to FIGS. 45-47 and 51-54, in one embodiment,
the first stator 4200A engages the first side face 4005 of the
center manifold 4000 (FIGS. 45 and 46), and the second stator 4200B
engages the second side face 4010 of the center manifold 4000. More
specifically, the center manifold engagement face 4213 (FIG. 55) of
each stator extension 4204 of the first stator 4200A engages the
first side face 4016A (FIGS. 46 and 49) of the base plate 4015, and
the center manifold engagement face 4213 of each stator extension
4204 of the second stator 4200B engages the second side face 4021B
(FIGS. 48 and 53) of the cover plate 4020. The first stator 4200A
is placed such that the control fluid communicating bolt hole 4232
(FIGS. 54 and 55) of the first stator 4200A aligns with the first
control fluid passage 4091 (FIG. 47) of the base plate 4015 and the
lubricant distribution channel 4085 of the cover plate 4020 aligns
with the lubricant port 4087 of the base plate 4015. In some
embodiments, the second stator 4200B can be placed such that
control fluid communicating bolt hole 4232 (FIGS. 53 and 54) of the
second stator 4200B aligns with the second control fluid port 4094
(FIG. 47) of the cover plate 4020 and the lubricant communicating
ports 4234 of the second stator 4200B align with the lubricant
ports 4087 of the cover plate 4020. In this manner, control fluid
can be communicated to and from the control piston receiving
chamber 4220 of the first stator 4200A independently of control
fluid communicated to and from the control piston receiving chamber
4220 of the second stator 4200B, and lubricant can be delivered to
various ports and jets of the stators 4200A, 4200B and oil galleys
4400A, 4400B independently of the control fluid.
[0209] As shown in FIGS. 44-46, the oil galleys 4400A, 4400B are
preferably, but not necessarily, essentially identical in
construction and will both sometimes be referred to herein
generically as the oil galley 4400. Referring now to FIGS. 60-62,
in one embodiment, the oil galley 4400 is generally circular and
includes a central bore 4402, an annular lubricant channel 4404, a
number of lubricant jet channels 4406, and lubricant flow passages
4408 (for example, a drill hole). The lubricant jet ports 4406 can
be arranged in groupings (for example, linear, cluster, etc.) that
are preferably, but not necessarily, spaced (example, uniformly)
around the central bore 4402. Each group of lubricant jet ports
4406 can be in fluid communication with the annular lubricant
channel 4404 by the respective lubricant flow passage 4408. The oil
galley 4400 includes stator bolt clearance cutouts 4410 configured
to allow access to bolts engaged within the bolt holes 4232, 4234
of the stators 4200 (FIGS. 45 and 46) that secure the stators 4200
to the center manifold 2300.
[0210] In some embodiments, the central bore 4402 can be configured
to engage the exterior surface of the receiver neck 4214 (FIGS. 45
and 46) of a respective stator 4200 by, for example, a press fit
interface. The oil galley 4400 can be positioned on the receiver
neck 4214 such that the annular lubricant channel 4404 aligns with
the oil galley feeding port 4238 (FIG. 56) of the stator 4200,
thereby facilitating supplying lubricant from the stator 4200 to
the oil galley 4400. In one embodiment, the oil galley 4400 is
angularly oriented such that each one of the groupings of the
lubrication jet channels 4406 is aligned with a respective planet
axle passage 4208 (FIGS. 45 and 54) of the respective stator 4200.
Accordingly, when lubricant is supplied to the oil galley 4400 from
the respective stator 4200A, 4200B a supply of lubricant is sprayed
into the respective planet axle passage 4208 for lubricating
components of an associated planet-and-shift-lever subassembly
2100.
[0211] Referring back to FIGS. 45 and 46, in one embodiment, the
stators 4200A, 4200B and the center manifold 4000 are securely
coupled in aligned orientation using a fastening structure such as,
for example, a bolt and nut (not shown). For example, an elongated
portion of a threaded fastening structure (such as the shank of the
bolt) extends through the bolt holes 4232, 4234 of the stators
4200A, 4200B and the lubricant ports 4087, 4089 of the center
manifold plates 4015, 4020. The threaded fastening structure is
tightened such that end portions of the threaded fastening
structure (for example, the head of the bolt) apply a compressive
force on the stators 4200 and the center manifold 4000 to form a
substantially rigid support structure for components and
subassemblies to be mounted thereon. In some embodiments, sealing
washers are used under the bolt head and nut to seal the
lubrication and control fluid passages.
[0212] Passing to FIGS. 63 and 64 now, certain structure and
functionality of the variator 1200 will be discussed. In some
embodiments, a first control piston 2208A (FIG. 63) of the
shift-cam-and-sun subassembly 2200 is slidably mounted within the
control piston receiving chamber 4220 (see FIGS. 56 and 57) of the
first stator 4200A, and a second control piston 2208B (FIG. 63) of
the shift-cam-and-sun subassembly 2200 is slidably mounted within
the control piston receiving chamber 4220 the second stator 4200B.
Through the selective control of control fluid volume within the
control piston receiving chambers 4220, the shift-cam-and-sun
subassembly 2200 can be selectively and controllably displaced
along the longitudinal axis LA1 of the main shaft 1000. As
discussed above, in on embodiment, the control pistons 2208A, 2208B
are constrained from rotation about the longitudinal axis LA1.
[0213] Simultaneous engagement of each planet 2102 (one shown in
FIG. 63) with the input traction ring 2010A, the output traction
ring 2010B, and the sun 2202 constrains axially and radially the
planet 2102 of each planet-and-shift-lever subassembly 2100. The
planet 2102 is rotatably mounted on the respective planet axle
2104. The skew roller 2122 (FIG. 63) of a planet-and-shift-lever
subassembly 2100 engages skew roller reaction surfaces 4228 of
adjacent shift lever guide flanges 4202 positioned within a
respective planet axle passage 4208, thereby substantially
precluding rotation of the respective planet-and-shift-lever
subassembly 2100 about any radial axis extending perpendicular to
the longitudinal axis LA1. The two shift guide rollers 2114 of each
shift lever 2106 engage respective shift guide roller reaction
surfaces 4230. Accordingly, a first one of the shift guide rollers
2114 engages a shift guide roller reaction surface 4230 on a first
side of the respective planet axle passage 4208, and a second one
of the shift guide rollers 2114 engages a shift guide roller
reaction surface 4230 on a second side of the respective planet
axle passage 4208. The semi-circular shape of the shift guide
roller reaction surfaces 4230 and the corresponding engagement by
the shift guide rollers 2114 serves to, among other things,
substantially preclude axial displacement of the respective
planet-and-shift-lever subassemblies 2100 with respect to relative
to the longitudinal axis LA1, as well as to reduce the force needed
to effect a tilting of the planet axles 2104. It should be noted
that the shift guide roller reaction surfaces 4230 cooperate with
the shift guide rollers 2114 to react the shift forces that arise
by the actuation of the planet-and-shift-lever subassemblies 2100
by the shift-cam-and-sun subassembly 2200.
[0214] Hence, in some embodiments, each planet-and-shift-lever
subassembly 2100 is substantially axially and radially constrained
relative to the longitudinal axis LA1, and constrained with respect
to rotation about any radial axis extending perpendicular to the
longitudinal axis LA1. Conversely, each planet-and-shift-lever
subassembly 2100 is pivotable about the respective tangential
reference axis TA1, which extends through a center point of the
respective planet 2102 substantially perpendicular to a radial
reference axis extending from the longitudinal axis LA1 through the
center point of the respective planet 2102. In some embodiments,
the planet 2102 is configured to freely move axially along the axis
LA2 to allow for dimensional tolerances stack up between the
traction components and the shift reaction surfaces. Additionally,
the center of rotation of the planet axle 2104 is not necessarily
coincident with the center of rotation of the planet 2102; such
configuration prevents, in some cases, efficiency losses, increased
shift forces, or outright binding of the variator 1200.
[0215] In some embodiments, the shift cam roller 2128 of each shift
lever 2106 couples to a cam surface of a respective shift cam 2206.
A differential control fluid pressure between the control piston
receiving chambers 4220 causes an axial translation of the
shift-cam-and-sun subassembly 2200 along the axis LA1. Such axial
translation results in force being exerted on the shift cam rollers
2128 coupled to the shift cam 2206 facing the direction of
movement, thereby causing the planet-and-shift-lever subassemblies
2100 to synchronously pivot about the respective tangential
reference axis TA1. The application of the same control fluid
pressure within the control piston receiving chambers 4220 serves
to hold the shift-cam-and-sun subassembly 2200 in a given position
due to equal and opposing reactive forces being applied by the
shift cams 2206 on the respective shift cam roller 2128. Thus,
adjustment of the speed ratio of the variator 1200 is facilitated
through axial translation of the shift-cam-and-sun subassembly 2200
along the longitudinal axis LA1.
[0216] Various detailed aspects of the torque converter subassembly
800 and the bell housing 1810 discussed above in reference to FIGS.
3A and 3B are shown in FIGS. 65-67. In one embodiment, the bell
housing 1810 includes a prime mover mounting portion 1812 and a
rear housing mounting portion 1814. The prime mover mounting
portion 1812 can be configured for attachment to a structural
portion of the prime mover (for example, a engine block, motor
casing, etc.), and the rear housing mounting portion 1814 can be
configured for attachment to the rear housing 1820 of the
transmission housing 1800 (FIG. 3A). As previously discussed, the
torque converter subassembly 800 is an embodiment of an input
interface, which is suitably configured for implementation between
a prime mover (not shown) and the variator 1200.
[0217] In some embodiments, the torque converter subassembly 800
can include a flex plate assembly 802, a torque converter 804
(FIGS. 66 and 67), and a transmission fluid pump 806 (FIGS. 66 and
67). The flex plate assembly 802 includes a flex plate 803 and
starter gear ring 807 for enabling a rotary apparatus (for example,
a starter motor) to turn moving components of the prime mover such
as for starting the prime mover. The flex plate 803 is configured
for attachment to a power output portion (for example, a crankshaft
or motor shaft) of the prime mover in a manner that precludes
relative rotation of the flex plate 803 with respect to the power
output portion of the prime mover, thereby enabling torque transfer
from the prime mover to the flex plate 803. For example, the flex
plate 803 typically connects to the prime mover with threaded
fasteners (such as bolts).
[0218] In one embodiment, the torque converter 804 includes a
converter torque output portion 805 (FIG. 66), a torque converter
housing 808, and various torque converting components (not shown)
within the torque converter housing 808 that enable torque
converter fluid within the torque converter housing 808 to be
conveyed within the housing 808 in a manner that transfers torque
applied to the torque converter housing 808 to the torque converter
output portion 805. In some embodiments, the torque converter
output portion 805 includes a turbine and a splined hub that
fixedly attach to the turbine. The splined hub mates with the
splines of the first end portion 1005 (FIGS. 3A, 4 and 5) of the
main shaft 1000. The torque converter housing 808 is configured for
attachment to the flex plate 803 in a manner that substantially
precludes relative rotation of the torque converter housing 808
with respect to the flex plate 803, thereby facilitating torque
transfer from the flex plate 803 to the torque converter housing
808. Examples of such ways for attaching the torque converter
housing 808 to the flex plate 803 include, but are not limited to,
threaded fastener structures, pins, and the like.
[0219] The transmission fluid pump 806 includes a pump housing 812,
a torque input shaft 814, and various fluid pumping components
within the pump housing that facilitate application of torque to
the torque input shaft 814 to cause transmission fluid to be drawn
into the pump housing 812 via a fluid supply input (not shown) and
supplied from within the pump housing 812 under pressure via a
fluid outlet (not shown). The pump housing 812 fixedly attaches to
a pump mounting structure 815 of the bell housing 1820. The torque
input shaft 814 attaches to the torque converter housing 808 in a
manner that substantially precludes relative rotation of the torque
input shaft 814 with respect to the torque converter housing 808,
thereby facilitating torque transfer from the torque converter
housing 808 to the torque input shaft 814.
[0220] Various aspects of one embodiment of the combining device
1400 discussed above in reference to FIGS. 3A and 3B are shown in
FIGS. 68-71. The combining device 1400 can be an output interface,
which is suitably configured for implementation between the main
shaft 1000, the variator 1200, and the rangebox 1600. More
specifically, the main shaft 1000 and the variator 1200 supply
power to the first power input portion 1405 and the second power
input portion 1410, respectively, of the combining device 1400, and
the power output portion 1422 of the combining device 1400 supplies
power to the rangebox 1600.
[0221] Referring to FIGS. 68-71, in some embodiments, the combining
device 1400 can include a hub 1416, a plurality of planet gears
1418, a plurality of planet gear axles 1419, a planet gear carrier
1420, a power output portion (or a transfer shaft) 1422, a needle
bearing 1424, a forward disk 1426, a rear disk 1428, a sun gear
1430, and a thrust ring 1432. The planet gears 1418 are each
rotatably mounted on the planet gear carrier 1420 via one of the
planet gear axles 1419 (FIG. 71). Each planet gear 1418 is
positioned within a pocket region of the planet gear carrier 1420
and the respective planet gear axle 1419 is engaged within
respective planet gear axle bores 1421 of the planet gear carrier
1420. The sun gear 1430 is positioned within the pocket region of
the planet gear carrier 1420, and the teeth of the sun gear 1430
are configured to engage the teeth of the planet gears 1418. In one
embodiment, the sun gear 1430 includes a central bore having
internal splines 1431, which are configured to engage splines at
the second end portion 1015 of the main shaft 1000.
[0222] In one embodiment, the transfer shaft 1422 includes splines
1434, 1436, 1438, and 1440. The splines 1434 engage mating splines
of an extension portion 1442 of the planet gear carrier 1420. In
one embodiment, the needle bearing 1424 is mounted within a pocket
of the transfer shaft 1422. As shown in FIG. 3A, a tip of the main
shaft 1000 engages the needle bearing 1424, thereby providing an
aligned and supported interface therebetween. As is discussed below
with reference to FIGS. 73 and 74, the splines 1436, 1438, and 1440
are engaged with mating components of the rangebox 1600.
[0223] As best shown in FIGS. 70 and 71, the rear disk 1428 can be
configured to engage teeth adjacent a rear edge 1444 of the hub
1416, thereby precluding relative rotation of the rear disk 1428
with respect to the hub 1416. The planet gear carrier 1420 is
positioned within the hub 1416 with a rear face of the planet gear
carrier 1420 abutting the rear disk 1428. The teeth of the planet
gears 1418 engage mating interior teeth of the hub 1416. In this
manner, the second power input portion 1410 of the combining device
1400 includes the hub 1416. The thrust ring 1432 is positioned
within the hub 1416, abutting a front face of the planet gear
carrier 1420. The forward disk 1426 engages internal splines formed
on a front edge 1446 of the hub 1416, thereby precluding relative
rotation of the forward disk 1426 with respect to the hub 1416.
Thus, the forward disk 1426 and the rear disk 1428 axially
constrain the planet gear carrier 1420, reacting axial thrust in
either direction from the sun gear 1430. A first circumferential
groove 1448 and a second circumferential groove 1450 are provided
adjacent the front edge 1446 and the rear edge 1444, respectively,
and are each configured for respectively receiving a retention
device such as, for example, a respective snap ring engaged therein
for axially constraining the disks 1426, 1428. Still referring to
FIGS. 69-71, exterior splines 1435 can be provided at the front
edge 1446 of the hub 1416. The exterior splines 1435 are configured
for coupling to splines of the output load cam 2005B, for example.
In this manner, the combining device 1400 is configured for
facilitating power transfer from the variator 1200 to the coupling
device 1400.
[0224] Various aspects of the interoperability of the variator 1200
and the rangebox 1600 discussed above in reference to FIGS. 3-4 are
shown in FIG. 72. In some embodiments, the main shaft 1000 can be
coupled directly to the input load-cam-and-traction-ring
subassembly 2000A and to a first power input portion 1405 of the
combining device 1400. Each of the planets 2102 (one shown) is
engaged between the input load-cam-and-traction-ring subassembly
2000A, the output load-cam-and-traction-ring subassembly 2000B, and
the sun 2202. With respect to the input load-cam-and-traction-ring
subassembly 2000A, the input load cam 2005A couples to the input
traction ring 2010A through the input load cam rollers 2015A. With
respect to the output load-cam-and-traction-ring subassembly 2000B,
the output load cam 2005B couples to the output traction ring 2010B
through the output load cam rollers 2015B. The output load cam
2005B couples to the second power input portion 1410 of the
combining device 1400.
[0225] In one embodiment, the transfer shaft 1422 of the combining
device 1400 couples to a direct clutch 1604 and to a sun gear 1606
of a first planetary gearset 1608 of the rangebox 1600. The first
planetary gearset 1608 is supported on a carrier 1609. A sun gear
1610 of a second planetary gearset 1612 is configured for being
selectively coupled to the transfer shaft 1422 through the direct
clutch 1604 or to the transmission housing 1800. The sun gear 1610
couples to the transmission housing 1800 through either a forward
clutch 1614, via an overrun clutch 1616 (for example, a one-way
mechanical diode), or a low clutch 1618. The sun gear 1610 couples
to the first planetary gearset 1608. A ring gear 1622 couples to
the first and second planetary gearsets 1608, 1612 and to a reverse
clutch 1624 of the rangebox 1600. An output shaft 1626 couples to
the carrier 1609. Preferably, but not necessarily, the output shaft
1626 and the carrier 1609 are one integral part.
[0226] In accordance with one embodiment, the rangebox 1600 is
provided in a vehicle having an engine supplying power to the
transmission 600. The rangebox 1600 is controlled in conjunction
with the variator 1200 for providing the transmission 600 with
multiple modes of operation, in which the shifting control of the
variator 1200 is based on engine speed, vehicle speed, and/or user
commands. A first power train operating mode (for example, Mode 1)
refers to the rangebox 1600 being engaged in a low gear range. A
second power train operating mode (for example, Mode 2) refers to
the rangebox 1600 being engaged in a high gear range with the
variator 1200 in overdrive (that is, speed output from the range
box is greater than speed input to the range box).
[0227] Operationally, for a vehicle acceleration event from a
standing start (meaning, operating in Mode 1), as the engine
initially increases speed, the variator 1200 is maintained in an
underdrive condition until the engine reaches a predetermined
engine speed set point such as, for example, 1800
revolutions-per-minute (rpm). Once the predetermined engine speed
set point is achieved, the engine speed is held constant while the
variator 1200 shifts its torque ratio in a manner that causes the
vehicle speed to increase. Vehicle speed continues to increase
until the variator 1200 reaches a torque ratio corresponding to
maximum overdrive, at which point, the engine speed increases up to
a predetermined maximum engine speed (for example, maximum
recommended engine rpm, peak horsepower, etc.). Once the engine
speed reaches the maximum set point engine speed, the rangebox 1600
is shifted from Mode 1 to Mode 2, with the variator 1200 in
overdrive. Following the rangebox 1600 being shifted to Mode 2, the
engine speed is initially decreased to cause synchronization
between vehicle speed and engine speed. The engine can then be
controlled to increase speed further by increasing engine speed
with the variator in overdrive.
[0228] In one embodiment, one or more data processing units are
programmed for facilitating the operating modes discussed above. A
power train controller, an engine controller, and/or a transmission
controller are examples of data processing units, which can be
programmed for providing the operating modes discussed above.
Various sensors and control devices are connected to the engine
and/or transmission 600 for facilitating the implementation of such
modes of operation. In some embodiments, a hydraulic control
structure having valving, among other things, can be used to
convert electronic control algorithms to hydraulic and mechanical
actuation of the variator 1200 and/or rangebox 1600.
[0229] Referring now to FIGS. 73 and 74, on embodiment of the
rangebox 1600 discussed above in reference to FIGS. 3A, 3B and 72
is provided. The rangebox 1600 can include an intermediate support
1640, a high and low mode subassembly 1642, and a reverse mode
subassembly 1644.
[0230] Various aspects of the rear housing 1820 of the transmission
housing 1800 discussed above in reference to FIGS. 3A and 3B are
shown in FIGS. 75-77. In one embodiment, a bell housing attachment
portion 1816 of the rear housing 1820 is configured for attachment
to the rear housing mounting portion 1814 of the bell housing 1810.
A tail housing attachment portion 1818 of the rear housing 1820 is
configured for attachment with a tail housing (not shown) of the
transmission 600 or to a housing of a related drivetrain
subassembly.
[0231] In some embodiments, the rear housing 1820 includes an
access port 1822 configured for receiving and supporting a sensor
(not shown) for monitoring speed of the input load cam 2005A. An
access port 1824 is configured for receiving and supporting a
sensor for monitoring speed of the output load cam 2005B. Passages
1826 are configured for receiving and supporting the cam dowels
4055 discussed above in reference to FIGS. 45-51. In one
embodiment, each passage 1826 is at least partially threaded for
receiving a threaded fastener (for example, a setscrew) used for
exerting a retention force on the respective cam dowel 4055. A
support flange 1828 is provided within an interior space of the
rear housing 1820 for locating and axially supporting the center
manifold 4000 through engagement with the locating pads 4045
discussed above in reference to FIGS. 45-51. A center manifold
footing engagement shoulder 1830 is provided for engaging the
footing 4040 of the center manifold 4000. Threaded holes 1831 (one
shown) are provided in the center manifold footing engagement
shoulder 1830 for attaching the footing 4040 to the center manifold
footing engagement shoulder 1830. In one embodiment, to facilitate
accurate positioning of the center manifold 2305, while at the same
time avoiding the need for a close tolerance along the body of the
rear housing 1820, a locating diameter 1832 is provided within the
interior space of the rear housing 1820. A series of clutch splines
1834 and grooves 1836 are formed in interior wall surfaces of the
rear housing 1800 and are configured for receiving and supporting
various components and/or assemblies of the rangebox 1600 (for
example, clutches, gears, gearsets, snap rings, etc.).
[0232] In some embodiments, various ports are provided in a bottom
wall 1838 of the rear housing 1820. Lubricant ports 1842 can be
configured for communicating lubricant to the lubricant inlet ports
4076 of the base plate 4015 of the center manifold 4000 (FIG. 50).
First and second control fluid ports 1844, 1846 are provided for
facilitating selective and independent communication of control
fluid with, respectively, the first and second control fluid inlet
ports 4078, 4080 of the base plate 4015 (FIG. 50). A group of
ancillary ports 1848 can be provided for facilitating selective and
independent communication of other desired fluids with transmission
components such as, for example, an external fluid cooler, an
external fluid pump, etc., and/or for facilitating the mounting of
one or more sensors (for example, a lubricant temperature sensor, a
lubricant level sensor, etc.).
* * * * *