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Patent Searching and Data


Title:
GEAR SYSTEM AND METHOD OF CONSERVING ENERGY
Document Type and Number:
WIPO Patent Application WO/2019/135258
Kind Code:
A2
Inventors:
RANGASWAMY, Guganesan (2/10 Rajaram Street, Radhanagar Chromepet, Chennai 4, 600044, IN)
Application Number:
IN2019/050008
Publication Date:
July 11, 2019
Filing Date:
January 04, 2019
Export Citation:
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Assignee:
RANGASWAMY, Guganesan (2/10 Rajaram Street, Radhanagar Chromepet, Chennai 4, 600044, IN)
International Classes:
F16H37/00
Attorney, Agent or Firm:
SINGH, Manisha (Lexorbis, 606-607 6th Floor, Gamma Block,Sigma Soft Tech Park No. 7, Whitefield Main Roa, Varthur Hobli Bengaluru 6, 560066, IN)
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Claims:
I CLAIM:

1. A method of conserving energy, the method comprising:

receiving mechanical energy with a torque at a minimum level; and

driving a single or multi stage gear mechanism using the mechanical energy such that the torque is adjusted using a torque adjusting factor based on a gear ratio of the gear mechanism to increase the mechanical energy received at each stage of the multi stage gear mechanism, respectively.

2. The method as claimed in claim 1, wherein the mechanical energy is received from one of an air motor, a hydraulic motor, a gear motor, and a direct drive high torque motor.

3. The method as claimed in claim 1, wherein the torque is adjusted with the torque adjusting factor ranging from 0.1 to 0.9 based on one or more of diameters, ratio and mass of the gear wheel and pinion used in speed increases stages.

4. The method as claimed in claim 1, wherein the torque adjusting factor is determined based on a theoretical output torque and an actual output torque.

5. The method as claimed in claim 1, wherein the gear ratio of the gear mechanism is selected based on an output RPM and torque required.

6. The method as claimed in claim 1, wherein the stages of the gear mechanism is selected based on an output energy required.

7. A gear system for conserving energy, the gear system comprising:

An input source for providing mechanical energy;

a speed increaser gear system coupled to the input source, wherein the speed increaser gear system is driven by the input source with a torque at a minimum level required, wherein the speed increaser gear system comprises a single or multi stage gear mechanism, wherein at each stage of the multi stage gear mechanism, torque is adjusted by a torque adjusting factor based on a gear ratio of the gear mechanism to increase the mechanical energy provided by the input source; and An energy converter coupled to the speed increaser gear system to receive the mechanical energy increased from the speed increaser gear system.

8. The gear system as claimed in claim 7, wherein the input source comprises one of an air motor, a hydraulic motor, a gear motor, and a direct drive high torque motor.

9. The gear system as claimed in claim 7, wherein the energy converter comprises one of an alternator, a dynamo and a compressor.

10. The gear system as claimed in claim 7, wherein the mechanical energy received from the input source is transmitted to the speed increaser gear system via shafts or Belt drive or direct mounting.

11. The gear system as claimed in claim 8, wherein the torque adjustment in speed increaser is achieved in a single stage.

12. The gear system as claimed in claim 7, wherein plurality of the single stage gear mechanism is coupled together to achieve multiple stages or multistage gear mechanism.

13. The gear system as claimed in claim 7, wherein the input source starting torque is at least greater than the breakaway torque of speed increaser gear system to reduce the inertia load in the input source.

14. The gear system as claimed in claim 12, wherein a diameter of the drive wheel is equal to or greater in the subsequent stage.

Description:
GEAR SYSTEM AND METHOD OF CONSERVING ENERGY

TECHNICAL FIELD

[001] The present disclosure relates to a gear system. More particularly, the present disclosure relates to a gear system in which torque is adjusted effectively to save energy consumption.

BACKGROUND

[002] It is very well known that gears are used in many industrial applications. Typically, a gear system comprises a wheel used for transmitting power from one part of a machine to another. The gears may be selected in different shape and size based on the requirement. Further, any number of gears may be selected for transmitting power required.

[003] Typically, the gears are used for increasing torque and/or increasing Revolutions per Minute (RPM). Generally, in order to increase the torque, a reduction gear box is used. In order to increase RPM, increaser gear box is used. However, when the torque is increased using the reduction gear box, RPM may reduce. Similarly, when the RPM is increased using the increaser gear box, torque is reduced.

[004] It is evident that in order to gain torque, one must reduce RPM or vice versa. Further, one must balance torque and RPM to obtain higher efficiency from the gear system. Therefore, there is a need to balance the torque without impacting the RPM to obtain higher efficiency.

SUMMARY

[005] The following summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, example embodiments, and features described above, further aspects, example embodiments, and features will become apparent by reference to the drawings and the following detailed description. [006] In one aspect of the present disclosure, a method of conserving energy is disclosed. The method comprises receiving mechanical energy with a torque at a minimum level. The method further comprises driving a multi stage gear mechanism using the mechanical energy such that the torque is adjusted using a torque adjusting factor based on a gear ratio of the gear mechanism to increase the mechanical energy received at each stage of the multi stage gear mechanism, respectively.

[007] In another aspect of the present disclosure, a gear system for conserving energy is disclosed. The gear system comprises an input source, a speed increaser gear system coupled to the input source, and an energy converter coupled to the speed increaser gear system. The input source provides mechanical energy. The speed increaser gear system is driven by the input source with a torque at a minimum level required. The speed increaser gear system comprises a multi stage gear mechanism. At each stage of the multi stage gear mechanism, torque is adjusted by a torque adjusting factor based on a gear ratio of the gear mechanism to increase the mechanical energy provided by the input source. The energy converter receives the mechanical energy increased from the speed increaser gear system.

[008] Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the present disclosure are described in detail herein and are considered a part of the present disclosure. For a better understanding of the present disclosure with advantages and features, refer to the description and to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[009] The foregoing summary, as well as the following detailed description of various embodiments, is better understood when read in conjunction with the drawings provided herein. For the purposes of illustration, there is shown in the drawings exemplary embodiments; however, the presently disclosed subject matter is not limited to the specific methods and instrumentalities disclosed.

[010] FIG. 1 illustrates a gear system, in accordance to an embodiment of the invention. [Oil] FIG. 2 illustrates a gear system implemented in an electric vehicle with single electrical energy output, in accordance to an embodiment of the invention.

[012] FIG. 3 and 4 illustrate a gear system implemented in a four wheel drive system with partial mechanical and partial electrical output, in accordance to exemplary embodiments of the invention.

[013] FIG. 5 illustrates a method for conserving energy, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

[014] The presently disclosed subject matter is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or elements similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the term“step” may be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.

[015] Referring now to FIG.l, a gear system 10 is shown, in accordance with one embodiment of the present disclosure. The gear system 10 comprises an input source 12. The input source 12 provides mechanical energy. The input source 12 may include but limited to one of an air motor, a hydraulic motor, a gear motor, and a direct drive high torque motor.

[016] The input source 12 is coupled to a speed increaser gear system 14. The speed increaser gear system 14 comprises a multi stage gear mechanism. The gear mechanism used may include a reduction gear box or an increaser gear box. In one example, the speed increaser gear system 14 comprises a single stage mechanism. In another example, the speed increaser gear system 14 comprises more than one e.g., five stage mechanism. Similarly, the speed increaser gear system 14 comprises any number of stages. When the single stage mechanism is used, a gear ratio of the gear mechanism is chosen based on the requirement e.g., to ran a motor of an electric vehicle. The gear mechanism is arranged in such a way that the torque is adjusted to increase the Revolutions per Minute (RPM) for the mechanical energy received from the input source 12. Specifically, the torque is adjusted by torque adjusting factor. The torque is adjusted so that mechanical energy received from the input source 12 is increased by maintaining the torque at optimum level and increasing the output generated by the speed increaser gear system 14 with the gear ratio chosen.

[017] Typically, the torque and the RPM are manipulated based on efficiency of the gear mechanism. In typical gear system, the efficiency is defined as ability of the gear to manipulate the torque respective to the gear ratio. As such, in the gear reduction box, the percentage of the torque increase respective to the gear ratio will be the efficiency. Typically, the efficiency is calculated using an equation below.

[018] Efficiency= [(Actual Output torque/Theoretical output torque) * 100 ]

[019] Output torque = (input torque * gear ratio)* Efficiency

[020] It is evident from above that the efficiency is an important factor to consider while determining the required torque and the RPM. As such, the gear system 10 is presented in such a way that the torque is maintained at optimum level using a torque adjusting factor with respect to the gear ratio of the gear mechanism and the RPM is increased to obtain maximum efficiency.

[021] The torque adjusting factor may comprise a torque reduction factor or a torque increaser factor. The torque reduction factor is used to determine the percentage of torque reduced with respect to the gear ratio in gear increaser box. The torque reduction factor is calculated using the formula given below.

[022] Torque reduction factor= (Theoretical output torque/ Actual Output torque)

Output torque = (input torque * gear ratio) /Torque reduction factor

[023] Similarly, the torque increaser factor is used to determine the percentage of the torque increased respective to the gear ratio in the gear reduction box. The torque increaser factor is calculated using the formula given below. [024] Torque increaser factor= (Theoretical output torque/ Actual Output torque)

Output torque = (input torque * gear ratio) /Torque increaser factor [025] Based on the above, the speed increaser gear system 14 will facilitate in increasing the RPM as per the gear ratio but the torque will not be reduced by 100 percent as per the gear ratio. In one example, the torque may be reduced by between 90 percent or by 65 percent as per gear ratio which results in increasing the mechanical energy received by the speed increaser gear system 14.

[026] For example in standard method to design 1 :50 ratio gear train, the center distance of consecutive stages will be equal or lesser since the torque reduce gradually according to gear ratio. However, in accordance with the present disclosure, the center distance is gradually increased in the speed increaser gear train or the gear ratio of each stage is increased in such a way to achieve the condition that drive wheel diameter should be equal or greater in adjacent stages.

[027] Considering that the input torque is 448 NM and the gear ratio of the speed increaser gear system 14 is 1 :5 in single stage, then the expected output torque will be (448/5=89.6). For the above scenario, the torque reduction factor may be calculated as shown in Table 1.

[028] Table 1: torque reduction factor

Table 1

[029] The above table describes how much energy is saved using a single stage speed increaser gear system 14 with respective torque reduction factor.

[030] Consider that a gear motor (or) direct drive motor with efficiency 90% is used to generate mechanical energy in form of RPM and Torque with provided electrical energy. For the above example, the torque will be reduced between 4.5 -3.25 times instead of 5 with the torque reduction factor of 0.90-0.65. In multistage speed increaser gear system in order to achieve (0.1 - 0.9) torque adjustment factor, the diameter of drive wheel should be equal or greater in the next stage. The torque reduction factor will keep reducing as stages progress depends on the center distance, diameter of gear wheel and pinion ,mass of the wheel and pinion.

[031] As a result, the power consumption is reduced by 10%— 55% with TRF 0.90- 0.60 from the expected input electrical energy to achieve the output mechanical energy. [032] Based on the above, it is evident that if the torque reduction factor is low, then more input energy is saved.

[033] After maintaining the torque and increasing the RPM in order to save the input energy, the output of the speed increaser gear system 14 is coupled to an energy converter 16. It should be understood that the energy converter 16 receives the higher power from the speed increaser gear system 14 than the input energy supplied by the input source 12 to the speed increaser gear system 14. In one implementation, the energy converter 16 comprises one of an alternator, a dynamo and a compressor.

[034] Referring to FIG. 2, the gear system 10 coupled to an electric vehicle is shown, in accordance with one exemplary embodiment of the present disclosure. As can be seen, the gear system 10 comprises an energy source 11 such as battery. The energy source 11 is coupled to a motor 12. Further, the motor 12 is coupled to a speed increaser gear system 14. Furthermore, the speed increaser gear system 14 is coupled to an energy converter 16. The output generated at the energy converter 16 may be fed back to the battery 11 for recharging the battery. Further, the output of the energy converter 16 may be coupled to a motor 18 of the electric vehicle to power/run the electric vehicle. In case of using input source without gear system, at least two speed increaser stages are required and from second stage onwards the torque adjustment factor will effect. The torque adjustment factor is possible because the additional force acting on the speed increaser gear train when it has been designed as discussed in the foregoing disclosure and in some cases, a negative torque adjustment factor is achievable. That means the output torque of speed increaser gear stage may be higher than the input torque.

[035] In the above example, the battery 11 may include a 48V 40Ah Lithium battery. The motor 12 may include a BLDC or PMDC Gear motor with 48 V -40 AMPS. After connecting the motor 12 to the speed increaser gear system 14, torque is adjusted to increase the energy received at the speed increaser gear system 14 as explained above. In one example, the output generated by the speed increaser gear system 14 may include mechanical energy with HP 6.5 (torque 34.5 NM & RPM 1349). Further, the output is transmitted to the energy converter 16. In the current example, the energy converter 16 may include a PMDC generator and convert the mechanical energy to electric energy in form of direct current with V 48 & I 80 AMPS. In one implementation, the output generated may be fed back to the battery 11 for recharging the battery. For example, 48 V -40 AMPS of the output may be fed back to the battery 11. Furthermore, the output may be transmitted to the motor 18 of the electric vehicle. In one example, the output of 48V and <40 AMPS may be transmitted to the motor 18.

[036] For the above example, the input parameters considered is shown in Table 2.

[037] Table 2: Input parameters:

Table 1

[038] The output parameters considered is shown in Table 2. [039] Table 2: Output parameter

Table 2

[040] Considering that the torque reduction factor is 0.8 and the speed increaser gear system 14 comprises 5 stages, the efficiency achieved using the speed increaser gear system 14 is shown in Table 3. [041] Table 3 : Efficiency achieved in 5 stage speed increaser gear system

Table 3

[042] The gear system 10 explained above can be used to increase the input mechanical energy received from the input source 12. Further, the efficiency of the gear system 10 can be improved while using the same input mechanical energy received from the input source 12. As can be seen, the efficiency is 126% in each stage of the gear mechanism.

[043] It should be noted that the gear system 10 can be used to increase the mechanical energy at the output as compared to the mechanical energy received at the input. As such, the gear system 10 can be used in any mechanism where the same input can be used to generate more output and thereby conserving the energy to run a system that requires output with a lesser source of input energy.

[044] Referring to FIG. 3, the gear system 10 with single output shaft used in a four wheel drive system is shown, in accordance with one exemplary embodiment of the present disclosure. As can be seen, the gear system 10 comprises a power train 20 of the four wheel drive system. The power train 20 comprises an accelerator 11 which is coupled to the Electric vehicle motor 17 through a DC controller 13. The Gear motor 14 may draw power from a battery 12. Further, the gear motor 14 is coupled to a speed increaser gear system 15. The speed increaser gear system 15 increases the input received from the gear motor 14, and the output generated by the speed increaser gear system 15 may be used to transmit to an energy convertor 16. Further, the output of the energy convertor 16 may be transmitted to recharge the battery 12. Further, the output of the energy convertor 16 is coupled to a second motor 17 through a DC controller and then the output is transmitted to drive the four wheel drive system.

[045] For the arrangement shown in FIG. 3, the input parameters may be considered as shown in Table 4. The torque reduction factor is considered as 0.8. [046] Table 4: Input parameters:

Table 4

[047] Table 5 shows the output parameters required for the arrangement. [048] Table 5: Output parameters

Table 5

[049] Considering that the torque reduction factor is 0.8 and the speed increaser gear system 14 comprises 5 stages, the efficiency achieved using the speed increaser gear system 14 is shown in Table 6.

[050] Table 6: Efficiency achieved in 5 stage speed increaser gear system

Table 6

[051] Referring to FIG. 4, the gear system 10 with double output shaft used in a four wheel drive system is shown, in accordance with one exemplary embodiment of the present disclosure. As can be seen, the gear system 10 comprises a power train 20 of the four wheel drive system. The power train 20 comprises an accelerator 11 which is coupled to a motor 14 through a DC controller 13. The motor 14 may draw power from a battery 12. Further, the motor 14 is coupled to a speed reduction gear system 15. The speed reduction gear system 15 will increase the torque and reduce the RPM. Further the Speed reduction gear system 15 connected to the speed increaser gear system 16. The speed increaser gear system 16 increases the input received from the speed reduction gear system 15, and the output generated by the speed increaser gear system 16 may be used to transmit to an energy convertor 17. Further, the output of the energy convertor 17 may be transmitted to recharge the battery 12. Further, the output shaft 18 of the speed increaser gearbox 16 is transmitted to drive the four wheel drive system.

[052] For the arrangement shown in FIG. 4, the input parameters may be considered as shown in Table 7. The torque reduction factor is considered as 0.8.

[053] Table 7: Input parameters:

Table 7

[054] Table 8 shows the output parameters required for the arrangement. [055] Table 8: Output parameters

Table 8

[056] Considering that the torque reduction factor is 0.8 and the speed increaser gear system 14 comprises 5 stages, the efficiency achieved using the speed increaser gear system 14 is shown in Table 9. [057] Table 9: Efficiency achieved in 5 stage speed increaser gear system

Table 9

[058] Referring to FIG. 5, a method 100 of conserving energy is disclosed. The method 100 is implemented at the speed increaser gear system 14 described using FIG. 1. At step 102, mechanical energy with a torque at a minimum level is received.

[059] At step 104, the torque received is adjusted to drive a multi stage gear mechanism using the mechanical energy. The torque is adjusted using a torque adjusting factor based on a gear ratio of the gear mechanism to increase the mechanical energy received at each stage of the multi stage gear mechanism, respectively.

[060] While there has been shown, and described herein what are presently considered the preferred embodiments of the present disclosure, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the present disclosure as defined by the appended claims.

[061] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present disclosure. Indeed, the novel methods, devices, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the methods, devices, and systems described herein may be made without departing from the spirit of the present disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the present disclosure.