This utility patent application is based on and claims the filing date benefit of U.S. provisional patent application (Application 62/480,183) filed on 3/31/2017.

TECHNICAL FIELD

This invention relates to linear drive actuators, and more particularly to portable, compact linear drive actuators.

BACKGROUND ART Linear driver actuators used with portable hand tools commonly include a hydraulic cylinder coupled to an internal or external gas or electricity powered hydraulic pump. The hydraulic cylinder and pump require periodic inspections and maintenance. Also, the hydraulic cylinder and pump limit the size of the actuator.

Linear drive actuators are desirable because they are compact and lightweight. Unfortunately, they use roller screws that need lubrication and produce heat.

DISCLOSURE OF THE INVENTION

It is an object of the present invention to provide a durable, lightweight, compact and versatile linear drive actuator that uses a roller screw as the mechanical linear drive mechanism.

It is another object of the present invention to provide a linear drive actuator that uses a roller screw with greater lubrication and heat dissipating features.

Disclosed herein is a linear drive actuator that includes an improved linear drive mechanism that uses a solid or hollow, threaded roller screw shaft with a low clearance, high capacity roller bearing, herein after called a tlirust bearing, integrally formed or shaped on its proximal end. An inner race with a plurality of non-helical grooves is formed on the proximal end of the shaft. Disposed longitudinally and axially around the inner race is a plurality of parallel rollers that include a plurality of teeth. Disposed around the rollers is a cylindrical outer race with a set of non-helical grooves configured to mesh with the teeth on the rollers.

Mounted over the distal end of the roller screw shaft is a roller screw nut. The roller screw nut includes an outer race, a plurality of grooved rollers axially aligned inside the outer race, and an inner race. When the roller screw shaft is rotated, the roller screw nut moves axially over the roller screw shaft. A hollow extension tube longitudinally aligned with the roller screw shaft and configured to axially move with the roller screw nut.

Surrounding and covering the roller screw housing and the extension tube is a closed main housing configured to be filled with lubricating fluid. The extension tube is sufficient in length, so its distal end extends from the distal end of the main housing and connects to an end termination or a tool implement.

The proximal end of the roller screw shaft connects to a drive axle from a gearbox assembly located in a gearbox housing. The gearbox housing is attached to a motor housing containing at least one primary motor. Located adjacent to the motor housing is a volume compensator housing with an internal filling cavity. A sealing piston divides the filling cavity into a lubricating holding chamber filled with a lubricant fluid and an air chamber that communicates with atmospheric air.

The gearbox housing and motor housing include fluid passages that allow lubricating fluid to flow back and forth through the main housing and into and around the roller screw shaft and the elongated tube. During operation, lubricating fluid flows through the motor housing, through the gearbox housing, through the roller screw shaft, through the extension tube and into the main housing. During operation, the axial movement of the nut body and the extension tube changes the volume of the main housing which causes lubricating fluid to flow back and forth between the lubricating holding chamber and the main housing. The lubricating fluid further acts as a heat transfer media which conducts heat away from the gearbox, the motors, the thrust bearing and roller nut to the main housing where the heat can be readily conducted to the external environment, cooling the system.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of an improved linear drive actuator shown herein.

Fig. 2 is an exploded, perspective view of the improved linear drive actuator.

Fig. 3 is a sectional, side elevational view of the improved liner drive actuator.

Fig. 4 is a sectional perspective view of the volume compensating housing.

Fig. 5 is a sectional perspective view of motor assembly.

Fig. 6 is a sectional, perspective view of the gearbox assembly.

Fig. 7 is a front perspective view of the multiple gear system used in the gearbox assembly.

Fig. 8 is a rear perspective view of the multiple gear system used in the gearbox assembly.

Fig. 9 is a sectional perspective view of the multiple gear system.

Fig. 10 is an end elevational view of the gearbox housing.

Fig. 11 is a sectional perspective view of the roller screw shaft attached to the gearbox housing.

Fig. 12 is an end elevational view of the roller screw shaft.

Fig. 13 is a sectional side elevational view of the distal end of the roller screw shaft with the rotating roller nut attached to the roller screw shaft that axially extends or retracts the elongated tube.

Fig. 14 is a partial, sectional side elevational view of the roller nut mounted on the drive screw.

Fig. 15 is sectional side elevational view of the main housing.

BEST MODE FOR CARRYING OUT THE INVENTION

Disclosed herein in Figs. 1-15 is a linear drive actuator 10 with a motor assembly 40, a multiple gear and torque sensing assembly 60, an improved linear drive mechanism 100, and an internal closed lubricating and cooling system 220.

The improved linear drive mechanism 100, (shown in Figs. 2, 11, and 13) uses a hollow, threaded roller screw shaft 102 with a low clearance, high capacity roller bearing, herein after called a thrust bearing 120. The thrust bearing 120 includes an inner race 126 with a plurality of non-helical grooves 128 formed on the proximal end 104 of the screw shaft 102. Disposed longitudinally and axially around the inner race 126 is a plurality of parallel rollers 130 that include a plurality of teeth 132. Disposed around the rollers 130 is a cylindrical outer race 122 with a set of non-helical grooves 124 configured to mesh with the teeth 132 on the rollers 130.

Mounted on the screw shaft 102 is a thrust bearing retainer plate 112 aligned over the distal opening formed on a gearbox housing 61 that houses a multiple gear and torque sensing system 60.

Mounted over the section distal end of the screw shaft 102 is a roller screw nut 136. The roller screw nut 136 includes an outer race, a plurality of grooved rollers axially aligned inside the outer race 138, and an inner race 140. When the roller screw shaft 102 is rotated, the roller screw nut 136 moves axially over the screw shaft 102. A hollow extension tube 145 is longitudinally aligned with the screw shaft 102 and configured to axially move with the roller screw nut 136. Attached to the distal end of the roller nut 137 is a hollow, elongated extension tube 145 Surrounding and covering the roller screw housing 137 and the extension tube

145 is a closed main housing 150. The extension tube 145 is sufficient in length so its distal end extends from the distal end opening on a main housing 150 and connects to a terminating end element of a tool implement (not shown).

Motor Assembly

As shown more clearly in Fig. 5, the motor assembly 40 is similar to the motor assembly disclosed in U.S. patent application 15/525,824, and now incorporated therein. The motor assembly 40 includes a motor bracket 41 with a cylindrical rear body 42 and a cylindrical front neck 46. Between the rear body 42 and the front neck 46 is a transverse support plate 45. Formed on the rear body 42 are two motor mounts 48, 49, that receive the primary motor 50 and secondary motor 55.

During assembly, the motors 50, 55 are axially aligned in the motor mounts 48, 49, respectively, so the drive shaft 52 on each motor 50 extends through the transverse plate 45. A pinion gear 54 is attached to each drive axle 52. Formed on the transverse plate 45 is at least one fluid hole 47 that allows the lubricating fluid 300 to flow back and forth through the transverse plate 45. In one embodiment, the drive shaft on the primary electric motor 50 is connected to pinion gear in the gearbox housing. Surrounding the pinion gear is a coaxially carrier ring with an appropriate number of equal size planet gears mounted thereon. The planet gears include teeth that mesh with exterior teeth on the pinion gear. Surrounding the carrier ring is a coaxially aligned outer ring gear with inner teeth that mesh with teeth on the planet gears. The outer ring gear is fixed relative to the pinion gears so the carrier ring and the pinion gears rotate inside the outer ring gear. The gear ratio of the roller screw shaft 20 to the primary electric motor 160 and the pinion gear is approximately 1 :5 but can vary over a wide range depending on the final application of the liner drive actuator 10.

Gearbox Assembly and Torque Sensing System

Positioned in front of the motor assembly bracket 41 is a multiple gearbox assembly and torque sensing system 60. The gearbox assembly 60 includes a gear box housing 61 with a distal end opening 62 and a proximal end opening 64. Formed inside the gear box 61 housing is a gear cavity 65 configured to receive the multiple gear system 68. Attached to the distal end opening 62 is a thrust bearing retainer plate 120.

The multiple gear system 68, shown in Figs 6-10 includes a first stage ring gear 70. When first stage ring gear 70, is fixed and not allowed to rotate, the overall speed reduction of the gearbox assembly 60 is maximized and the output speed

(rotation rate of drive pins 72) of the gearbox assembly 60 is minimized. When the internal brake holding ring gear 70 is released and secondary motor 55 is energized so the first stage ring gear 70 is rotated, then the effective speed reduction (gear ratio) of the first stage of the gearbox 60 is reduced thereby decreasing the overall speed reduction of the entire gearbox 60 and increasing its output speed.

The second and third stage ring gear sleeve and flange 73 is supported radially and axially by the gearbox housing 61 but may rotate within the gearbox housing 61. It is supported in the circumferential direction (rotationally) by a plurality of coil springs 76 which progressively compress as the output torque of the system increases. The deformation of these coil springs 76 results in the progressive rotation of the second and third stage ring gear sleeve and flange 74, the second stage ring gear 78 and the cylindrical extension elements 80. Cylindrical extension elements 80 are positioned to apply a normal force to profile incorporated into the inner surface of friction brake element 84. The rotation of these extension elements 80 in response to the output torque of the gearbox provides the control feedback for the system thus acting as a torque sensing system. In the current embodiment, the progressive rotation of control profile 91 relative to the stationary external gearbox housing 61 is used to open or close a control switch (not shown) for the secondary motor 55.

The internal surface of the cylindrical extension element 80 bears upon a profile or cam shape 85 on the interior surface of the friction brake element 84. The cylindrical extension element 80 rotates progressively along with all the other components in response to the deformation of the coil spring supports 76. Prior to the application of the ring gear brake, when the output force of the actuator 10 is low, the cam shape 85 is positioned so a control switch (not shown) is closed and the secondary motor 55 is activated which causes the ring gear 70 to rotate, reducing the gear ratio from the primary motor 50 to the output drive pins 71. The output speed of the gearbox 60 decreases as the actuator's internal drive torque and overall output force increases.

Improved Linear drive mechanism

Located in front of the gear box housing 61 is an improved linear drive mechanism 100 that includes a hollow roller screw shaft 102 with a wide cylindrical inner race 126. Attached to the front or distal end of the gear box housing 61 is a end cap 115. Formed inside the end cap 115 is an inner cavity 66 that forms the outer race 122 to holds a separately inserted outer race 122. During assembly, the proximal end of the screw shaft 102 is inserted into the closed cavity. Disposed between the outer race 122 and the inner race 126 are a plurality of rollers 130. In combination, the screw shaft 102, outer race 122, the inner race 126 and rollers 130 form a thrust bearing similar too the low clearance high capacity roller bearing disclosed in U.S. Patent Application 15/523620, filed on May 1, 2017, now incorporated by reference. The screw shaft 102, shown more clearly in Fig. 11, includes a longitudinally aligned center bore 108 and a cylindrical shaped, wide inner race 126 integrally formed near the proximal end 104. Located inside the front cavity 66 on the gearbox housing 61 is a fixed outer race 122. Formed on the inside surface of the outer race 122 are non-helical grooves 124. Disposed between the inner race 126 and the outer race 106 are a plurality of parallel and longitudinally aligned rollers 130. Each roller 130 includes a plurality of teeth 132 configured to mesh with the non-helical grooves 128 formed on the inner race 126. Formed and extending the full length of the screw shaft 102 are helical threads 110.

The inner race 126 is integrally formed on the proximal end of the screw shaft 102. As shown in Fig. 12, the proximal end surface of the inner race 126 includes four pegs holes 129 that receive the pegs 71 on the gearbox assembly 60. When the pegs 71 are rotated, the inner race 126 rotates inside the outer race 122 which causes the entire screw shaft 102 to rotate. As the screw shaft 102 rotates, the roller nut 134 discussed further below moves axially over the screw shaft 102.

Roller Screw Nut

The roller screw nut 134 is similar to the geared planetary roller screw shown in U.S. Patent No. 2,683,379 (Strandgren) which is now incorporated herein. The roller screw nut 134, shown in Fig. 14, includes an outer nut holder 136, that surrounds a roller nut body 137. Located inside the roller nut body 137 is a plurality of rollers 138. Located on each end of the screw nut 134 in an alignment spacer 139 and a pre-load ring. (See Fig. 13).

When the screw shaft 102 is rotated, the roller nut 134 moves longitudinally over the screw shaft 102. Formed on the distal end of the roller nut 134 is a recessed circular groove 139 that receive a tab 149 formed on the proximal end of the extension tube 145 to securely connect the nut body 137 to the extension tube 145.

Extension Tube and Main Housing

As mentioned above, and shown in Figs 3, 10, and 12 attached to the roller nut housing 132 is a hollow extension tube 145. The distal end of the extension tube 145 is closed with a clevis 148. Longitudinally aligned over the screw nut 134 and the extension tube 145 is an elongated main housing 150. Attached to the distal end of the main housing 150 is a sealing end cap 156. During assembly, the screw shaft 102 is inserted into the roller nut 134 and the roller nut 134 and the extension tube 145 are longitudinally aligned and inserted into the main housing 150. The distal end of the extension tube 145 includes a clevis 148 or other similar end connector that extends from the bore formed on the end cap 156 on the distal end of the main tube 150 and connects to a tool or application. When the screw shaft 102 is rotated, the roller nut 134 and the extension tube 145 move axially inside the main housing 150.

Lubricating and Cooling Fluid Flow System

The linear drive actuator 10 includes a lubricating and cooling system 220 used to continuously lubricate and cool the actuator during operation. The system 220 includes volume compensation housing 222 located adjacent to the motor assembly 40 and opposite the multiple gearbox and torque sensing system 60. The volume compensation housing 222, shown in Fig. 4, includes an opened proximal end 32 and an opened distal end 34. Located inside the housing 222 is a transversely aligned intermediate wall 224.

Extending into the proximal end opening 226 is an end cap 228 that includes an end plate 230 and a cylindrical body 232 that extends perpendicularly from the inside surface of the end plate 230. The inside void area in the cylindrical body 232 forms a filling cavity 234. An o-ring 237 is mounted between the inside surface of the volume compensation housing 222 and the outside surface of the cylindrical body 232 to form a water tight seal.

Located inside the filling cavity 234 a transversely aligned piston 240 that divides the filling cavity 234 into a rear air chamber 242 and a front lubricant holding chamber 246. An air hole 244 is formed on the end plate 230 which connects the air chamber 242 to the atmosphere. The piston 240 is configured to slide inside the cylindrical body 232. An o-ring 248 is placed between the outer edge of the piston 240 and the inside surface of the cylindrical body 232 to create a watertight seal.

Between the intermediate wall and the piston 240 is a coil spring 250 configured to create a rearward biasing forcing on the piston 240.

Dispensing into the lubricating holding chamber 246 is a lubricating fluid 300, such as mineral oil. Formed on the intermediate wall is a fluid hole 260 that enables lubricating fluid 300 to flow into the lubricant holding chamber 246. Formed on the front plate 224 is a fluid hole 225

During operation, the piston 240 moves longitudinally inside the filling cavity 234 in response to differences in pressure between the atmosphere and the pressure exerted on the lubrication volume created by movement of the roller nut bearing housing and the extension tube 145 discussed further below.

Operation

During assembly, lubricating fluid 300 is poured into the lubricating holding chamber 246 formed in the volume compensation housing 222. Lubricating fluid 300 then flows into the front cavity 228 of the volume compensation housing 222 around the primary and secondary motors 55, 60 through the motor bracket and into the gearbox cavity. The lubrication fluid 330 then flows around the thrust bearing 120, around the screw shaft 102 and into the roller screw bore 108. The lubrication fluid 300 then flows into the extension tube 145. The entire system is closed so that when the volume for the lubricating fluid 300 inside the extension tube 145 changes, lubricating fluid 300 flows back and forth between the filling cavity and the extension tube 145 according to pressure differences between the atmosphere and the extension tube 145. For example, when the extension tube 145 is extended, the volume for the lubricating fluid 300 inside the extension tube 145 is increased which draws lubricating fluid 300 from the lubrication fluid chamber 246 into the motor bracket, through the gearbox housing 61 , into and around the screw shaft 102. The piston 240 moves so atmospheric air 200 is drawn into the air chamber 24. When the extension tube 140 is retracted, the volume for lubricating fluid 300 inside the extension tube 145 is reduced which causes lubricating fluid 300 to flow back into the lubrication fluid chamber 246. Air inside 320 the air chamber 242 is forced outward. The piston moves to accommodate the changes of volume of the lubricating fluid 300 in the chamber 246.

In compliance with the statute, the invention described has been described in language more or less specific as to structural features. It should be understood, however, that the invention is not limited to the specific features shown, since the means and construction shown comprises the preferred embodiments for putting the invention into effect. The invention is therefore claimed in its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted under the doctrine of equivalents.

INDUSTRIAL APPLICABILITY

This invention has application in the tools and machinery industry. More specifically, in industries that require linear drive activators and roller screws and roller bearings.