GEARLESS VARIABLE SPEED REDUCER

PROBLEM DEFINITION

There are many machines and mechanical units that under varying circumstances make it
desirable to be able to drive at an barely perceptible speed , an inter mediate speed or a high speed.
Thus a infinitely variable (or stepless speed variation in which it is possible to get any desirable
speed . Some mechanicals hydraulic and electrical devices serve as such stepless drives .However
the torque Vs speed characteristics of these drives do not match that of stepless drives at increased
driving torque at low speeds.
Hence the need of an stepless drive with the following characteristics
1) Stepless or infinitely variable speed.
2) Wide range of speed variation ie(Nmax to Nmin).
3) Shifting form one speed to another should be
shockless .
4) Minimum no of controls for speed changing .
5) Ease of operation.
6) Compact construction .

THE SOLUTION
In many drives , it is desirable to be able to shift from one speed to another without
stopping the machine and also be able to obtain any speed between the max and min . A design
which meets these requirements is the
GEARLESS VARIABLE SPEED REDUCER.

GEARLESS VARIABLE SPEED REDUCER is a mechanical adjustable speed drive .The speed
range is infinitely adjustable from 0 to of input speed under full rated load.
This is generally stated as 0 to 400 rpm under full rated load assuming an input of 1800 rpm.
Zeromax drive may be connected to any rotating power source upto 2000 rpm. Speed adjustments
are easily made by moving a lever control through an arc. Precise speed control settings are possible.













PRINCIPLE OF OPERATION




Externally, the GEARLESSVARIABLE SPEED REDUCER consists of a rugged case, an input shaft, output
shaft and speed control. Speed of the output shaft is regulated precisely and easily through a control lever which includes
a convenient locking mechanism or a screw control to hold speed at a desired setting.
The general principle of operation of GEARLESSVARIABLE SPEED REDUCERs gives infinitely adjustable
speed by changing the distance that three or more one-way clutches rotate the output shaft when they move back and
forth successively. The number of strokes per clutch per minute is determined by the input speed. Since one rotation of
the input shaft causes each clutch to move back and forth once, it is readily apparent that the input speed will determine
the number of strokes or urgings the clutches give the output shaft per minute. For example, with four clutches working
in series and an input of 1800 RPM, the output shaftis urged 7200 times per minute (1800 x 4) or 120 times per second
(7200 60). If the input speed is dropped to 900 RPM, the shaft is urged only 3600 times per minute and the maximum
output speed will be cut in half.
Looking at Figure 1, the input section , consisting of a shaft (A), eccentrics (B), and connecting rods (C), converts rotary
motion into linear motion. At the zero setting, the main links (D) pivot on points (H) and (J) without moving the
clutches. At any setting other than zero, the clutches (E) transfer the linear motion back into rotary motion and drive the
output shaft (F). A control link (G) swings through arc (K) when the control lever is moved. At any point along arc (K)
a different output speed is produced because the direction of throw of the connecting rod is altered from vertical (Figure
1 zero RPM position) toward horizontal (Figure 2 maximum speed position), varying the length of the strokes the main
links deliver to the overrunning clutches.









GEARLESS VARIABLE SPEED REDUCER CONSTRUCTION










CONSTRUCTION

A) ELECTRIC MOTOR
Electric motor is the source of energy in this stepless drive. It has the following
specifications
SINGLE PHASE AC MOTOR
230 volt, 50 Hz , 0.5 amp
Power = 50 watt. (1/ 15 Hp)
Speed = 0 to 9000
TEFC CONSTRUCTION
COMMUTATOR MOTOR.

B) REDUCTION PULLEY
This arrangement is for transmitting the power from the motor shaft to the
input shaft , the power is transmitted by means of an v-belt.

C) INPUT SHAFT
Input shaft is an high grade steel (EN 24) construction coupled to the motor by
coupling at one end .Input shaft is an special construction with eccentrics in built in
the shaft it self. The input shaft is an integrated construction comprising of three
sets of built in cranks . Each crank constitutes of two crank webs and the input shaft
connects the webs by means of input shaft pin and int_pin.

D) CONNECTING ROD :-
Connecting rod is an element which is imparted oscillating motion by the input
shaft .Connecting rod is connected to the input shaft by the eccentric pin at the
other end.

E) CONNECTING LINK :-
Connecting link is the member that connects the connecting rod to the output
yoke. The connecting link carries a ball bearing at its each end . At one end the
connecting rod is connected and at the other end it is connected to the output yoke.
F) CONTROL LINK
The control link is the speed governing member , it changes the position of the
joint of the connecting link with conrod. This control link is connecting link is
mounted in bearing on an pin mounted in the conrod. The onther end of the
control link lies on the control shaft.

G) OUTPUT YOKE:-
Out put yoke is connected to the connecting link which oscillates it about the output
shaft. Output yoke houses an unidirectional clutch called roller clutch that is
mounted on the output shaft.









H) UNIDIRECTIONAL CLUTCH;-
The unidirectional clutch is very much similar in action to the bicycle free
wheel. The construction of this unidirectional clutch in shown in the figure . The
inner driving member is connected to the output shaft and the outer one is
connected to the output yoke . The driving member as shown in fig has five steps .
In each step there are springs mounted rollers.
when the driving member is rotating in the direction shown in fig the driven
member will also be rotating in the same direction . But when the driving member
rotates in opposite direction the inner member will not rotate along with the outer
one. Thus the output shaft is located from the output yoke for second half of the
oscillation.

I) SPEED CHANGING MECHANISM
The speed changing mechanism is simple in construction. It consists of a
control shaft that is mounted on two cranks that are hinged to the frame . The
control shaft carries an handle. Turning the handle changes the position of the
connecting link conrod joint which will lead to change in the degree of oscillation of
the output yoke thereby speed change of the output shaft


J) CASING
Casing in our case is an fabricated one; due to the fact that the present model is
an demonstration model . The actual casing of oil sump for lubrication
purpose & dust proof arrangement .





WORKING

The speeds are instantly changed by turning the handle indicated by G .
On the drive shaft A is mounted a series of eccentrics B. These eccentrics are
connected to connecting links C by connecting rod D.
As the drive shaft rotates , the eccentrics impart an oscillating movement to
the left hand ends of the connecting links C and as these are pivoted to the output
yoke E they impart oscillatory movement to the roller clutches within yokes E .Each
reciprocating movement of clutch will cause the drive shaft to rotate a fraction of a
revolution , and as the eccentrics are spaced uniformly about the drive shaft , the
impulse given to the driven shaft will be successive and over lapping .In this way a
uniform rotary movement of the driven shaft is obtained .

The oscillating movement of the right hand end of the link C determines
the amount the driven shaft turns during each impulse, and this oscillating movement
depends upon the position of joint M along the path determined bi the control link
end when the control shaft is rotated about hinge K by handle G
For example if joint M is moved towards the right by which reciprocating
movement of clutch will be shorter , and a longer time will be required to rotate the
driven shaft thereby reducing the speed of the output shaft..
Obviously an entire range of speeds is covered smoothly , enabling the
mechanism to glide from one speed to another.








ADVANTAGES OF GEARLESS VARIABLE SPEED REDUCER
Features
Compact
Benefits
Easy to handle/compact
Simple to install No special wiring/training
Simple operation. Easy to operate with lever or screw control -
Repeatable
Use anywhere on machine Accepts input to 2,000 RPM. Ideal secondary
controller
Constant torque Delivers constant torque throughout the speed range
4:1 speed reduction Often usable without additional speed reduction
Change speed anytime Speed set-ups are made quickly and easily
Change speed frequently Permits slow or fast, small or large speed changes
Change speed continuously Ideal for dancer applications/ constant speed changes
Leave at one setting No daily speed cycling
Accurate speed holding No "wear-in" period/constant speed operation
Accepts any input World's most versatile, economical secondary drive
Goes to zero output Ideal for use as a clutch
Simple maintenance Easily lubricated
Low cost Ideal for users and original equipment manufacturers
Proven design More than a million sold
Shaft/control/motor options Versatile
Infinitely adjustable 0-400 RPM speed range with 1800 RPM input.

1. Stepless variation of speed :-
Any speed between Nmax to N min can be obtained . The conventional gives fixed speed
ratios that too in steps.
2. Wide range of speeds Ratio :-
The speed ratio can be varied one a wide range which is not possible in conventional
gearbox where it is fixed speed ratio.
3. Compact size :-
The size of the gear less variable speed reducer is very compact; which makes it low weight
and occupies less space in any drive.
4. Ease of operation :-
The changing of speeds is gradual one hence no calculations of speed ratio required for
change gearing .Merely by rotating hand wheel speed can be changed .
5. Singular control :-
Entire range of speeds is covered by a single handle control .
6. Low cost .

APPLICATIONS OF ZERO-MAX DRIVE
1. Automatic transfer lines.
2. Assembly automation.
3. Conveyor drives
4. Bottle filling plants
5. CO
2
/ arc welding table drives.
6. Spot welding robot feed drives.
Textile Machinery,etc