Title of Invention

ROTARY ACTUATOR.

Abstract A rotary actuator(100) incorporating a shell(102), an output plate(134) and a cross-roller bearing retaining the output plate within the shell(102). A prime mover(122), disposed within the shell(102), exerts torque on a gear train (124)within the shell(102). A pair of gears(104 & 106), disposed on either side of the cross-roller bearing(108), made with one or more gears(110 & 112) in the gear train(124). Depending on the application, the gear train(124) may be a planetary epicyclic or an eccentric hypocyclic type.
Full Text ROTARY ACTUATOR
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of U.S.
Provisional Patent Application Serial No. SO/429,276, filed
November 25, 2002.
TECHNICAL FIELD OP THE INVENTION
(0002] The present invention relates in general to rotary
power devices, and specifically to rotary actuators for use in
automated machinery.
BACKGROUND ART
[0003] Most automated mechanical systems developed today
are built as unique custom one-off systems employing little or
no standardized architecture. This one-off design methodology
tends to result in systems exhibiting relatively high cost and
a low rate of change and diffusion of new technology.
[0004] Another undesirable effect of custom mechanical
design methodology is rapid obsolescence. In general,
operator interfaces are cumbersome, maintenance training is
complex, and the logistics trail for maintenance is a
permanent and expensive user obligation.
[0005] Often, the designer of an automated mechanical
system .is first faced with the design of a machine joint,
which, owing to the relative absence of standardised machine
joint solutions, must be performed beginning from basic
structural components, such as plates, beams, and bearings.
[0006] Given a machine joint of sufficient rigidity, the
machine designer then moves to specification and selection of
a prime mover, a power source for the prime mover, positional
and velocity feedback sensors for the joint, a control system
for the prime mover, all necessary wiring, and any necessary
intermediate geartrain and power transmission elements.
Generally, these components will be discrete components.
Although certain components may be designed to interface with
the related components, a relatively high degree of
engineering effort must still be exerted to ensure that the
various components will work together properly under a variety
of operating conditions.
[0007] One area in which integration has been effectuated
with some degree of success is integration of the prime mover
and the gear train. Modules incorporating both a prims mover
and a gear train are known as "gearmotors" or "gearhead
motors." Although somewhat successful, this integration has
suffared from the use of inadequate gear train designs,
thereby limiting the overall effectiveness of such modules.
[O0O8] Development work in gear trains has been largely
stagnant for many years, with the conventional wisdom being
that all the science available has borne all the results that
are feasible. Generally, system designers would prefer to
eliminate the gear train entirely, along with its weight,
backlash, noise, cost, and presumed complexity.
[0009] Hypocyclic gear trains were first developed and
patented in the late nineteenth century. A further surge in
patenting occurred in the mid-1930s. Several industrial
manufacturers presently produce gear transmissions using
hypocyclic gear trains, but their designs mimic older designs,
which contain many parts and bearings, a circuitous force
path, and two opposing wobble plate gears, for balancing
purposes. The balancing issue has limited, to a certain
extent, the use of wobble gear designs/ but so long as the
driving eccentric for these gears is relatively small, on the
order Of 3% or lass, they can be well-balanced using modern
methods of precision balancing.
[0010] In some hypocyclic gear trains produced presently,
only one wobble plate gear mesh is used. These designs use
pins through the plates to transmit torque to the output
plate, adding a further level of complexity and a number of
dimensions having critical tolerances.
[0011] For perhaps thirty years., a low level of interest
has been shown in the design of hypocyclic motors with the
claim that they produce high torque at low speeds. They do,
but no one has heretofore found a satisfactory means to get
that high torque to a concentric rotating output shaft.
[0012] At least three principal variations of cycloidal
drive gear trains currently exist. These include the designs
produced by SUMITOMO™ (Japan), TEIJIN 3B1KI" (Japan) and
ANDANTEXTM (France) . These designs all depend on dual wobble
plate differencing gears, set 180 degrees out of phase for
balancing, driven either by a precision cycloidal surface or a
dual set of eccentrics. The force path for these devices
between input and output is long and circuitous, requiring a
large, and very heavy, hoop structure to keep all the forces
contained.
[0013] These devices use rollers on curved surfaces and
cantilevered pins to provide the final drive to their output
plates. Also, this type of drive is connected to a small
output shaft supported by additional bearings. All of this
adds considerably to the compliance and lack of rigidity of
the gear train. Because of their unique geometry, complexity,
volume and weight, these gear trains are very difficult to
integrate into self-contained actuator modules.
DISCLOSURE OF THE INVENTION
[0014] As discussed above, automated mechanical systems are
generally custom, one-off systems designed essentially from
the ground up. The inventor of the standardized rotary
actuator module described herein believes that the level of
custom engineering required for the implementation of a motion
contol system can be drastically reduced though the
development and use of standardized modules of the type
described herein.
[0015] As a solution to the "custom design" dilemma for
automated machines, the inventor suggests the implementation
of an open architecture, using standardized building blocks
including standardized actuators, links, end-effector tools,
controllers, and related components, which can be assembled on
demand and operated by standardised operating system software.
[0016] To this end, the present invention is an integrated
standardized rotary actuator incorporating a prime mover, a
gear train, and a rotary machine joint in a single package.
These elements are integrated into a single self-contained
module that is easily scalaable to meet a wide variety__of
application demands. The rotary actuator may incorporate as
few as five principal parts fitted with a minimum of critical
tolerances, resulting in a system that is substantially
insensitive to tolerance and temperature variations.
[0017] In certain embodiments, the rotary actuator modules
of the present invention may be produced in standardized
geometries and sizes. An appropriate set of standardized
sizes facilitates the standardization of machine architecture
accordingly. This standardization enables the machine
designer to assemble or reconfigure machines on demand, in a
similar manner to that employed presently for the
configuration of personal_ computers. The use of standards
enables the diffusion of new technology, tending to increase
performance while decreasing costs.
[0018] One object of the present invention is to create a
standardized rotary actuator which can be mass produced at low
cost, low weight and low volume, and still maintain a high
level of performance- Various levels of ruggedness— for
example, light, medium, and heavy—may be developed for
various applications.
[0019] The present invention is a new high-performance
rotary actuator in a variety of embodiments sharing certain
characteristic features. Xn general, a high level of
performance can be preserved even for low cost versions of the
present invention. Depending on the application, each of the
embodiments incorporates features generating one or more of
certain advantages.
[0020] The novel design of certain embodiments of the
present invention provide simplicity of design using a minimal
number of parts and a minimized list of parameters, thereby
allowing for a relatively small form . factor exhibiting
exceptional compactness, stiffness and load capacity, along
with quiet and efficient operation. They can be designed for
easy assembly, ideal for mass production at various quality
levels.
[0021] Certain embodiments of the present invention may be
especially useful in low speed and high torque applications of
the type found in dextrous machines having complex duty
cycles. Examples of these types of applications include those
found in robots, manufacturing cells and aircraft actuators.
[0022] The rotary actuators described herein have the
potential to be more compact, simpler, more easily assembled
and less expensive than any rotary actuator developed before.
These devices may also be configured to exhibit lower inertia
and provide higher stiffness than any rotary actuator
developed before.
[0023] Xn a first embodiment, the present invention is a
rotary actuator incorporating an actuator shell having a
planetary cage disposed therein. A prime mover having a first
prime mover portion rigidly fixed to the actuator shell and a
second prime mover portion, adjacent to, and movable with
respect to, the first prime mover portion, is rigidly fixed to
the planetary gear cage. A cross-roller bearing locates an
output attachment plate within the shell. A shell gear is
rigidly fixed to the actuator shell and an output gear is
rigidly fixed to the output attachment plate. One or more
planetary gears, disposed in the planetary cage, each have a
first gear portion meshed to the shell gear and a second gear
portion, adjacent to the first gear portion, meshed to the
output gear.
[0024] In a second embodiment, the present invention is a
rotary actuator incorporating an actuator shell with an
eccentric cage and. prime mover disposed therein. One portion
of the prime mover is rigidly fixed to the shell, while a
cross-roller bearing secures an output attachment plate within
the shell. A shell gear is rigidly fixed to the actuator
shell, and an output gear is rigidly fixed to the output
attachment plate. An eccentric, disposed about the eccentric
cage, has a first gear portion meshed to the shell gear and a
second gear portion, adjacent to the first gear portion,
meshed to the output gear.
[0025] In a third embodiment, the present invention is a
rotary actuator incorporating an actuator shell having a prime
mover and a two stage planetary gearset disposed therein. The
prime mover is connected to rotate the planet gear cage of the
first stage of the gearset with respect to the actuator shell.
A shaft, having a shaft gear rigidly fixed thereto, ia
disposed within the actuator shell.
[0026] Also in this third embodiment, a second planetary
gear cage, rotatable with respect to the first planetary gear
cage and the shaft, has a cage gear rigidly fixed thereto.
One or more first stage planetary gears disposed in the first
planetary gear cage, each have a first gear portion meshed to
the shaft gear and a second gear portion, adjacent to the
first gear portion, meshed to the cage gear. A cross-roller
bearing secures an output attachment plate within the shell.
[0027] In order to facilitate the communication of
mechanical power out of the actuator, a shell gear is rigidly
fixed to the actuator shell and an output gear is rigidly
fixed to the output attachment plate. Finally, one or more
second stage planetary gears are disposed in the second
planetary gear cage, each having a first gear portion meshed
to the shell gear and a second gear portion, adjacent to the
first gear portion, meshed to the output gear.
BRIEF DESCRIPTION OF DRAWINGS
[0028] For a more complete understanding of the features
and advantages of the present invention, reference is now made
to the detailed description of the invention along with the
accompanying figures in which corresponding numerals in the
different figures refer to corresponding parts and in which:
Figure 1 is a cutaway isometric view of a rotary
actuator in accordance with one embodiment of the present
invention;
Figure 2 is a cutaway isometric view o£ a rotary
actuator in accordance with a second embodiment of the
present invention;
Figure 3 is a cutaway isometric view of a rotary
actuator in accordance with a third embodiment of the
present invention;
Figure 4 is a cutaway isometric view of a rotary
actuator in accordance with a fourth embodiment of the
present invention;
Figure 5 is a cutaway isometric view of a rotary
actuator in accordance with a fifth embodiment of the
present invention;
Figure S is a cutaway isometric view of a rotary
actuator in accordance .with a sixth embodiment of the
present invention;
Figure 7 is a cutaway isometric view of a rotary
actuator in accordance with a seventh embodiment of the
present invention;
Figure 8 is a cutaway isometric view of a rotary
actuator in accordance with certain embodiments of the
present invention;
Figure 9 is a aide view of a circular arc gear tooth
mesh in accordance with certain embodiments of the
present invention;
Figure 10 is a side view of a single circular arc
gear tooth in accordance with certain embodiments of the
present invention;
Figure 11 is a side view of a single circular arc
gear tooth in accordance with certain embodiments of the
present invention; and
Figure 12 is a side view of a single circular arc
gear tooth in accordance with certain embodiments of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] While the making and using of various embodiments of
the present invention are discussed in detail below, it should
be appreciated that the present invention provides many
applicable inventive concepts, which can be embodied in a wide
variety of specific contexts. The specific embodiments
discussed herein are merely illustrative of specific ways to
make and use the invention and do not delimit the scope of the
invention.
[0030] Certain embodiments of the present invention are
standardized rotary actuators which can be mass produced at
low cost and still maintain a high level of performance.
Various levels of ruggedness—for example, light, medium, and
heavy-may be employed for various applications. In fact,
certain of the actuator concepts described herein will be
found sufficiently rugged in their basic design that parts
made of plastic or formed metal can be used to reduce cost
"while still providing a highly-versatile actuator useful in a
variety of applications. These applications may include, but
are not limited to, portable tools, educational robots, toys,
and automobiles.
[0031] The present invention is a new high-performance
rotary actuator in a variety of embodiments sharing certain
characteristic features. Depending on the application, each
of the embodiments incorporates features generating one or
more of certain advantages.
[0032] The novel design of certain embodiments of the
present invention provide simplicity of design using a
relatively small number of parts and a minimized list of
parameters/ thereby allowing for a relatively small form
factor exhibiting exceptional compactness/ stiffness and load
capacity/ along with quiet and efficient operation. They are
designed for easy assembly, ideal for mass production at
various quality levels.
[0033] In general, these actuators are of exceptionally
rugged design exhibiting relative inaensitivity to
temperature and tolerance effects. The actuators of the
present invention incorporate a relatively short force path
across a high-Stiffness cross roller bearing, thereby
maximizing stiffness and strength. In certain embodiments,
the actuators of the present invention incorporate
standardized attachment architetures.
[0034] In order to promote standardization/ the rotary
actuator of the present invention can be configured to serve
as a standardized building block within a ystem. such a
building block may, for example, be intelligent and adaptable,
provide for a maximum performance envelope, be compact and
rugged, be optimized in its structural design, provide
standardized interfaces for quick replacement by technicians
anywhere in the world, and be produced in large enough
quantities to take advantage of economies of scale in
manufacturing.
[0035] Prime mover requirements may be met either by D.C.
brushlesa motors or switched reluctance motors, either in
cylindrical or pancake format. The gear trains may be made
unique, compact, rugged and cost effective under production in
large quantities.
[0036] In certain embodiments, cross-roller bearings are
used to form the joint bearings themselves. Cross-roller
bearings are selected not only for their stiffness but also
owing to their proper geometric configuration. In certain
embodiments/ the cross-roller bearing acts as the principal
gear train bearing at the same time. Precision large and
small-scale actuators can be used separately or combined to
satisfy demanding positional accuracy requirements.
[0037] In manufacturing cells, the rotary actuator modules
of the present invention may be used directly as simple
transfer devices, drivers of conveyers, or joint actuators in
2 degree-of-freedom manipulators. At the other end of the
complexity continuum, highly dextrous manipulators having 10
degrees of freedom and above can be assembled on demand. Each
of the above systems could be assembled as needed, all with
the same interfaces, and all with the same maintenance
requirements, perhaps from only 5 basic sizes in each cell
application, and all driven by one universal software package
to reduce cost increase performance, and to open up the
architecture of such system.
Figure 1
[0038] Figure 1 depicts an isometric cutaway view of a
rotary actuator 100 in accordance with one embodiment of the
present invention. Rotary actuator 100 shown in Figure 1 may
be configured to be vary rugged, having high levels of both
stiffness and shock resistance.
[0039] A rotary actuator such as rotary actuator 100 can
have a number of geometrical configurations. In one such
configuration, a rotary actuator has a "pancake" geometry,
being relatively narrow in thickness along its centerline and
relatively large in diameter. Rotary actuator 100 shown in
Figure 1 has such a geometry. In alternate embodiments, a
rotary actuator may have a "coffee can" geometry, being
relatively wide along the centerline and relatively small in
diameter. Rotary actuator 200 shown in Figure 2 has this type
of geometry.
[0040] Generally, the pancake version is driven by a
switched reluctance motor (SRM) and optimized to produce
higher torques at lower speeds. The "coffee can" version is
generally optimized for use in slim/dexterous machines such as
serial robot manipulators. This version is usually driven by
a brushless D.C. motor of somewhat lower torque and higher
speed ranges as compared to the SRM.
[0041] In general, it is desirable to satisfy as many
design objectives as possible while at the same time
minimizing complexity. This combination of design criteria
argue in favor of combining functions when possible- In
certain embodiments, the rotary actuator of the present
invention is constructed so as to not merely provide rotary
power to a joint, but to function as the joint itself,
incorporating sufficient structural rigidity as to make
additional rotary bearing structure extraneous.
[0042] In certain embodiments, the incorporation of quick-
change interfaces into the input/output attachment structures
of the rotary actuators provides the designer with the ability
to assemble machines on demand. The geometry of one
embodiment of such a quick-change interface is described in
detail in connection with Figure 8, below. In certain
embodiments, the self-contained actuator may incorporate 80%
or more of the machine"s complexity, including electronics,
brakes, buses, sensors, bearings, motor, gear train, and all
necessary attachments and interfaces.
[0043] Rotary actuator 100 makes use of internal bull gear
104 and sun gear 106 as part of the attachment components of
the rotary actuator 100, separated by a principal cross roller
bearing 108. The bull gear 104 and sun gear 106 are driven by
planet gears 110 and 112 supported by bearings 114 on press
fit shafts 116 passing through the sides of the planet cage
118.
[0044] Because the bull gear 104 and sun gear 106 are part
of the structure of the rotary actuator 100, the required
weight goes down while the stiffness goes up. Also, because
this design employs a large diameter cross-roller bearing 108,
the structural stiffness of the rotary actuator 100 is also
greatly improved. In certain embodiments, the bearing races
can be machined directly into the bull gear 104 and / or sun
gear 106 so as to improve the structural integrity of the
design. A ball bearing may be used in place of cross-roller
bearing 108 in less-demanding applications. Accordingly, the
structure of the rotary actuator 100 can be made much smaller,
lighter in weight, and more cost effective, through a
reduction in the number of parts and simplified assembly. The
planets 110 and 112 may be used in a Ferguson paraox gear
train mechanism to further improve manufacturing simplicity.
[0045] Magnet disk 120 of the prime mover 122 is rigidly
attached to the planet cage 118 to form the simplest possible
configuration between the prime mover 122 and the gear train
124. Planet cage 118. and magnet disk 120 are supported by
bearing 12 € in the bull gear 104 and needle bearings 128 on
stationary shaft 130. This design provides a very rugged
support for the moving structure of rotary actuator 100 so as
to best resist shock.
[0046] Planet cage 118 can be made lighter in order to
reduce inertia in cases where additional responsiveness is
desirable. The number of planets 110 and 112 may be as small
as 2 or as large as 9 depending on the relative dimensions,
speed, desired stiffness, inertia requirement, tooth sizing
required for loading, and other factors.
[0047] Bearing 132 on shaft 130 is used to provide
additional support to the output attachment plate 134 of
rotary actuator 100. Where stiffness is an important
consideration, the attachments to the neighboring structures
on shell 102 and plate 134 may be placed in close proximity to
bearing 108 in order to maximize the resulting structural
stiffness of the system. In rotary actuator 100/ field 136 is
larger than magnet disk 120. This additional size
accommodates end turns in the field 136.
Figure 2
[0048] The switched reluctance motor (SRM) geometry shown
in Figure 1 is designed to maximize torque, and this design
may be optimized for applications wherein high rotational
speed is not a principal concern. A wide variety of aspect
ratio considerations may be met employing both the SRM and DC
prime movers. Given a cylindrical prim© mover such as a D.C.
brushless motor of higher relative speed and lower relative
torque as compared to the switched reluctance motor, the
geometry of actuator 100 can be modified into a coffee can
geometry having all the other attributes of the pancake-shaped
rotary actuator 100. Such an actuator is shown in Figure 2
and generally designated 200.
[0049] In one embodiment/ rotary actuator 200 may operate
at speeds as much as ten times higher, but produce ten times
less torque, than rotary actuator 100 of Figure 1. In rotary
actuator 200, there is a much higher concern for inertia in
the moving structure and less concern for stress in the gear
[0050] figure 2 depicts rotary actuator 200 in an isometric
cutaway view. Rotary actuator 200 is typically longer than
rotary actuator 100, and there is more concern for the
stiffness of the planet cage 218. Accordingly, additional
support is provided by bearing 226, embedded in the stiff
attachment shell 202 of actuator 200. In order to simplify
the design of rotary actuator 200, the planets 210 and 212 are
supported by bearings 214 which ride on shafts 216, which are
press fit into the planet cage 218 to further increase the
stiffness of planet cage 218.
[00S1] The output attachment plate 234 and central
stationary shaft 230 are mutually supported by bearing 232.
Generally, because of higher velocities in the D.C. motor, the
structure of the planet cage 218 will be lightened to reduce
inertia and the bearings 208, 214, and 226 will be chosen for
this higher velocity regime.
[0052] As will be appreciated by those of skill in the art,
additional planets tend to increase stiffness, reduce
backlash, and improve positional accuracy at the expense of
complexity and increased inertia. Large gear train ratios
require the use of multiple stages or Fergeson Paradox type
epicyolic gear trains. Generally, the planet gear cage will
represent the most complex part of the rotary actuator, adding
to cost, complexity, and assembly issues.
[0053] In alternate embodiments, compound gears can ba used
in certain cases. Such gear trains incorporate, however,
inherent limitations. These types of gear trains can give a
realistic reuction of no greater than 10 to 1 further
these gear trains tend to exhibit considerable backlash and
have high rotary inertia. Finally, they are insufficiently
rigid in rotary compliance, are heavy and are not space
efficient.
[0054] Accordingly, epicyclic gear trains are better for
rotary actuators because of their compatible geometry to the
rotary prime mover. Unfortunately, these gear trains exhibit
limitations as well. The maximum realistic gear reduction of
such a mechanism is on the order of 160:1. Compound epicycle
gear trains can, of course, provide reductions higher than
100:1 through the use of multiple stages. Compound gear
trains, however, incorporate the limitations described above.
In general, epicyclic gear trains exhibit a significant degree
of backlash, require high tolerances, and are temperature
sensitive. In fact, backlash generally must be designed in to
account for tamperaturs-related dimensional changes. Finally,
the involute gear teeth used in epicyclic gear trains are
often designed to be relatively tall, in order to maintain
between one to two teeth in mesh. This geometry increases the
loading at the root as well as sliding velocity, reducing both
the strength and the efficiency of the mechanism.
[0055] In order to overcome the above limitations of
epicyclic gear trains, elements are described below employing
a single planet driven by an eccentric to make a "wobble"
plate design while satisfying all the kinematic requirements
normally associated with epicyclio gear trains.
Figure 3
[0056] One object of the present invention is to make the
standardized electro-mechanical actuator a simple continuum of
deaign choices among switched reluctance or brushleas D.C.
motors and multi-planet or eccentric single planet hypocyclic
gear trains. Ideally, each choice can be considered as a
plug-in substitute for the other with no other primary design
changes.
[0057] Accordingly, certain embodiments of the present
invention may incorporate a single eccentric planet gear train
in place of the multi-planet gear train used in Figures 1 and
2. The eccentric hypocyclic gear train incorporates a number
of advantages, as described below.
[0058] In many embodiments, the actuators of the present
invention incorporate a hypocyclic gear train, which may have
a gear reduction ratio as high as 5000:1. These hypocyclic
gear train assemblies may incorporate relatively short
circular arc gear teeth, with up to 15 or more teeth in
contact at a time.
[0059] The unique design characteristics of the hypocyclic
gear- trains provide reduced contact stresses, reduced bending
stresses, lower sliding velocity, reduced energy loss, and the
potential for preloading the mesh as the tooth comes into its
central position.
[0060] Bach gear tooth can be profiled to be slightly
preloaded as it cornea into its central position, in order to
reduce the generation of lower-order harmonics and control
backlash and lost motion. This preloading can be accomplished
through the introduction of a slight interference between that
tooth and the mating teeth as that tooth conies into its
central position. In certain embodiments, a cavity may be "
introduced within each tooth in order to tailor the stiffness
of the teeth and reduce closing noise.
[0061] Circular tooth profile gear trains exhibit a reduced
degree of wear and noise, smooth and gradual load transfer
among the teeth, and a reduced or eliminated necessity for
critical tolerances, as circular are teeth do not require the
critical tolerances generally associated with involute teeth.
A circular tooth profile can also exhibit increased strength,
as clearances for external involute teeth are not required.
Finally, in certain embodiments, a reduction in the sliding
velocity between the mating gear teeth reduces the frictional
losses within the mechanism.
[0062] Figure 3 depicts a cutaway isometric of a rotary
actuator 300 incorporating an eccentric hypocyclic gear train.
Rotary actuator 300 incorporates a central stationary shaft
330 holding support bearings 328 that support the rotating
motor armature 320 that drives the eccentric 218. Support
bearings 314 on the eccentric 218 drive the wobble cylinder,
which contains the planetary gears 310 and 312 that mesh with
the bull gear 304 and sun gear 306 separated by the principal
cross roller bearing 308.
[0063] Bull gear 304 is attached directly to the shell 302
of rotary actuator 300 while sun gear 306 is attached directly
to the output attachment plate 334. The motor armature 336 is
also held stationary by the actuator shell 302. End plate
screws (not shown) assist in making the assembly rather
direct, holding the stationary shaft 330 for support bearings
328.
[0064] Bearing 332 in the output attachment plate 334
supports the end of the stationary shaft 330. Seal 338
separates the output attachment plate 334 from the shell 302
and protects the cross roller bearing 308 from the elements.
This design incorporates an additional bearing 326 to support
the motion and force variation on the eccentric 318.
[0065] Rotary actuator 300 is notable for its inherent
simplicity. The motor field 336 and armature 320, eccentric
318, planetary gears 310 and 312, bull and sun gears 304 and
306 and the principal roller bearing 308 are the primary
components of rotary actuator 300. Secondary components
include bearings 328, 332 and 326. The remainder are
stationary, machined components.
[0066] Even though rotary actuator 300 is able to provide
very high power density in a very small package, it can be
adapted to a wide range of application requirements by means
of minor design changes, such as numbers of gear teeth, motor
winding characteristics and current and voltage levels, as
examples. The inherent simplicity and versatility of rotary
actuator 300 enables mass production of most of the
subcomponents, thereby providing economies of scale and
attendant cost reductions. The characteristics of a
particular embodiment of rotary actuator 300 may be scaled to
one of a number of pre_selected standardized sizes, in order
to provide an "off-the-shelf" solution to the system designer.
In one example of a standardized set of such actuators,
sixteen separate standardized scaled actuators can be provided
to meet a wide range of design applications. A set of
actuators of the type shown in Figure 3 may be constructed
according to standard sizes. As one example, a set of sixteen
actuator sizes spanning from 0.25" diameter up to 45" in
diameter could support the construction of a large population
of machines, rapidly assembled and made operational as needed.
[0067] Simplicity not only brings with it lower cost, it
also results in components that are forgiving in their design,
manufacture and operation. In particular, rotary actuator 300
should be relatively insensitive to rather large variations In
temperature.
[0068] The use of a hypocyclic gear train wherein up to
fifteen gear teeth or more ,can be in contact at a given time
brings with it the ability to carry very heavy loads
eliminate backlash, minimise lost motion, and resist high
levels of shock with relatively modest levels of gear tooth
stress, thereby providing both high endurance and reduced
wear.
[0069] The number of design parameters is rather low. They
are, to a great extent, independent choices, and each has
clear and explicit meaning to the designer. Hence, not only
is rotary actuator 300 exceptional in performance in terms of
weight, volume, endurance, output inertia, and power density,
it is easily understood by most designers, helping to assure
its acceptance in the design community.
[0070] As described above, the eccentric offset e within
the hypocyclic gear train is driven by an electric prime mover
and supported by a bearing on a stationary shaft. Given N1, N2
to be the gear tooth numbers for the bull and sun gears,
respectively, and Ni1, N21 those associated meshing gears on the
wobble planet, then the total gear train ratio is given simply
by r = (N11N2) / (N11N2-N1N21) .
[0071] The ratio can range from 10-to-l up to 5000-to-l,
the higher ratios depending on the choice of gear tooth
geometry that can be designed for high load capacity, low
noise, high precision, or low cost depending on the
application. In certain embodiments, the appropriate ratio
can be attained using meshing gears wherein the number of
teeth between the two varies by a single tooth.
[0072] in connection with the hypocyclic gear train shown
in Figure 3, the wobble gears 310 and 312 are disposed side-
by-side. This construction has a tendency to improve
rigidity. For lower gear train ratios, tha diameter of gear
310 may differ by as much as 30% or more from the diameter of
gear 312. In such a case, gears 310 and 312 may be disposed
with one inside the other, so that all gear meshes occur in a
single plane.
[0073] Not only can the hypocyclic gear train be directly
plugged into any of the epicyclic designs, its key design
parameters are always visible to the designer/ thereby
removing the aura of black magic in this area of design.
Since the planet gear wobbles, it must be balanced by a
counterweight. In many embodiments, the mass of the
counterweight required is small relative to the mass of the
planet gear itself. In one embodiment, the planet gear is
balanced by drilling a small hole in the body of the planet
gear.
Figure 4
[0074] Rotary actuator 400, shown in Figure 4, incorporates
a central stationary shaft 430 holding support bearings 428
that support the rotating motor armature 420 that drives the
eccantric 418. Support bearings 414 on the eccentric 418
drive the wobble cylinder, which contains the planetary gears
410 and 412 that mesh with the bull gear 404 and sun gear 406
separated by the principal cros3 roller bearing 403.
[0075] Rotary actuator 400 employs a pancake configuration
that incorporates an SRM prime mover 422 to produce a high
torque/low speed rotary actuator 400.
[007 6] Bearing 432 in the output attachment plate 434
supports the end of the stationary shaft 430. Seal 438
separates the output attachment plate 434 from the shell 402
and protects the cross roller bearing 403 from the elements.
Figure 5
[0077] Figure 5 depicts a fifth embodiment of a rotary
actuator 500 in accordance with certain embodiments of the
present invention.
[0078] This geometrically different format for a hypocyclic
actuator concept is shown in Figure 5 and generally designated
500. As seen in Figure 5, the bull gear 504 and stator 536 of
actuator 500 are rigidly connected to the outer shell 502 and,
closed at the end by end plate 514.
[0079] Armature 520 contains wobble plate gears 510 and
512, which mesh with bull gear 504 and sun gear 506. Sun gear
506 is separated from bull gear 504 by the principal cross-
roller bearing 508, which also may function as the principal
bearing for the joint of the machine into which rotary
actuator 500 is incorporated.
[0080] As seen in Figure 5, the bull gear 504 and stator
536 of actuator 500 are rigidly connected to the outer shell
502 and closed at the end by end plate 514.
[0081] Rotary actuator 500 further incorporates bearings
542 and 544 to preload the mesh of the wobble plata gears 510
and 512, so as to ensure that they do not separate and to
reduce vibration and the effect of wear.
[0082] Bearings 542 and 544 are centered on a second
eccentric offset of a, 180° out of phase with the wobble
armature eccentric 518. Bearings 542 and 544 roll on
cylindrical surfaces machined into the end plate 514 and
output plate 534, both of which are concentric with the
canterline of the rotary actuator 500.
[0083] The high torque, low output velocity rotary actuator
500 shown in Figure 5 is a combination of a hypocyclic
switched reluctance motor, which may generate up to five times
higher torque than a standard switched reluctance motor, and a
hypocyclic gear train, which may have up to five times higher
load capacity than a similar epicyclic gear train.
Accordingly, rotary actuator 500 can be said to have, in
certain embodiments, an enhanced performance envelope up to 25
times higher than prior deigns.
[0084] This overall performance enhancement factor of 25 is
achieved in rotary actuator 500 with five basic parts, the
removal of five additional ancillary bearings and few, if any,
components incorporating dimensions having any critical
tolerances.
[0085] In rotary actuator 500, the wobble motor armature
520 is incorporated into the same part as the wobbla plate
gear pair. Rotary actuator 500 incorporates a number of
distinct advantages over prior designs, including: the need
for only one principal cross-roller bearing 508 and two
ancillary bearings 542 and 544,- and simplified controller
technology owing to the fact that each stator pole is switched
on and off only once in a wave as the armature 520 walks
through an angle of 360 degrees x e (where e is the
eccentricity of the wobble configuration) during each
electrical cycle.
[0086] | The result of the above is a form of magnetic
gearing where the electric cycle occurs at an angular velocity
rate of 1/e relative to the rotational velocity of the
armature 520]. Given an angular velocity of the electrical
field and the wobble speed wf = we = 6667 with e=0.015, for
example; the output attachment plate 534 would rotate at 100
RPM and the output velocity, w0, would equal 1 RPM given a gear
reduction ratio of 100. Because of this electrical wave/
torque ripple 13 virtually non-existent. Also, given a value
of e-0.015/ a balancing mass at r=30e means that only 1/900,
or 0.111%, of the mass of armature 520. needs to be removed to
perfectly balance armature 520. The attributes of actuator
500 are such that certain variations of this design may be
employed effectively as a backdriveable generator to produce
energy from a mechanical power source, such as a wind turbine.
[0087] For at least the embodiments shown in figures 3-5,
each gear tooth can be profiled to be slightly preloaded as it
comes into its central position, in order to reduce the
generation of lower-order harmonics and control backlash and
lost motion. This preloading can be accomplished through the
introduction of a slight interference between that tooth and
the mating teeth as that tooth comes into its central
position. In certain embodiments, a cavity may be introduced
within each wobble gear tooth in order to tailor the stiffness
of the teeth and reduce closing noise.
[0088] Figure 9 shows the sequence of motion, within a
sun/bull gear mechanism 900, of a sun gear tooth as it enters
and exits its central position within the body of the
stationary bull gear 902.
[0089] Tha initial position of the sun gear tooth at time
TO, prior to engagement with the bull gear 902 is designated
904. The central position of the sun gear tooth at time Tl,
some period of time after time TO, is designated 904".
[0090] In certain embodiments/ the geometry of mechanism
900 may be such that a slight interference is encountered as
the sun gear tooth moves into the central position 904". In
such embodiments, the gear tooth stiffness and tha level of
interference in the central position 904" will determine the
forces generated by tha elastic deformation of the bull gear
S02 and the top of the sun gear tooth. This interference will
tend to reduce or eliminate any free motion in any of the
bearings supporting the sun gear, it can be seen in Figure 9
that the sun gear tooth shown incorporates a cavity in order
to reduce its stiffness, as will be described in more detail
below in connection with Figures 10-12,
[0091] After time Tl, at which point maximum interference
and deformation, if any, occur, the sun gear tooth will move
out of engagement with the bull gear 902. The position of the
sun gear tooth at a point in time T2 after time Tl is
designated 904" .
[0092] Examples of gear tooth geometry useful in connection
with gear mechanism 900 and similar gear mechanism are shown
in Figures 10-12. Figure 10 depicts a side view of a circular
arc gear tooth 1000 having a body 1002, and first flank 1004,
a second flank 1006, and a circular cavity 1008 disposed at
the top of the body 1002. The position and diameter of cavity
1008 will be determined by the requirements of a particular
application. In general, the stiffness at the peak of gear
tooth 1000 will be reduced as the diameter of the cavity 1008
is increased or its central axis is moved closer to the peak
of gear tooth 1000. Reducing the diameter of the cavity 1008
or moving it further down into the body 1002 will have the
opposite effect tending to stiffen the peak of gear tooth
1002.
[0093] Figure 11 depicts a side view of a circular arc gear
tooth 1100 having a body 1102, and first flank 1104, a second
flank 1106, and a circular cavity 1108 disposed at the top of
the body 1102. Gear tooth 1100 further incorporates a slot
1110 at the top of circular cavity 1108/ so as to reduce the
rigidity of the top of the body 1102 of gear tooth 1100.
[0094] Figure 12 depicts a side view of a circular arc gear
tooth 1200 having a body 1202, and first flank 1204r a second
flank 1206, and a cavity 1208 disposed at the top of the body
1202, Cavity 1208 is composed of two circular cavities 1110
and 1112, which overlap in the center of gear tooth 1200.
This design preserves the local stiffness at the top of the
gear tooth 1200.
[0095] In the embodiments described above, the tooth ends
may need more ductility than the remainder of the tooth
surface, which should generally be hardened. In certain
embodiments, the cavity or cavities may be drilled and/or
slotted before hardening. The tooth surface may then be
hardened. The tooth tips may be annealed locally to improve
the fatigue resistance at the deforming part of the tooth.
This annealing may, in certain embodiments be performed by a
laser.
[0096] For at least the embodiments shown in Figures 3-5,
the following additional specific comments apply: (a) In
certain embodiments, the gear teeth are circular gear teeth in
order to enhance smoothness, reduce noise from gear tooth
impact and reduce the contact Hertzian stress. In other
embodiments, triangular gear teeth may better satisfy the
application requirements. In other embodiments, specialized
gear tooth geometry may be included where unique application
requirements must be met; (b) Wiring may be disposed entirely
in the stationary stator as part of the outer shell and bull
gear; (c) The force path through the actuator is short; (d)
Armatures may be solid or laminated metal; (e) Few, if any,
critical dimensions are required, thereby reducing the
influence of manufacturing tolerances and temperature
variations on performance, {£) The use of short gear teeth
reduces bending stresses and reduce friction losses; and (g)
The meshing of up to thirty teeth picks up and releases the
load slowly to reduce noise.
Figure 6
[0097] Certain applications may require a rugged rotary
actuator with a stiff output gear train of high reduction
ratio in a compact configuration. Depending on the specifics,
such an actuator may be driven either by a pancake switched
reluctance motor (SRM) prime mover or a cylindrical brushless
D.C. Motor (DCM). Figures 6 and 7 are cutaway isometric views
of these alternate embodiments.
[0098] Rotary actuator 600 of Figure 6 has a "coffee can"
profile, while rotary actuator 700 of Figure 7 has the shape
of a circular pancake disk. Rotary actuator 600 is designed
for use in robotics, while rotary actuator 700 is useful in
confined spaces between two walls. Both rotary actuators 600
and 700 are capable of producing relatively high torque at
relatively low speeds. All other things being equal/ rotary
actuator 600 will generally have a higher maximum speed than
rotary actuator 700 and a somewhat lower maximum torque.
[0099) Figure 6 is a cutaway isometric view of a rotary
actuator 600 with the first stage of the epicyclic gear train
650 inside the magnet cylinder 620 of the relatively high
speed D.C. motor field 636. Th« planets 652 and 654 ride on
bearings 656 in a planet cage 658 attached to the magnet
cylinder 620, which, in turn, rides on bearings 660. This
embodiment is ideal for use in dextrous machines.
[00100] Planets 652 and 654 may form a Fergeson paradox
configuration driving moving external sun gear 664 and
stationary external bull gear 662 attached to the central
shaft 630 of rotary actuator 600. Central shaft 630 is
attached to the outer shell 602 using machine bolts.
[0100J In certain embodiments, the first stage may be
designed to reduce its inertia, as it experiences higher
speeds and lower torque. Planetary gears 652 and 654 may be
made relatively narrow and still carry the necessary load.
The specific design parameters of these planetary gears 652
and 654 are dictated by the application.
[0101] There will be a trade off between the size of the
motor components 620 and 636 and the outer diameter of the
first stage gear train 650. The smaller the internal diameter
of magnetic cylinder 620 and field 636, the larger the torque
produced. The stationary shaft 630 is long in this design and
subject to flexure, it is, therefore, supported by bearing
640.
[0102] Sun gear 664 is rigidly connected to the driving
cage 618 of the second stage epicyclic gear train 666 riding
on large needle bearings 628 carrying planet gears 610 and 612
riding in bearings 614. These planet gears 610 and 612 mesh
with stationary internal bull gear 604, which is attached to
the outer shell 602, and internal sun gear 606 attached
directly to the output attachment plate 634.
[0103] Seal 668 separates the attachment shell 602 from the
plate 634. Sun gear 664 and its planet cage 658 support a
bearing 670, which is held in place by the outer shell 602.
The shape of outer shell 602 supporting bearing 670 not only
strengthens the outer shell 602 but also improves the rigidity
of the central stationary shaft 630.
[0104] Internal sun gear 606 is rigidly attached to the
output attachment plate 634, which contains bearing 632, to
further strengthen the output structure of rotary actuator
600.
[0105] The second stage 666 of the epicyclic gear train
uses an internal bull gear 604 and sun gear 606. This
arrangement conforms to the basic configuration of the
structure, minimizing weight while at the same time making
rotary actuator 600 particularly rugged and stiff.
[0106] In the second stage 666, the velocities are lower so
the concern for inertia goes down accordingly, but the regard
for stiffness and load capacity go up. Hence, the size of the
gear teeth in the second stage 666 must meet the requirement
for load as a first priority, with stiffness as a second
priority. This may require, in certain applications, the use
of as many planets 610 and 612 as the geometry will allow.
[0107] The principal bearing in this configuration is the
cross roller bearing 608. it separates bull gear 604 and
shell 602 from sun gear 606 and output attachment plate 634,
Bearing 608 also performs the load bearing tasks for the
machine using this actuator. Because of the position of
bearing 608, bull gear 604 can be made very stiff, as can sun
gear 606. For maximum stiffness and minimum deflection under
load, the attachments to the neighboring links should be made
close to bearing 608.
[0108] Figure 7 depicts, in a cutaway isometric view, an
embodiment of a rotary actuator 700 the present invention
configured for a relatively low speed pancake SRM, which
produces relatively high torque. The bull gear 704 is made
especially strong and is rigidly attached to the attachment
shell 702 and supporting bearing 732 to the primary stationary
shaft 730, so as to further strengthen the output attachment
plate 734 for this design.
[0109] Magnet disk 720, in concert with field 736, directly
drives the first stage planet cage 718 for planet gears 710
and 712, which are supported in bearings 714. Planet cage 718
must be carefully designed to accommodate the planet gears 710
and 712 while maintaining sufficient structural integrity.
[0110] The second stage planet cage 740 is driven by, and
rigidly attached to, sun gear 7 64, which is supported by three
bearings 742, 744 and 746 in order to maximize its support.
This support is incorporated to resist twisting moments
generated by the second stage planets 748 and 750 supported in
bearings 752- The first stage sun gear 7 64 and bull gear 7 62
are external gears. Bearing 732 supports the first planet
gear cage 718 in the moving sun gear 764, which drives the
second planet gear cage 740.
[0111] The second stage sun gear 706 and bull gear 704 are
internal gears. This arrangement serves to match the
structural geometry of the rotary actuator 700 so as to
stiffen the structure. Sun gear 706 and bull gear 704 are
separated by the principal cross-roller bearing 708 which acts
as the principal bearing in the gear train while also serving
as the principal bearing of the joint into which tha rotary
actuator 700 is incorporated. In order to maximize rigidity,
the attachments to the outer attachment shell 702 and to the
output attachment plate 734 should be placed close to cross-
roller bearing 708.
[0112] Since the bull gear 704 and sun gear 706 in the
second stage are relatively large in diameter, they are able
to accommodate more planets 748 and 750 and larger gear teeth.
Accordingly, planet gears 748 and 750 are shown to ba
relatively large as compared to planet gears 710 and 712 in
Figure 7.
[0113] Because of the lower speeds encountered in the
second stage gear train, concern for Inertia is superseded by
a concern for the. load capacity of the gear teeth. This is
also true, to a lesser extent, in the first stage of the gear
train. The outer envelope of the first stage is smaller in
diameter than the outer envelope of the second stage, which is
appropriate since it carries less load but operates with
larger angular velocities.
Figure 8
[0114] Figure 8 depicts a rotary actuator 800 incorporating
a quick-change attachment architecture in accordance with
certain embodiments of the present invention. Rotary actuator
800 incorporates an actuator shell 802 containing a bull gear
804, and sun gear 806, separated by a cross-roller bearing
808. Planet gears 810 and 812 mesh with bull gear 804 and sun
gear 806, respectfully.
[0115) As seen in Figure 8, actuator 800 rigidly connects a
first mechanical link 820 to a second mechanical link 822.
First mechanical link 820 is rigidly connected to actuator
shell 802 by a first wedge clamp 824, whils second mechanical
link 822 is rigidly connected to output attachment plate 834
by second wedge clamp 826. In one embodiment, each of wedge
clamps 824 and 826 takes the form of a pair of semi-circular
wedge clamp halves tightened against actuator 800 by an
external band clamp. Other equivalent structures may, of
course, be employed without departing from the spirit and
scope of the present invention.
[0116] In the embodiment shown in Figure 8, wsdge clamps
824 and 826 are tightened by a pair of tensioning mechanisms
828 and 830. Depending on the particular application,
tensioning mechanisms 828 and 830 may be integral to the wedge
clamps 824 and 826, or they may be integral to separate band
clamps disposed around wedge clamps 824 and 826.
[0117] Each of wedge clamps 824 and 826 incorporates a pair
of generally-conic internal surfaces, together forming a
groove about the internal surface of the wedge clamp 824 and
826. The internal profile of each of these internal surfaces
conforms to a mating external surface on either the actuator
800 or one of the mechanical links 320 and 822. As the
tensioning mechanisms 823 and 830 are tightened, the normal
force between the generally-conic internal surfaces and the
mating external surfaces will draw the mating components
together into a tight and rigid mechanical connection. In
certain embodiments, the design of wedge clamps 824 and 826
will conform to one of a standard set of sizes. Within each
standard size, there may be two or more strength classes,
similar to the types of classification employed for
standardized threaded fasteners.
[0118] Mechanical links 820 and 822 are disposed closely
adjacent to one another and to principal cross-roller bearing
808. With the attachment of mechanical links 820 and 822 in
this manner, closely adjacent one another and to principal
cross-roller bearing 808, it can be seen that the joint
rigidly resists motion about five of the six degrees of
freedom, with the remaining degree of freedom controlled by
the prime mover and gear train combination.
[0119] It can be seen that the "force path" through the
rotary actuator 800 is extremely short,and passes through a
combination of highly rigid mechanical structures and
connections and associated rigid structures. This short force
path and associated rigid structures enable the rotary_
actuator 800 to serve as the rotary joint for the machine
itself/ rather than serving merely as a torque input device,
as in prior designs.
[0120] It will be appreciated by those of skill in the art
that, although the quick-change attachment structures of
rotary actuator 800 are shown in connection with a particular
embodiment of the present invention, the attachment structures
shown in Figure 8 can be employed in connection with any of
tha embodiments described herein without departing from the
spirit and scope of the present invention. where simplicity
is desired, simple bolt circles may prove adequate where
accuracy and repeatability of the interface are not high
priorities, or where a quick change of the actuator out of the
system is not considered important to the application.
[0121] The structures shown and described in connection
with Figure 8 applies to all rotary actuators described
herein. The geometry of a machine built from the actuators
described herein will be primarily dependent on the members
attached to the actuators rather than on the actuators
themselves. Depending on the application, the links may be
parallel to ona another, perpendicular to one another, or
disposed at any general spatial orientation to one another.
The link geometry provides a machine designer with a great
deal of freedom to design the system without the necessity for
customized component*. The use of standardized componentry
can, in many instances, reduce cost, owing to the availability
of mass production, of both the actuators and the links
connecting them. At the same time, a high degree of
generality and flexibility can be preserved for the designer,
even when using standardized,components.
[0122] Although preferred Embodiments of the invention have
been described in detail, it will be understood by those
skilled in the art that various modifications can be made
therein without departing from the spirit and scope of the
invention as set forth in the appended claims.
I CLAIM :
1. A rotary actuator comprising :
an actuator shell;
a planetary cage, disposed within the actuator shell;
a prime mover having a first prime mover portion rigidly fixed to the actuator shell and a
second prime mover portion, adjacent to, and movable with respect to, the first prime mover portion,
rigidly fixed to the planetary gear cage, and capable of exerting a torque on the first prime mover
portion;
a cross-rollerbearing having a first bearing portion rigidly fixed to the actuator shell and a
second bearing portion, movable with respect to the first bearing portion;
an output attachment plate rigidly fixed to the second bearing portion;
a shell gear rigidly fixed to the actuator shell;
an output gear rigidly fixed to the output attachment plate; and
one or more planetary gears, disposed in the planetary cage, each having a first gear portion
meshed to the shell gear and a second gear portion, adjacent to the first gear portion, meshed to the
output gear.
2. The rotary actuator as claimed in claim 1, having a first structural link rigidly connected to the
actuator shell and a second structural link rigidly connected to the output attachment plate.
3. The rotary actuator as claimed in claim 2, wherein the first link and second links are attached
to the actuator shell and output attachment plate, respectively, by quick-change attachment structures.
4. The rotary actuator as claimed in claim 3, wherein each of the quick-change attachment
structures comprises a first radial groove in the structural link, a second radial groove, adjacent to the
first radial groove, in the mating portion of the rotary actuator, and a radial clamp, extending about
the circumference of the first and second radial grooves.
5. The rotary actuator as claimed in claim 2, wherein the first structural link is attached to the
actuator shell immediately adjacent to the cross-roller bearing and the second structural link is
attached to the output attachment plate immediately adjacent to the cross-roller bearing.
6. A rotary actuator comprising :
an actuator shell;
an eccentric cage, disposed within the actuator shell;
a prime mover having a first prime mover portion rigidly fixed to the actuator shell and a
second prime mover portion, rotatable with respect to the first prime mover portion, rigidly fixed to
the eccentric cage, and capable of exerting a torque on the first prime mover portion;
a cross-roller bearing having a first bearing portion rigidly fixed to the actuator shell and a
second bearing portion, free in rotation with respect to the first bearing portion;
an output attachment plate rigidly fixed to the second bearing portion;
a shell gear rigidly fixed to the actuator shell;
an output gear rigidly fixed to the output attachment plate; and
\ an eccentric, disposed about the eccentric cage, having a first gear portion meshed to the shell
\gear and a second gear portion, adjacent to the first gear portion, meshed to the output gear.
7. The rotary actuator as claimed in claim 6, having a first structural link rigidly connected to
the actuator shell and a second structural link rigidly connected to the output attachment plate.
8. The rotary actuator as claimed in claim 7, wherein the first link and second links are attached
to the actuator shell and output attachment plate, respectively, by quick-change attachment structures.
9. The rotary actuator as claimed in claim 8, wherein each of the quick-change attachment
structures comprises a first radial groove in the structural link, a second radial groove, adjacent to the
first radial groove, in the mating portion of the rotary actuator, and a radial clamp, extending about
the circumference of the first and second radial grooves.
10. The rotary actuator as claimed in claim 7, wherein the first structural link is attached to the
actuator shell immediately adjacent to the cross-roller bearing and the second structural link is
attached to the output attachment plate immediately adjacent to the cross-roller bearing.
11. The rotary actuator as claimed in claim 6, wherein one or more of the first and second gear
portions employs gear teeth having a circular profile.
12. The rotary actuator as claimed in claim 11, wherein the gear teeth having a circular profile
are dimensioned to have a slight interference.
13. The rotary actuator as claimed in claim 12, wherein one or more of the gear teeth having a
circular profile have a cavity disposed therein in order to reduce the stiffness of the gear teeth.
14. The rotary actuator as claimed in claim 6, wherein ten or more gear teeth within one or more
of the first and second gear portions are in contact at any point in time.
15. A rotary actuator comprising :
an actuator shell;
a first planetary cage, disposed within the actuator shell;
a prime mover having a first prime mover portion rigidly fixed to the actuator shell and a
second prime mover portion, rotatable with respect to the first prime mover portion, rigidly fixed to
the first planetary gear cage, and capable of exerting a torque on the first prime mover portion;
a shaft, having a shaft gear rigidly fixed thereto;
a second planetary gear cage, rotatable with respect to the first planetary gear cage and the
shaft, having a cage gear rigidly fixed thereto;
one or more first stage planetary gears disposed in the first planetary gear cage, each having a
first gear portion meshed to the shaft gear and a second gear portion, adjacent to the first gear
portion, meshed to the cage gear;
a cross-roller bearing having a first bearing portion rigidly fixed to the actuator shell and a
second bearing portion, free in rotation with respect to the first bearing portion;
an output attachment plate rigidly fixed to the second bearing portion;
a shell gear rigidly fixed to the actuator shell;
an output gear rigidly fixed to the output attachment plate; and
one or more second stage planetary gears disposed in the second planetary gear cage, each
having a first gear portion meshed to the shell gear and a second gear portion, adjacent to the first
gear portion, meshed to the output gear.
22. The rotary actuator as claimed in claim 21, wherein one or more of the gear teeth having a
circular profile have a cavity disposed therein in order to reduce the stiffness of the gear teeth.
23. The rotary actuator as claimed in claim 15, wherein ten or more gear teeth within one or
more of the first and second gear portions are in contact at any point in time.
A rotary actuator (100) incorporating a shell (102), an output plate (134) and a cross-roller
bearing (108) retaining the output plate (134) within the shell (102). A prime mover (122), disposed
within the shell (102), exerts torque on a gear train (124) within the shell (102). A pair of gears (104
& 106), disposed on either side of the cross-roller bearing (108), made with one or more gears (110
& 112) in the gear train (124). Depending on the application, the gear train (124) may be a planetary
epicyclic or an eccentric hypocyclic type.

Documents:

935-kolnp-2005-granted-abstract.pdf

935-kolnp-2005-granted-claims.pdf

935-kolnp-2005-granted-correspondence.pdf

935-kolnp-2005-granted-description (complete).pdf

935-kolnp-2005-granted-drawings.pdf

935-kolnp-2005-granted-examination report.pdf

935-kolnp-2005-granted-form 1.pdf

935-kolnp-2005-granted-form 18.pdf

935-kolnp-2005-granted-form 3.pdf

935-kolnp-2005-granted-form 5.pdf

935-kolnp-2005-granted-gpa.pdf

935-kolnp-2005-granted-letter patent.pdf

935-kolnp-2005-granted-reply to examination report.pdf

935-kolnp-2005-granted-specification.pdf


Patent Number 214100
Indian Patent Application Number 935/KOLNP/2005
PG Journal Number 05/2008
Publication Date 01-Feb-2008
Grant Date 30-Jan-2008
Date of Filing 19-May-2005
Name of Patentee TESAR DELBERT
Applicant Address 8005 TWO COVES DRIVE, SUSTIN, TX 78730
Inventors:
# Inventor's Name Inventor's Address
1 TESAR DELBERT 8005 TWO COVES DRIVE, AUSTIN, TX 78730
PCT International Classification Number F16J
PCT International Application Number PCT/US2003/037753
PCT International Filing date 2003-11-21
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/429,276 2002-11-25 U.S.A.