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Pattern Classification and Gear Design of Spatial
Pattern Classification and Gear Design of Spatial
Pattern Classification and Gear Design of Spatial
sciences
Article
Pattern Classification and Gear Design of Spatial Noncircular
Gear Continuously Variable Transmission
Yongquan Yu 1 , Chao Lin 1, * and Ping Xu 2
1 State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044, China;
20160702017@cqu.edu.cn
2 Chongqing Panlian Transmission Technology Co., Ltd., Chongqing 400060, China; xuping_cq@126.com
* Correspondence: linchao@cqu.edu.cn; Tel.: +86-134-529-11958
Abstract: Noncircular gear and curve face gear are collectively referred to as spatial noncircular
gear. Combined with the transmission characteristics of spatial noncircular gear, a new classification
design method of spatial noncircular gear continuously variable transmission (CVT) pattern was
proposed, including two categories named addition type and multiplication type, with a total of
five subcategories. Through the combination of the transmission ratio changing mechanism and
transmission selection mechanism, it can realize the CVT. The overall transmission ratio depends
on the phase angle between the spatial noncircular gear pairs and is independent of the input
rotation angle. Firstly, the CVT principle and transmission ratio characteristics of each pattern were
analyzed. Then the tooth profile classification design of spatial noncircular gear was carried out,
and the general parametric design equations of the tooth surface with different tooth profiles were
obtained. Finally, through simulation, the overall transmission ratio of each pattern was compared
between theory and simulation, which verified the correctness of the CVT classification design
method. The advantages and disadvantages of the two categories were analyzed. Moreover, through
the transmission experiments of curve face gear pairs with different tooth profiles, the transmission
ratios were compared between theory and experiment. Considering the influencing factors such as
Citation: Yu, Y.; Lin, C.; Xu, P. Pattern machining error, assembly error and measurement error, the experimental error is within a reasonable
Classification and Gear Design of error range, which verified the correctness of the tooth profile classification design method. This
Spatial Noncircular Gear Continuously study provides a new idea for the further research and application of spatial noncircular gear CVT.
Variable Transmission. Appl. Sci.
2022, 12, 2715. https://doi.org/ Keywords: CVT pattern; general equation; simulation and experiment; spatial noncircular gear;
10.3390/app12052715 tooth profile classification design
Academic Editor: César M. A.
Vasques
Appl. Sci. 2022, 12, 2715 In this paper, the pattern classification and design, transmission principle, and3 sim‐ of 22
ulation of spatial noncircular gear CVT pattern were carried out. The pitch curve, tooth
surface classification design, and transmission experiment of curve face gear pairs with
different
tooth toothwere
profiles profiles were introduced
introduced in detail. in
Thedetail. The correctness
correctness of theclassification
of the pattern pattern classifica‐
and
tion and design of spatial noncircular gear CVT was verified, with the
design of spatial noncircular gear CVT was verified, with the hope of creating hope of creating
a certaina
certain foundation
foundation forresearch
for further further research and
and for the for the application
application of spatial noncircular
of spatial noncircular gear CVT. gear
The
CVT. The
research research
process wasprocess
shownwas shown1.in Figure 1.
in Figure
Figure1.1.Research
Figure Researchworkflow
workflowof
ofspatial
spatialnoncircular
noncirculargear
gearCVT.
CVT.
2.
2. Pattern
Pattern Classification
Classificationof ofSpatial
SpatialNoncircular
NoncircularGear
GearCVT
CVT
Spatial
Spatial noncircular gear CVT
noncircular gear CVTpattern
patterncan
canbebe divided
divided into
into twotwo categories,
categories, withwith a
a total
total of subcategories,
of five five subcategories, as shown
as shown in 1Table
in Table and 1Figure
and Figure
2. Type2.I isType I is the addition
the addition method,
method,
including including classes
classes A, B, andA,C,B,named
and C,NG‐PBGT,
named NG-PBGT,
NG‐PCGT,NG-PCGT, and CFG-BG-PCGT,
and CFG‐BG‐PCGT, respec‐
respectively.
tively. Type II is the multiplication method, including classes D and and
Type II is the multiplication method, including classes D E, named
E, named CFGCFGand
and
NG,NG, respectively.
respectively.
Table1.1.CVT
Table CVTpattern
patternofofspatial
spatialnoncircular
noncirculargear.
gear.
I:I:Addition
Addition method
Method II:Multiplication
II: Multiplication method
Method
Type
Type
Class
ClassAA Class
Class BB Class
Class C C Class Class
D D Class
Class E E
Name
Name NG‐PBGT
NG-PBGT NG‐PCGT
NG-PCGT CFG‐BG‐PCGT
CFG-BG-PCGT CFG CFG NGNG
Noncircular gear Curve face gear
Curve face gear pair, pair,
Transmission ra‐ Noncircular gear pair Noncircular
Transmission ratio gearpair
Noncircular gear pair bevel gear pair and
pair
and and plane‐
planetary bevel and planetary bevel gear pair and Curve
Curve face gearface
pair gear Noncircular
Noncircular gear pair
tio changing
changing mechanism
gear train
andcylindrical
planetary cylindri‐planetary cylindrical
gear train
tary bevel gear planetary
gear traincylindrical pair gear pair
mechanism cal gear train
train gear train
In Figure 2, ω i and ω o are the input and output angular velocities, respectively. The
spatial noncircular gear CVT mechanism includes three parts. The first part is the phase
switching mechanism, which is responsible for adjusting the phase angle between the two
driving spatial noncircular gears and synchronizing their rotation speed at the same time.
The second part is the transmission ratio changing part, which is responsible for integrating
the transmitted variable transmission ratio to achieve a constant speed output within a
certain range of input rotation angle. The third part is the transmission selection mechanism,
which is responsible for selecting the transmission ratio transmitted in order to only output
a constant rotation speed during the transmission. Through the transmission selection
mechanisms of multiple branches, the transmission ratio of each branch at different input
rotation angles was integrated, and finally a constant rotation speed output with the input
rotation angle in the range of 0 to 360◦ was realized.
Appl.
Appl. Sci. Sci. 11,
2022, 2022, 12, 2715
x FOR PEER REVIEW 4 of 224 of 23
(a)
(b)
Figure 2. 2.
Figure CVTCVTpattern
patternof
of spatial noncircular
spatial noncircular gear.
gear. (a) (a)
TypeType I: Addition
I: Addition method.
method. (b)II:Type
(b) Type II: Multi‐
Multipli-
plication method.
cation method.
In The structure
Figure 2, ωi of
andtheωphase
o are switching
the inputmechanism
and outputand the transmission
angular selection
velocities, mech- The
respectively.
anism of the five patterns are the same, but the transmission ratio changing part is
spatial noncircular gear CVT mechanism includes three parts. The first part is the phasedifferent.
For the three classes included in type I, the transmission ratio changing part is composed
switching mechanism, which is responsible for adjusting the phase angle between the two
driving spatial noncircular gears and synchronizing their rotation speed at the same time.
The second part is the transmission ratio changing part, which is responsible for integrat‐
ing the transmitted variable transmission ratio to achieve a constant speed output within
a certain range of input rotation angle. The third part is the transmission selection mech‐
ferent input rotation angles was integrated, and finally a constant rotation speed output
with the input rotation angle in the range of 0 to 360° was realized.
The structure of the phase switching mechanism and the transmission selection
mechanism of the five patterns are the same, but the transmission ratio changing part is
Appl. Sci. 2022, 12, 2715 different. For the three classes included in type I, the transmission ratio changing part is
5 of 22
composed of different spatial noncircular gear mechanisms and differential mechanisms.
Through the addition method, the transmission ratios of gear pairs were integrated to
of different
achieve spatialspeed
a constant noncircular gearFor
output. mechanisms and differential
the two classes included mechanisms. Through
in type II, the the
transmission
addition method, the transmission ratios of gear pairs were integrated to
ratio changing part is composed of different spatial noncircular gear mechanisms.achieve a constant
speed output. For the two classes included in type II, the transmission ratio changing part
Through the multiplication method, the transmission ratios of gear pairs were integrated
is composed of different spatial noncircular gear mechanisms. Through the multiplication
to achieve a constant speed output. The structural composition of the transmission ratio
method, the transmission ratios of gear pairs were integrated to achieve a constant speed
changing
output. part of each pattern
The structural is shown
composition of theintransmission
Table 1. ratio changing part of each pattern
is shown in Table 1.
3. Principle and Classification Design of Spatial Noncircular Gear CVT
3. Principle and Classification Design of Spatial Noncircular Gear CVT
3.1. Principle of Each CVT Pattern
3.1. Principle of Each CVT Pattern
The principles of the five CVT patterns are described in detail later. The phase switch‐
The principles of the five CVT patterns are described in detail later. The phase switch-
inging
mechanism
mechanismand andtransmission selectionmechanism
transmission selection mechanism areare applicable
applicable to five
to the the five patterns,
patterns,
so only class
so only AAwas
class wastaken
taken as
as an exampletotoexplain
an example explain them.
them.
(1)(1)
Class A: NG‐PBGT
Class A: NG-PBGT
Figure
Figure 3 3shows
showsthe
thetransmission principleofof
transmission principle class
class A. A.
Figure 3. Transmission
Figure 3. Transmissionprinciple of class
principle of classA.
A.
This
This mechanismincludes
mechanism includes four
four parts.
parts.The
Thefirst
firstpart
partis is
thethe
phase
phaseswitching
switchingmechanism,
mechanism,
which is composed of a rotating end, a fixed end, an outer
which is composed of a rotating end, a fixed end, an outer shaft, and an inner shaft, and an inner shaft.shaft.
The The
outer shaft is connected with the fixed end and the noncircular gear 1 at the same time,
outer shaft is connected with the fixed end and the noncircular gear 1 at the same time,
and the inner shaft is connected with the rotating end and the noncircular gears 3 at the
andsame
the time.
innerStep
shaft1, isbyconnected
rotating the with the rotating
rotating end, there endis aand the noncircular
required phase angle gears 3 at the
between
same time. Step
noncircular 1, 1by
gears and rotating
3. Step 2,the rotating
connect end, there
the rotating is a required
end with phase
the fixed end angle between
to synchronize
noncircular gears 1 and 3. Step 2, connect the rotating end with
the rotation speed of noncircular gears 1 and 3. In steps 1 and 2, the phase angle the fixed end to was
synchro‐
nize the rotation
switched. speedpart
The second of noncircular gearsgear
is the noncircular 1 and 3. which
pair, In steps 1 and 2, theforphase
is responsible angle was
generating
the required variable transmission ratio. The third part is the differential
switched. The second part is the noncircular gear pair, which is responsible for generating mechanism, which
theisrequired
composedvariable
of a planetary bevel gear
transmission train.The
ratio. It is third
responsible
part isfortheintegrating the variable
differential mechanism,
transmission ratios of the driven noncircular gears 2 and 4 to
which is composed of a planetary bevel gear train. It is responsible for integrating achieve a constant speed the
output within a certain range of input rotation angle. The fourth part is the transmission
variable transmission ratios of the driven noncircular gears 2 and 4 to achieve a constant
selection mechanism, which is composed of a clutch and a ring gear. The outer ring of
the clutch is connected to the inside of the ring gear, and the outside of the ring gear is
connected to the output end. The clutch only transmits one-way rotational motion. When
the inner ring of the clutch rotates in one direction, the roller was driven to roll to the
narrow side of the wedge groove to be clamped with the outer ring of the clutch, thereby
ring of the clutch is connected to the inside of the ring gear, and the outside of the ring
gear is connected to the output end. The clutch only transmits one‐way rotational motion.
When the inner ring of the clutch rotates in one direction, the roller was driven to roll to
the narrow side of the wedge groove to be clamped with the outer ring of the clutch,
Appl. Sci. 2022, 12, 2715 thereby driving the outer ring of the clutch to rotate. When the inner ring of 6the of 22clutch
rotates in reverse, the roller rolls to the wide edge of the wedge groove and is in a relaxed
state with the outer ring of the clutch, resulting in the outer ring of the clutch not rotating.
This branch
driving thedoes
outernotringtransfer rotation
of the clutch at this
to rotate. time.the
When Byinner
integrating theclutch
ring of the transmission
rotates inratios
of reverse,
multiplethe branches,
roller rollsthe
to constant speed
the wide edge of output
the wedge with the input
groove and isrotation angle
in a relaxed inwith
state the range
of the
0 toouter
360°ring
was of realized.
the clutch,Theresulting
CVTincanthe be
outer ring of by
realized the continuously
clutch not rotating. This branch
changing the phase
does not transfer rotation at this time. By integrating the transmission ratios of multiple
angle.
branches,
In brief,thetheconstant
rotation speed output
speed with the input
transmission rotation
process of angle
class in
A the range
is as 360◦ 1, the
of 0 toStep
follows.
was realized. The CVT can be realized by continuously changing the phase angle.
input rotation speed was transmitted to the noncircular gears 1 and 3 with a certain phase
In brief, the rotation speed transmission process of class A is as follows. Step 1,
angle. Step 2, the planetary bevel gear train composed of the bevel gears 5, 6, and 7 inte‐
the input rotation speed was transmitted to the noncircular gears 1 and 3 with a certain
grated
phasethe variable
angle. Step 2,rotation speeds
the planetary of noncircular
bevel gears 2 and
gear train composed of the4.bevel
Step gears
3, the5,bevel
6, andgear 7
outputted
7 integrated the variable rotation speeds of noncircular gears 2 and 4. Step 3, the bevelplanet
a constant rotation speed within a certain input rotation angle. The gear car‐
rier7 outputted
H is connected to the
a constant noncircular
rotation gear a2,certain
speed within and the bevel
input gear angle.
rotation 5 is connected
The planetto the
carrier H is
noncircular gear 4. connected to the noncircular gear 2, and the bevel gear 5 is connected to the
noncircular gear 4.
(2) Class B: NG‐PCGT
(2) Class
Figure 4 isB:the
NG-PCGT
transmission principle of class B, and the transmission process is as
Figure 4 is the transmission principle of class B, and the transmission process is as
follows. Step 1, the input rotation speed was transmitted to the noncircular gears 1 and 3
follows. Step 1, the input rotation speed was transmitted to the noncircular gears 1 and
with a certain phase angle. Step 2, the planetary cylindrical gear train composed of the
3 with a certain phase angle. Step 2, the planetary cylindrical gear train composed of the
ring
ring gear5,5,planetary
gear planetary gear
gear 6,6, and
andcenter
centergear
gear 7 integrated
7 integrated thethe variable
variable rotation
rotation speeds speeds
of of
noncircular
noncirculargears gears22 and
and 4.4. Step
Step 3,3,the
theplanetary
planetary carrier
carrier H outputted
H outputted a constant
a constant rotationrotation
speed
speed within
withinaacertain
certain input rotationangle.
input rotation angle.TheThe ring
ring gear
gear 5 is5connected
is connected tononcircular
to the the noncircular
gear
gear 4, 4, andthe
and thecenter
center gear
gear 77 is
is connected
connectedtoto the noncircular
the noncirculargeargear
2. 2.
Figure 4. 4.
Figure Transmission
Transmission principle ofclass
principle of classB.B.
(3)(3) ClassC:
Class C:CFG‐BG‐PCGT
CFG-BG-PCGT
Figure 5 is the transmission
Figure 5 is the transmission principle of class
principle C. The
of class C.transmission process process
The transmission is as follows.
is as fol‐
Step 1, the input rotation speed was transmitted to the curve face gears 1 and 3 with a
lows. Step 1, the input rotation speed was transmitted to the curve face gears 1 and 3 with
certain phase angle. Step 2, two pairs of bevel gear pairs adjusted the variable rotation speed
a certain phase angle. Step 2, two pairs of bevel gear pairs adjusted the variable rotation
of noncircular gears 2 and 4 and changed their directions, respectively. Step 3, the planetary
speed
cylindrical gear train gears
of noncircular 2 and
consisting 4 and
of the changed
cylindrical their
gears directions,
9, 11, respectively.
and 13 and the bilateral Step
gears 3, the
planetary
10 and 12cylindrical gear
integrated the train consisting
rotational of the
speeds of the cylindrical
bevel gears 6 andgears 9, 4,11,
8. Step theand 13 and the
planetary
bilateral
carrier H outputted a constant rotation speed within a certain input rotation angle. The gear 8.
gears 10 and 12 integrated the rotational speeds of the bevel gears 6 and 9 Step
is connected to the bevel gear 6, and the gear 13 is connected to the bevel gear 8.
Appl. Sci. 2022, 11, x FOR PEER REVIEW 7 of 23
4, the planetary carrier H outputted a constant rotation speed within a certain input rota‐
Appl. Sci. 2022, 12, 2715 7 of 22
tion angle. The gear 9 is connected to the bevel gear 6, and the gear 13 is connected to the
4, the planetary
bevel gear 8. carrier H outputted a constant rotation speed within a certain input rota‐
tion angle. The gear 9 is connected to the bevel gear 6, and the gear 13 is connected to the
bevel gear 8.
Figure
Figure 5. Transmissionprinciple
5. 5.
Transmission principleof
of class
class C.
Figure Transmission principle of class C.C.
Figure6.6.Transmission
Figure Transmissionprinciple
principleofofclasses
classesDDand
andE.E.
In Table 2, θ 1 and θ 3 = θ 1 + θ p are the rotation angles of gears 1 and 3 under each
pattern, respectively. θ p is the phase angle. i21 and i43 are the transmission ratios of the
corresponding gear pairs, respectively. Ioi is the overall transmission ratio between the
output shaft and input shaft. a1 , b1 , a2, and b2 are the parameters of the transmission ratios
i21 and i43 of type I. K is the characteristic parameter of the differential mechanism of type I.
a is the parameter of the transmission ratios i21 and i43 of type II.
For class A, z5 , z6 , and z7 are the teeth number of bevel gears 5, 6, and 7, respectively.
i7i is the transmission ratio between the bevel gear 7 and the input shaft. Constant io7 is
the transmission ratio between the output shaft and the bevel gear 7. For class B, z5 and
z7 are the teeth number of the ring gear 5 and center gear 7, respectively. z6i and z6o are
the number of internal teeth and external teeth of planetary gear 6, respectively. IHi is
the transmission ratio between the planet carrier H and input shaft. Constant ioH is the
transmission ratio between the output shaft and the planet carrier H. For class C, z9 , z11 ,
and z13 are the teeth number of the corresponding gears, respectively. z10i , z10o , z12i , and
z12o are the teeth number of the inner and outer rings of the corresponding bilateral gears.
iHi is the transmission ratio between the planet carrier H and input shaft. Constant ioH is
the transmission ratio between the output shaft and the planet carrier H. For classes D and
E, i42 is the transmission ratio between gear 4 and gear 2. Constant io4 is the transmission
ratio between the output shaft and gear 4.
As can be seen from Table 2, when the coefficient related to the rotation angle θ 1 is 0,
the overall transmission ratio ioi of each pattern is a function related only to the variable
phase angle θ p . By continuously changing θ p , combined with the transmission selection
mechanisms of multiple branches, the CVT with an input rotation angle in the range of 0 to
360◦ can be realized. The parameter conditions that each pattern need to meet were shown
in Table 3.
Appl. Sci. 2022, 12, 2715 9 of 22
where, i01 (θ 1 ) is the transmission ratio in the working area. i02 (θ 1 ) is the transmission ratio
in the transition area. mj is the polynomial coefficient. Φ is the maximum rotation angle of
noncircular gear 1 in the working area. U = 2π/n1 is the period of the transmission ratio,
and the positive integer n1 is the order of noncircular gear 1.
According to Equation (2), the unknown parameters in i21 (θ 1 ) can be solved.
2π
RΦ RU
n2 = 0 i01 ( θ1 )dθ1 + Φ i02 ( θ1 )dθ1
i01 (Φ) = i02 (Φ)
i0 01 (Φ) = i0 02 (Φ)
where the positive integer n2 is the order of noncircular gear 2. i0 01(θ 1), i00 01(θ 1), i0 02(θ 1), and
i00 02(θ 1) are the first and second derivatives of i01(θ 1) and i02(θ 1) with respect to θ 1, respectively.
According to the above analysis, take the parameters in Table 4 and analyze the
transmission ratio of each pattern, as shown in Figures 7 and 8. ni is the number of cycles
of the input gear and nl is the number of branches.
where θemin = 2π/(ni∙nl) is the minimum length of the effective working area.
Figure7.7.Transmission
Figure Transmissionratio variation
ratio law of
variation lawclass A. A.
of class
In Figure 7, i21‐1, and i43‐1 are the transmission ratios of the corresponding gear pair
in the first branch, respectively. i7i‐1, i7i‐2, and i7i‐3 are the transmission ratios between the
bevel gear 7 and the input shaft in the three branches, respectively. Here, Φ is 220°, θp i
30° and θe is 190°. As can be seen, by integrating the transmission ratios i21 and i43 in the
three branches, respectively, i7i‐1, i7i‐2, and i7i‐3 are constant in a certain area. Specifically
i7i ‐1 is constant when θ1 varies from 0 to 190°. i7i‐2 is constant when θ1 varies in the range
0~70° and 240~360°. i7i‐3 is constant when θ1 varies in the range 120~310°. Finally, by inte
grating the transmission ratios i7‐1, i7i‐2, and i7i‐3, the overall transmission ratio ioi is alway
constant when θ1 varies from 0 to 360°.
Figure 8 shows the variation law of the transmission ratios of classes B~E.
Figure 8. Transmission
Figure 8. Transmissionratio
ratiovariation lawofof
variation law class
class B~E.
B~E.
Figure 78,isi21the
In Figure ‐1, variation
and i43‐1law
areof thetransmission
the transmission ratio
ratiosofof
class
theA. θ e = Φ − θ p is the
corresponding gear pairs
length of the effective working area, that is, the area where each branch outputs a constant
in the first branch, respectively. ioi is the overall transmission ratio between the output
rotation speed. To achieve a constant rotation speed output with an input rotation angle in
shaftthe
and input
range of 0 shaft.
to 360◦In Figure (3)
, Equation 8a,b, thebeinput
must rotation angle is θ1. iHi‐1, iHi‐2, and iHi‐3 are
satisfied.
the transmission ratios between the planet carrier H and input shaft in each branch, re‐
spectively. In Figure 8c,d, the input rotation θe ≥ θemin ,
angle is θ2. i42‐1, i42‐2, and i42‐3 are (3) the trans‐
mission ratios between gear 4 and gear 2 in the three branches, respectively. Similarly, the
where θ emin = 2π/(ni ·nl ) is the minimum length of the effective working area.
maximum working
In Figure 7, i21angle
-1, andΦi43of
-1 class
are theB~E are 220°,ratios
transmission 100°,of110°, and 200°. The
the corresponding phase
gear pairsangle θp
of class
in theB~E
firstare 30°, respectively.
branch, 10°, 30°, and 30°.
i7i -1, The
i7i -2, andlength
i7i -3 areofthe
the effective working
transmission area the
ratios between θe of class
Φ ◦ , θ is
B~E are 190°, 90°, 80°, and 170°. By integrating the transmission ratios i21 and pi43 of each
bevel gear 7 and the input shaft in the three branches, respectively. Here, is 220
30◦ and
branch, θ e is 190◦ . AsiHi
respectively, can be seen,
and i42 ofbyeachintegrating
branch theare
transmission in a i21
constantratios and i43area.
certain in the Finally
three branches, respectively, i7i -1, i7i -2, and i7i -3 are constant in a certain area. Specifically,
through the integration of the transmission ratios of multiple branches, each pattern can
achieve a constant rotation speed output throughout the area. CVT can be realized by
continuously changing the phase angle.
Appl. Sci. 2022, 12, 2715 11 of 22
i7i -1 is constant when θ 1 varies from 0 to 190◦ . i7i -2 is constant when θ 1 varies in the range
0~70◦ and 240~360◦ . i7i -3 is constant when θ 1 varies in the range 120~310◦ . Finally, by
integrating the transmission ratios i7 -1, i7i -2, and i7i -3, the overall transmission ratio ioi is
always constant when θ 1 varies from 0 to 360◦ .
Figure 8 shows the variation law of the transmission ratios of classes B~E.
In Figure 8, i21 -1, and i43 -1 are the transmission ratios of the corresponding gear pairs
in the first branch, respectively. ioi is the overall transmission ratio between the output
shaft and input shaft. In Figure 8a,b, the input rotation angle is θ 1 . iHi -1, iHi -2, and iHi -3
are the transmission ratios between the planet carrier H and input shaft in each branch,
respectively. In Figure 8c,d, the input rotation angle is θ 2 . i42 -1, i42 -2, and i42 -3 are the
transmission ratios between gear 4 and gear 2 in the three branches, respectively. Similarly,
the maximum working angle Φ of class B~E are 220◦ , 100◦ , 110◦ , and 200◦ . The phase angle
θ p of class B~E are 30◦ , 10◦ , 30◦ , and 30◦ . The length of the effective working area θ e of
class B~E are 190◦ , 90◦ , 80◦ , and 170◦ . By integrating the transmission ratios i21 and i43 of
each branch, respectively, iHi and i42 of each branch are constant in a certain area. Finally,
through the integration of the transmission ratios of multiple branches, each pattern can
achieve a constant rotation speed output throughout the area. CVT can be realized by
continuously changing the phase angle.
Figure 9. Tooth
Figure 9. Toothprofile
profileclassification ofcurve
classification of curveface
face gear
gear pair.
pair.
4.1.4.1. TransmissionPrinciple
Transmission Principle and
and Pitch
PitchCurve
Curve
According to the gear meshing principle, the pitch curve of the curve face gear pair is
According to the gear meshing principle, the pitch curve of the curve face gear pair
independent of the tooth profile. Figure 10 is the meshing coordinate system of the pitch
is independent
curve of the curved of theface
tooth
gearprofile.
pair. σ1Figureand σ2 are 10 isthethe meshing coordinate
corresponding pitch curves, system of the pitch
respectively.
curve of the curved face gear pair. σ
ω 1 and ω 2 are the corresponding angular velocities, respectively. The coordinate system respec‐
1 and σ 2 are the corresponding pitch curves, Sf
tively.
(Of –X ωf1Yand
Z
f f ), ω 2 are the as
abbreviated corresponding
S f , is the fixed angular
coordinate velocities,
system of respectively.
the noncircular The
gear coordinate
frame.
system Sf (Of –XfYsystem
The coordinate fZf), abbreviated
S1 (O1 –X1 Yas 1 ZS f, is
1 ), the fixed coordinate
abbreviated as S1 , is the system
follow-up of the noncircular
coordinate
system of the noncircular gear. The coordinate
gear frame. The coordinate system S1 (O1–X1Y1Z1), abbreviated system S m (O m –X Y
m as Z
m Sm ), abbreviated
1, is the follow‐upas co‐
Sm , is the
ordinate fixed of
system coordinate system ofgear.
the noncircular the curve face gear frame.
The coordinate systemTheScoordinate
m (Om–XmYsystem S2
mZm), abbrevi‐
(O 2 –X 2 Y 2 Z 2 ), abbreviated as S 2 , is the follow-up coordinate
ated as Sm, is the fixed coordinate system of the curve face gear frame. The coordinate system of the curve face gear.
system S2 (O2–X2Y2Z2), abbreviated as S2, is the follow‐up coordinate system of the curve
face gear. When the gear pair is in the initial meshing situation A, S1 and Sf coincide and
S2 and Sm coincide. When the gear pair changes from situation A to situation B, the rotation
axes Z1 and Z2 of the two gears are fixed, and the meshing point of the pitch curve changes
is independent of the tooth profile. Figure 10 is the meshing coordinate system of the pitch
curve of the curved face gear pair. σ1 and σ2 are the corresponding pitch curves, respec‐
tively. ω1 and ω2 are the corresponding angular velocities, respectively. The coordinate
system Sf (Of –XfYfZf), abbreviated as Sf, is the fixed coordinate system of the noncircular
gear frame. The coordinate system S1 (O1–X1Y1Z1), abbreviated as S1, is the follow‐up co‐
Appl. Sci. 2022, 12, 2715 ordinate system of the noncircular gear. The coordinate system Sm (Om–XmYmZm), abbrevi‐ 12 of 22
ated as Sm, is the fixed coordinate system of the curve face gear frame. The coordinate
system S2 (O2–X2Y2Z2), abbreviated as S2, is the follow‐up coordinate system of the curve
face
When gear.
the When
gear pair the isgear pairinitial
in the is in the initial situation
meshing meshing A, situation
S1 andA, Sf Scoincide
1 and Sf coincide
and S2 andandSm
S and S coincide. When the gear pair changes from situation A
coincide. When the gear pair changes from situation A to situation B, the rotation axes
2 m to situation B, the rotation
axes
Z1 andZ1 and
Z2 ofZ2the of thetwo two gears
gears areare fixed,and
fixed, andthe
themeshing
meshing pointpoint ofof the
thepitch
pitchcurve
curvechanges
changes
from
from P P11 to
toPP22. .θθ1 1and
andθθ2 2are
arethe
therotation
rotationangles
anglesofofthethenoncircular
noncirculargear gear and
andcurve
curveface gear
face gear
respectively.
respectively. rr11(θ (θ11) )and
andrr2(θ 2) )are
(θ
2 2 are the
thepitch
pitch curve
curve parameter
parameter equation
equation of the
of thenoncircular
noncircular
gear
gear and
and curve
curve face facegear,
gear, respectively.
respectively. RRisisthethedistance
distancefromfromthe theprojection
projectionofofpoint
pointP1Pon
1 on
the pitch curve of curve face gear in plane X O Y to O . V and V
the pitch curve of curve face gear in plane Xm Om Ym to O2 . V 1 and V 2 are the speeds at the
m m m 2 1 2 are the speeds at the
meshing
meshing points
points of of the
the two
twocurves,
curves,respectively.
respectively.
Figure
Figure 10.
10. Pitch
Pitchcurve
curvecoordinate
coordinatesystem
systemofofthe
thecurve
curveface
facegear
gearpair.
pair.
−R
0 0 1
0 1 0 0
Mm f =
−1 0 0
. (5)
E
0 0 0 1
The coordinates of point P2 in S1 are [r1 (θ 1 )cos(θ 1 ), r1 (θ 1 )sin(θ 1 ),0,1]T, then the coordi-
nates of point P2 in S2 can be expressed as
− R cos θ2
x2 r1 (θ1 ) cos θ1
y2 r1 (θ1 ) sin θ1 R sin θ2
z2 = M21
=
E − r1 ( θ1 ) . (8)
0
1 1 1
Therefore, the pitch curve equation of the curve face gear can be obtained as
x2 = − R cos θ2
y = R sin θ2 . (9)
2
z2 = E − r1 ( θ1 )
It can be seen from Equation (9) that the pitch curve of the curve face gear is a
cylindrical curve with R as the radius.
The speeds V 1 and V 2 satisfy Equation (10).
V1 = r1 (θ1 )ω1
V = Rω2 . (10)
2
Appl. Sci. 2022, 11, x FOR PEER REVIEW V1 = V2 14 of 23
1
21
rω r1 ( θ1 )
i21 i21
1 (θ1 )2 =
=. . (11) (11)
1 ωR1 R
Figure 11.
Figure 11.The
Thetooth surface
tooth generating
surface processprocess
generating of curveof
face gear face
curve pair. gear pair.
The global coordinate systems of both the helical and curvilinear tooth generating rack
are expressed as Sr (Or –Xr Yr Zr ), abbreviated as Sr , as shown in Figure 12a,d. In Figure 12b,
St (Ot –Xt Yt Zt ), abbreviated as St , is the cross-section coordinate system of helical rack in
the tooth width direction. Ot Xt coincides with the rack pitch line and Ot Yt coincides with
the cogging symmetry line. Ha and Hb are the addendum and dedendum, respectively.
M is the module, αr is the profile angle and ur is the tooth height direction parameter. In
Figure 12e, Sn (On –Xn Yn Zn ), abbreviated as Sn , is the normal section coordinate system of
curvilinear rack. The normal section tooth profile of the curvilinear rack is the same as the
cross-section tooth profile of the helical rack in the tooth width direction. Figure 12c,f show
the transformation process from coordinate systems St and Sn to Sr , respectively. βr and
br are the helical angle and tooth width parameter of the helical rack respectively. θ r and
ρr are the arc angle and arc radius of the curvilinear rack, respectively. m is the module
of the rack.
The tooth profile equations in St and Sn can be expressed as
±ur sin αr ±
πm
4
ur cos αr
rt ( u r ) = rn ( u r ) = , (12)
0
1
where, the positive and negative signs, respectively, represent the left and right tooth
surfaces of the rack.
Appl. Sci. 2022, 12, 2715 15 of 22
1 0 0 −br tan β r
Mrt (br ) = 0 1 0 0
0 0 1 br
0 0 0 1
. (13)
−
sin θ r 0 cos θr ρr sin θr
0 1 0 0
Mrn (θr ) =
cos θr 0
sin θ r ρ r cos θr
0 0 0 1
Then, the tooth surface equations of the three kinds of tooth profiles in Sr can be
expressed by rr (ur , br , θ r ).
rr1 (ur , br ) = Mrt (br )rt (ur )
T
= ±ur sin αr ± πm 4 − br tan β r ur cos αr br 1
rr (ur , br , θr ) = (14)
rr2 (ur , θr ) = Mrn (θr )rt (ur )
T
= ±ur sin αr ± πm sin θr + ρr sin θr ur cos αr ±ur sin αr ± πm
cos θr + ρr cos θr 1
4 4
where rr1 (ur , br ) and rr2 (ur , θ r ) are the tooth surface equation of the helical rack and
curvilinear rack, respectively. When βr = 0, the tooth surface equation of the straight rack
can be obtained by rr1 (ur , br ).
The three kinds of cylindrical generating gears have the same generation process.
Through the envelope principle, the tooth surface of the generating gear can be obtained
by the generating rack, as shown in Figure 13. The coordinate system Sr is fixed with the
generating rack. The coordinate system Sg (Og –Xg Yg Zg ), abbreviated as Sg , is the fixed
coordinate system of the generating gear frame. The coordinate system Sc (Oc –Xc Yc Zc ),
Appl. Sci. 2022, 11, x FOR PEER REVIEW
abbreviated as Sc , is the follow-up coordinate system of the generating gear. rc is the radius 16 of 2
of the generating gear. When the rotation angle of the generating gear is ϕ, the displacement
distance of the generating rack is rc ϕ.
Figure
Figure The
13.13. generating
The process
generating fromfrom
process the generating rack torack
the generating cylindrical gear.
to cylindrical gear.
Based on the principle of spatial coordinate transformation, the transformation matrix
Based
from the on thesystem
coordinate principle
Sr toof
Sgspatial
is coordinate transformation, the transformation ma
trix from the coordinate system Sr to Sg is
1 0 0 −r c ϕ
0 1 0 −rc rc
1 0 0
Mgr 0 0 10 1 0 0 . rc
= (15)
M gr
0 0 00 0 1 1 0 (15
0 0 0 1
.
−sinϕ
cos ϕ 0 0
sinϕ cos ϕ 0 0
Mcg =
0
. (16)
0 1 0
0 0 0 1
The tooth surface equation of the generating gear in Sc can be expressed by rc (ur , br , θ r ).
Figure 14 is the generating process from the generating gear to the curve face gear
pair. σc , σ1 , and σ2 are the pitch curve of the generating gear, noncircular gear, and curve
Appl. Sci. 2022, 11, x FOR PEER REVIEW face gear, respectively. When σ1 is purely rolling around σ2 , σc is purely rolling inside 17 of 2
σ1 . According to the relative motion relationship between σ1 and σ2 , the relative motion
relationship between σc and σ2 can be obtained.
Figure 14.14.
Figure The generating
The generating process fromthe
process from the generating
generating geargear
to thetocurve
the curve face
face gear gear pair.
pair.
r2 (θ )+ L2 −r2
q
ξ 1 = arccos 1 2r11 (θ1 )cLc c , Lc = r12 (θ1 ) + rc2 − 2rc r1 (θ1 ) sin µ
R θ1 q . (20)
0 r12 (θ1 )+(dr1 (θ1 )/dθ1 )2 dθ1 r (θ )
θ = π/2 + ξ − θ − µ, ξ = arctan dr (1θ )1/dθ
c 2 1 2 rc ,µ =
1 1 1
The tooth surface equation of the curve face gear in S2 can be expressed as
Appl. Sci. 2022, 11, x FOR PEER REVIEW By selecting the corresponding parameters, the tooth surfaces of the curve face gear 18 of 23
pair with a straight, helical, and curvilinear tooth can be obtained, respectively. Combined
with the transmission ratio equation in Section 3 and the tooth surface classification design,
the 3D model of the curve face gear pair can be obtained.
5. Simulation and Experiment
Since the main
5. Simulation difference between the five patterns is the transmission ratio changing
and Experiment
part, and
Sinceitsthe
complex key components
main difference arefive
between the thepatterns
curve face
is thegear pair, the ratio
transmission overall transmis‐
changing
sion
part,ratio
and of
its each pattern
complex was verified
key components areby
thesimulation, andpair,
curve face gear thethe
transmission ratio of the
overall transmission
ratioface
curve of each
gearpattern wasverified
pair was verifiedby
byexperiment.
simulation, and the transmission ratio of the curve
face gear pair was verified by experiment.
5.1. Overall Transmission Ratio Simulation of CVT Mechanism
5.1. Overall Transmission Ratio Simulation of CVT Mechanism
The mechanism models of five patterns were imported into the software ADAMS,
The mechanism models of five patterns were imported into the software ADAMS, and
and then
then the the overall
overall transmission
transmission ratiosratios with different
with different phasewere
phase angles angles were simulated.
simulated. Taking theTak‐
ing the phase angle in the range of
◦ 0 to 60° as an example, the comparison between the
phase angle in the range of 0 to 60 as an example, the comparison between the theoretical
theoretical and simulation
and simulation results wasresults
shown was shown
in Figure 15. in Figure 15.
Figure
Figure15.
15.Comparison
Comparisonbetween theoreticaland
between theoretical andsimulation
simulation results
results of overall
of overall transmission
transmission ratio.ratio.
InInFigure
Figure15,
15,A
Att,,BBtt,,C
Ctt,,D
Dtt,,and
and E
Ett are
are the
the theoretical
theoreticalresults
resultsof of
thethe
overall transmission
overall transmission
ratio of each pattern, respectively. As, Bs, Cs, Ds, and Es are the simulation results of
ratio of each pattern, respectively. A s , Bs , Cs , Ds , and Es are the simulation results of the
the overall transmission ratio. As can be seen, the overall transmission ratio values of
overall transmission ratio. As can be seen, the overall transmission ratio values of classes
classes A, B, and D are no less than 0, which means that the output shaft turns in the
A, B, and D are no less than 0, which means that the output shaft turns in the same direc‐
tion as the input shaft. The overall transmission ratio values of classes C and E are less
than 0, which means that the output shaft turns in the opposite direction as the input shaft.
Moreover, for classes A and C, the absolute values of ioi gradually decrease with the in‐
crease of phase angle θp. For classes B, D, and E, the absolute values of ioi gradually in‐
Appl. Sci. 2022, 12, 2715 18 of 22
same direction as the input shaft. The overall transmission ratio values of classes C and
E are less than 0, which means that the output shaft turns in the opposite direction as the
input shaft. Moreover, for classes A and C, the absolute values of ioi gradually decrease
with the increase of phase angle θ p . For classes B, D, and E, the absolute values of ioi
gradually increase with the increase of phase angle θ p . Further, for classes A, B, and C,
the overall transmission ratio ioi can be zero by selecting the appropriate parameters. At
this time, no matter what the input rotation speed is, the output rotation speed is zero.
However, for classes D and E, due to the limitation of transmission ratio principle, the
overall transmission ratio ioi cannot be zero. On the whole, the simulation results are in
good agreement with the theoretical results, and the overall transmission ratio changes
continuously with the continuous change of the phase angle, that is, the CVT was realized.
Figure 16 shows the maximum relative error of overall transmission ratio simulation
for each pattern. For classes A~E, the maximum relative errors are 6.2%, 6.9%, 7.6%, 4.9%,
Appl. Sci. 2022, 11, x FOR PEER REVIEWand 5.4%. The reason why the error of type I is greater than that of type II is19thatof 23the
structure of type I mechanism is more complex, and the transmission chain is longer,
resulting in greater transmission ratio loss and transmission ratio error.
Figure
Figure 16.16. Maximum
Maximum relative
relative error
error of overall
of overall transmission
transmission ratio
ratio simulation.
simulation.
In In summary,
summary, thethe
CVTCVT mechanism
mechanism characteristics
characteristics of types
of types I andIIIand II shown
were were shown
in Ta‐ in
bleTable
5. 5.
Table 5. CVT mechanism characteristics of types I and II.
Table 5. CVT mechanism characteristics of types I and II.
TypeType I: Addition
I: Addition Method
Method TypeType II: Multiplication
II: Multiplication Method
Method
Class
Class
A: NG‐PBGT
A: NG-PBGT B: NG‐PCGT
B: NG-PCGTC: CFG‐BG‐PCGT
C: CFG-BG-PCGT D: D:
CFGCFG E: E:
NGNG
Simple design;
Simple design; Complex design;
Complex design;
Larger transmission ratio range;
Larger transmission ratio range; Smaller transmission
Smaller transmissionratio range;
ratio range;
LessLess
parameter restrictions;
parameter restrictions;
More parameter restrictions;
More parameter restrictions;
Characteristics
Characteristics Complex structure; Simple structure;
Complex structure; Simple structure;
Large volume Small volume;
Large volume Small volume;
Longer transmission chain Shorter transmission chain
Longer transmission chain Shorter transmission chain
The type I mechanism has the advantages of simple design, larger transmission ratio
range, and
Theless
typeparameter restrictions,
I mechanism while the type
has the advantages II mechanism
of simple has thetransmission
design, larger advantages ratio
of
simple structure, small volume, and shorter transmission chain.
range, and less parameter restrictions, while the type II mechanism has the advantages of
simple structure, small volume, and shorter transmission chain.
5.2. Transmission Experiment of the Curve Face Gear Pair
5.2.InTransmission Experiment
order to verify of the Curve
the correctness of theFace Gear
tooth Pair classification design of the curve
profile
face gearInpair,
ordera to
transmission experimentofisthe
verify the correctness needed. Takingclassification
tooth profile the first pair design
of the curve
of theface
curve
gear pairs
face gearinpair,
class C as an example,
a transmission the parameters
experiment is needed.inTaking
Tablesthe4 and 6 were
first pair selected
of the curvetoface
gear the
obtain pairs in class
curve faceCgear
as an example,
pairs the parameters
with three in Tables
different tooth 4 andby6 5‐axis
profiles were selected to obtain
CNC milling.
the curve face gear pairs with three different tooth profiles by 5-axis CNC milling.
Table 6. Specific properties of the curve face gear pair.
Figure 17. Transmission experiment of the curve face gear pairs with different tooth profiles.
The 17.
Figure
Figure
experimental
Transmissiontransmission
17.Transmission experiment
ratios
experimentofofthe
the were
curveface
curve
compared
facegear
gear pairswith
pairs
with the
withdifferent
different theoretical
tooth
tooth profiles.
profiles.
transmis‐
sion ratios, as shown in Figure 18. it is the theoretical curve of transmission ratio. is, ih and
ic are the The
The experimental
experimental
measured curves transmission
transmission
of transmission ratios
ratios were
were compared
compared
ratios with
of curve withthe the
face theoretical
theoretical
gear transmis‐
transmission
pairs with straight
sion
ratios,ratios,
as as
shown shown
in in
Figure Figure
18. i 18.
is it istheoretical
the the theoretical
curve
tooth, helical tooth, and curvilinear tooth, respectively. As can be seen, when
t curve
of of transmission
transmission ratio.
ratio. i s , i his,and
ih and
ic rota‐
the
ic are
are thethe measured
measured curves
curves of of transmission
transmission ratios
ratios of of curve
curve face facepairs
gear gear with
pairsstraight
with straight tooth,
tional angle θ2 varies from 0 to 360°, the transmission ratio i21 varies in the range of 1.6~2.4,
tooth, tooth,
helical helicalandtooth, and curvilinear
curvilinear tooth, respectively.
tooth, respectively. As can be As seen, canwhenbe seen, when theangle
the rotational rota‐
and the number of cycles of i21 is 2. Moreover, as can be seen from the total comparison
◦ , the
2 varies
θtional from
angle θ 2 0 to
varies360 from 0 transmission
to 360°, the ratio i
transmission
21 varies
ratioini the
21 range
varies in of
the 1.6~2.4,
range of and the
1.6~2.4,
andnumber
single
and theof comparison,
cycles of the
of icycles three measurement curves of the transmission and single are in
ratio
number 21 is 2. ofMoreover, as can be seen
i21 is 2. Moreover, as canfrom
be the
seentotal
from comparison
the total comparison
good andagreement
comparison, thewith
threethe
single comparison, theoretical
measurement curve,ofwhich
curves
the three measurement indicated
the transmission
curves of the the
ratio correctness
are in goodratio
transmission of the
agreement are theoret‐
in
icalwith
method.
goodthe theoretical
agreement curve,
with which indicated
the theoretical curve,the correctness
which indicated ofthethecorrectness
theoretical ofmethod.
the theoret‐
ical method.
Figure 18. Comparison between the theoretical and experimental transmission ratios of the curve
Figure
Figure 18. Comparisonbetween
between the
the theoretical
theoreticaland experimental transmission ratiosratios
of the of
curve
face18.
gearComparison
pair. and experimental transmission the curve
face gear
face gear pair.pair.
Figure 19 shows the maximum relative error of the transmission ratio experiment.
Figure 19 shows the maximum relative error of the transmission ratio experiment.
Figure 18. Comparison between the theoretical and experimental transmission ratios of the curve
Appl. Sci. 2022, 12, 2715 face gear pair. 20 of 22
Figure 19 shows the maximum relative error of the transmission ratio experiment.
Figure 19 shows the maximum relative error of the transmission ratio experiment.
The experimental curves of the transmission ratios of the three curve face gear pairs are
close to the theoretical curve, and the matching degree from low to high is the transmission
ratio curve of the straight tooth, helical tooth, and curvilinear tooth curve face gear pair,
respectively. The maximum relative errors of the corresponding transmission ratios are
5.5%, 4.6%, and 3.9%, respectively. The main reason for this difference is that the tooth
profile has an important influence on the transmission stability of the curve face gear pair.
The curvilinear tooth transmission is the most stable, followed by the helical tooth, and
finally the straight tooth.
Besides, the causes of experimental errors mainly include machining errors, instal-
lation errors, and measurement errors. Considering the influence of the above errors,
the experimental errors were within a reasonable range. The correctness of tooth profile
classification design method was verified by the transmission experiment of curve face
gear pair, which laid a foundation for the further research of CVT mechanism.
6. Conclusions
Through the study of pattern classification and gear design of spatial noncircular gear
CVT, the following conclusions can be drawn.
(1) Under the condition of choosing appropriate parameters, all the five patterns can
realize the CVT. Compared with type I, type II has the advantages of a simpler structure,
smaller volume, shorter transmission chain, and higher transmission efficiency. However,
it is more complex in design, relatively limited by parameters and has a smaller range of
transmission ratio. According to the actual working situation and requirements, different
patterns can be selected to realize the required CVT;
(2) The curve gear face pair can realize variable transmission ratios between intersect-
ing shafts. Through the tooth profile classification design method, the curve face gear pairs
with straight tooth, helical tooth, and curvilinear tooth can be obtained. Compared with
the straight tooth curve face gear pair, the helical tooth and curvilinear tooth curve face
gear pair have a more complex design, but a greater contact ratio and load capacity, which
can meet the requirements of different working situations;
(3) The overall transmission ratio of each pattern was simulated, and the simulation
errors were within a reasonable range, which verified the correctness of the theoretical
analysis of each pattern. Through transmission experiments, the correctness of the tooth
profile classification design method of the curve face gear pair was verified, which provided
a strong proof for the correctness of the whole design method to a certain extent;
(4) The CVT principle and transmission ratio characteristics of each pattern were
analyzed only from the aspect of kinematics here. However, the dynamic characteristics
and performance of each pattern should be further studied in the follow-up work, such as
vibration, noise, carrying capacity, and transmission efficiency, which have an important
impact on the working performance of the spatial noncircular gear CVT system.
Appl. Sci. 2022, 12, 2715 21 of 22
Author Contributions: Conceptualization, Y.Y. and C.L.; data curation, P.X.; formal analysis, Y.Y.; funding
acquisition, C.L.; investigation, Y.Y.; methodology, Y.Y.; project administration, C.L.; resources, C.L.;
software, Y.Y.; supervision, C.L.; validation, Y.Y.; visualization, Y.Y. and P.X.; writing—original draft, Y.Y.;
writing—review and editing, Y.Y. and C.L. All authors have read and agreed to the published version
of the manuscript.
Funding: This research was funded by National Natural Science Foundation of China, grant
number 51675060.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
Nomenclature
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