阅读说明：本技术 用于利用反齿隙传动装置来进行紧凑齿轮减速的系统和方法 (System and method for compact gear reduction with anti-backlash transmission ) 是由 约翰·杰里德 斯蒂芬·威廉·蒂洛森 钱德拉·苏达卡尔·古迪梅特拉 马赫什·巴萨万塔帕·哈利克里 于 2020-03-02 设计创作，主要内容包括：本发明题为“用于利用反齿隙传动装置来进行紧凑齿轮减速的系统和方法”。本发明公开了用于齿轮减速的示例性系统、设备和方法。示例性系统包括第二齿轮,该第二齿轮被配置为设置成与联接到输入轴的第一齿轮啮合。系统还包括托架外壳,该托架外壳被配置为固定地设置在第二齿轮内。系统还包括第三齿轮,该第三齿轮被配置为设置在托架外壳内；第四齿轮,该第四齿轮被配置为设置成与第三齿轮啮合,其中第三齿轮进一步被配置为围绕第四齿轮旋转；反齿隙齿轮,该反齿隙齿轮联接到第四齿轮并且被配置为设置成与第三齿轮啮合；以及第五齿轮,第五齿轮被配置为与第三齿轮啮合。第二齿轮、第四齿轮、反齿隙齿轮和第五齿轮被配置为沿着公共旋转轴设置。(The invention provides a system and method for compact gear reduction using anti-backlash transmission. Exemplary systems, apparatus, and methods for gear reduction are disclosed. An example system includes a second gear configured to be disposed in meshing engagement with a first gear coupled to an input shaft. The system also includes a carrier housing configured to be fixedly disposed within the second gear. The system further includes a third gear configured to be disposed within the carriage housing; a fourth gear configured to be disposed in mesh with the third gear, wherein the third gear is further configured to rotate about the fourth gear; an anti-backlash gear coupled to the fourth gear and configured to be disposed in mesh with the third gear; and a fifth gear configured to mesh with the third gear. The second gear, the fourth gear, the anti-backlash gear, and the fifth gear are configured to be disposed along a common rotational axis.)

1. A system for gear reduction, the system comprising:

a second gear configured to be disposed in mesh with the first gear coupled to the input shaft;

a carrier housing configured to be fixedly disposed within the second gear;

a third gear configured to be disposed within the carriage housing;

a fourth gear configured to be disposed in mesh with the third gear, wherein the third gear is further configured to rotate about the fourth gear;

an anti-backlash gear coupled to the fourth gear and configured to be disposed in mesh with the third gear; and

a fifth gear configured to mesh with the third gear,

wherein the second gear, the fourth gear, the anti-backlash gear, and the fifth gear are configured to be disposed along a common axis of rotation, and

wherein the second gear, the third gear, the fourth gear, the anti-backlash gear, and the fifth gear are configured to be disposed along a common gear interaction plane.

2. The system of claim 1, wherein the first gear is an input shaft drive gear.

3. The system of claim 1, wherein the second gear is a sun gear.

4. The system of claim 1, wherein the third gear is a planetary gear.

5. The system of claim 1, wherein the fourth gear is a stationary gear.

6. The system of claim 1, wherein the fifth gear is an opposing gear of the fourth gear.

7. The system of claim 1, wherein the system further comprises the first gear.

8. The system of claim 1, wherein the system further comprises a sixth gear coupled to the fifth gear and configured to be disposed in mesh with a seventh gear coupled to a sensing device.

9. The system of claim 8, wherein the sensing device is a rotational position sensing device.

10. The system of claim 8, wherein the system further comprises the seventh gear, wherein the anti-backlash gear is a first anti-backlash gear, and wherein the system further comprises a second anti-backlash gear coupled to the seventh gear and configured to be disposed in meshing engagement with the sixth gear.

Technical Field

Exemplary embodiments of the present disclosure relate generally to gear reduction and, more particularly, to planetary gear reduction systems having anti-backlash gearing.

Background

Industrial and commercial applications, including aerospace applications, increasingly use measurement devices, such as rotational position sensing devices, that utilize gear reduction systems. These gear reduction systems must be adapted to ever decreasing package sizes while also reducing cost and weight without sacrificing accuracy, quality or safety.

The applicant has identified a number of drawbacks and problems associated with conventional gear reduction systems. Many of these identified problems have been addressed by efforts, wisdom, and innovations through development solutions included in embodiments of the present disclosure, many examples of which are described in detail herein.

Disclosure of Invention

Systems, apparatus, and methods (including but not limited to manufacturing methods) for providing a dual stage, single plane, planetary gear reduction are disclosed herein. Also disclosed herein, in some embodiments, are systems, apparatuses, and methods for providing a compact anti-backlash transmission.

In one exemplary embodiment, a system for gear reduction is provided. The system may include a second gear configured to be disposed in meshing engagement with the first gear coupled to the input shaft. The system may also include a carrier housing configured to be fixedly disposed within the second gear. The system may also include a third gear configured to be disposed within the carrier housing. The system may also include a fourth gear configured to mesh with the third gear. The third gear may be further configured to rotate about the fourth gear. The system may also include an anti-backlash gear coupled to the fourth gear and configured to be disposed in meshing engagement with the third gear. The system may also include a fifth gear configured to mesh with the third gear. The second gear, the fourth gear, the anti-backlash gear, and the fifth gear may be configured to be disposed along a common rotational axis. The second, third, fourth, anti-backlash, and fifth gears may be configured to lie along a common gear interaction plane.

In another exemplary embodiment, an apparatus for gear reduction is provided. The apparatus may include a second gear configured to be disposed in meshing engagement with the first gear coupled to the input shaft. The apparatus may also include a carrier housing configured to be fixedly disposed within the second gear. The apparatus may also include a third gear configured to be disposed within the carriage housing. The apparatus may also include a fourth gear configured to mesh with the third gear. The third gear may be further configured to rotate about the fourth gear. The apparatus may also include an anti-backlash gear coupled to the fourth gear and configured to be disposed in meshing engagement with the third gear. The apparatus may also include a fifth gear configured to mesh with the third gear. The second gear, the fourth gear, the anti-backlash gear, and the fifth gear may be configured to be disposed along a common rotational axis. The second, third, fourth, anti-backlash, and fifth gears may be configured to lie along a common gear interaction plane.

In another exemplary embodiment, a method for manufacturing an apparatus for gear reduction is provided. The method may include providing a first gear. The first gear may be coupled to the input shaft. The method may also include mounting a second gear to the first gear. The second gear is engaged with the first gear. The method may also include mounting the carrier housing within the second gear. The method may also include mounting a third gear within the carrier housing. The method may also include mounting a fourth gear to the third gear. The fourth gear may be meshed with the third gear. The third gear is rotatable about the fourth gear. The method may also include mounting the anti-backlash gear to a third gear. The anti-backlash gear may be coupled to the fourth gear and engaged with the third gear. The method may also include mounting a fifth gear to the third gear. The fifth gear may be meshed with the third gear. The second gear, the fourth gear, the anti-backlash gear, and the fifth gear may be disposed along a common rotational axis. The first gear, the second gear, the third gear, the fourth gear, the anti-backlash gear, and the fifth gear may be disposed along a common gear interaction plane.

The above summary is provided merely for purposes of summarizing some example embodiments so as to provide a basic understanding of some aspects of the disclosure. Accordingly, it should be understood that the above-described embodiments are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. It should be understood that the scope of the present disclosure encompasses many possible embodiments, some of which are further described below, in addition to those summarized above.

Drawings

Having thus described certain exemplary embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings, which illustrate exemplary embodiments and features of the present disclosure and which are not necessarily drawn to scale. It should be understood that the components and structures shown in the figures may or may not be present in the various embodiments of the present disclosure described herein. Thus, some embodiments or features of the disclosure may include fewer or more components or structures than those shown in the figures without departing from the scope of the disclosure.

Fig. 1A, 1B, 1C, 1D, and 1E illustrate exemplary top and isometric views of an exemplary gear reduction system according to some exemplary embodiments described herein.

Fig. 2A and 2B illustrate exemplary isometric views of an exemplary gear reduction system according to some exemplary embodiments described herein.

Fig. 3A and 3B illustrate exemplary isometric views of an exemplary gear reduction system according to some exemplary embodiments described herein.

Fig. 4 illustrates an exemplary exploded view of an exemplary anti-backlash mechanism, according to some exemplary embodiments described herein.

Fig. 5 illustrates an exemplary flow chart showing an exemplary method according to some exemplary embodiments described herein.

Fig. 6 illustrates an exemplary resolver sensing element measurement, according to some exemplary embodiments described herein.

Fig. 7A and 7B illustrate exemplary error measurements according to some exemplary embodiments described herein.

Detailed Description

The following description should be read with reference to the drawings, in which like reference numerals represent like elements throughout the several views. The detailed description and drawings show several embodiments, which are intended to be illustrative of the disclosure. It will be understood that any numbering (e.g., first, second, etc.) of the disclosed features and directional terminology used with the disclosed features (e.g., front, back, top, bottom, side, etc.) is a relative term denoting exemplary relationships between the related features.

It should be understood at the outset that although illustrative embodiments of one or more aspects are illustrated below, the disclosed components, systems, and methods may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the exemplary embodiments, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents. Although dimensional values for various elements are disclosed, the drawings may not be to scale. The word "example" as used herein is intended to mean "serving as an example, instance, or illustration. Any embodiment described herein as "exemplary" is not necessarily preferred or advantageous over other embodiments.

Typically, when a position sensor with high accuracy and high gear amplification and deceleration in a compact size is required, it is common practice to use a multi-stage gear train (e.g., a combination of a planetary gear train and a simple gear train) to achieve the required gear ratio. However, conventional gear train designs may not be able to accommodate these requirements within a defined envelope. Accordingly, there is a need for a compact, highly accurate gear reduction system that can use two or more stages of reduction for sensitive measurement devices such as rotary position sensors. These gear systems need to be adapted to ever decreasing package sizes while also reducing cost and weight without sacrificing accuracy, quality or safety. However, typical dual stage gear reduction systems have three axes and two planes, and are therefore too large (e.g., their packaging size exceeds design requirements) and costly for many modern applications.

The exemplary embodiments described herein address these needs by describing a unique design of a dual-stage, dual-shaft, single-plane, planetary gear reduction system with a compact anti-backlash transmission. The gear reduction system disclosed herein utilizes a first gear to drive a modified epicyclic gear train layout to reduce the typical three-axis layout to an improved two-axis layout. Due to this reduction in required shafts, the disclosed gear reduction system further reduces the typical biplane layout to an improved monoplane layout. The combination of the dual-axis and single plane layouts provides a highly accurate, compact gear reduction system due to the reduction in required parts, shaft and gear interface planes. The gear reduction system disclosed herein provides engineering design advantages in minimizing the amount of space required, while achieving higher gear reduction and minimizing costs without additional envelope.

The exemplary embodiments described herein provide systems, apparatus and methods for a gear reduction system that provides compact gear reduction using anti-backlash gearing. In some embodiments, an input shaft with a drive gear transmits rotational motion from an input interface (e.g., shaft # 1). The pinion interface (e.g., shaft #2) defines a first gear stage reduction. The pinion gear is an integral part of the subassembly, which combines an in-line indexing planetary gear train consisting of the carrier housing and the shaft and an idler gear engaging the in-line indexing planetary gear train. The in-line indexing planetary gear train includes a stationary (e.g., fixed) indexing gear and an opposing gear that engages the idler gear and defines a second stage reduction along the same shaft (e.g., shaft # 2). The stationary modified gear has one tooth smaller than the opposite gear. An output drive gear is added to control multiple output devices, such as two sensing devices (e.g., rotational position sensing device, resolver, synchronizer). These output devices may be mounted with an input pinion defining a third shaft (e.g., shaft # 3). All three gear center axes may be defined by the desired gear center distance calculations and recommendations.

As the input shaft drives a gear (e.g., gear #1) to rotate about a first shaft (e.g., shaft #1), it transmits rotational motion to an interface gear (e.g., gear #2) on a second shaft (e.g., shaft #2) that defines a first stage. An interface gear (e.g., gear #2) is attached to the carrier housing and an idler gear (e.g., gear #3) that rotates about a modified stationary gear (e.g., gear # 4). The opposite gear (e.g., gear #5) of the stationary gear (e.g., gear #4) is indexed to 1 tooth per revolution of the carrier housing defining the second stage reduction. An output pinion (e.g., gear #6) attached to an opposing gear (e.g., gear #5) rotates about a second axis (e.g., axis #2) and defines a second gear interaction plane. When the final pinion (e.g., gear #6) rotates, the final gear (e.g., gear #7) rotates about the third shaft (e.g., shaft #3) and moves the sensing device. The gear reduction system disclosed herein may be used with any additional standard gear layout (e.g., a tandem transmission) to achieve reductions in excess of 10,000: 1.

Furthermore, to meet accuracy requirements, anti-backlash mechanisms may be utilized to reduce lost motion in the gear train that is typically caused by backlash in the gear mesh. When the direction of rotation of the gear train is reversed, lost motion typically manifests itself. Although a variety of techniques may be used to achieve low backlash, the embodiments described herein use anti-backlash gears. Generally, conventional gear reduction systems use an anti-backlash mechanism at the last stage of the gear train (e.g., simple gear train) that drives the sensing device (e.g., resolver, synchronizer) to meet accuracy requirements. However, when the accuracy requirements are more stringent, it is desirable to eliminate or reduce the wobble or eccentricity at all stages and provide additional anti-backlash mechanisms other than the last stage, such as on planetary gear mechanisms, because higher gear reductions and amplification can occur at this stage and many unforeseen variables (e.g., design and process variations) can cause significant degradation in accuracy at this stage. However, due to envelope constraints, it is quite difficult to provide an anti-backlash mechanism (e.g., anti-backlash gear) at the planetary gear train. Thus, conventional sensors do not include a separate anti-backlash mechanism for the planetary gear mechanism, particularly when parallel shafts and multi-stage gear trains are used.

The exemplary embodiment described herein with reference to fig. 3A and 3B addresses these requirements by: a single gear shaft 320 supported at its ends is used in place of the two separate components (e.g., carrier shaft 220 and intermediate shaft 223 described with reference to fig. 2A and 2B) and externally supports the carrier subassembly through higher load-rated bearings (e.g., ball bearings 319, 321). This design allows the gear reduction system to include anti-backlash mechanisms (e.g., anti-backlash spring 332 and anti-backlash gear 333) for the planetary gear mechanism that, in combination with higher load-rated bearings, provide a margin of safety with respect to life and load requirements. Accordingly, the exemplary embodiments described herein provide systems, apparatus and methods for a gear reduction system that provide a compact, highly reliable and fairly cost-effective (e.g., relatively low cost) method as follows: when parallel shafts and a multi-stage gear train are used, it is possible to provide an independent anti-backlash mechanism for the planetary gear mechanism, and to make the gear train mechanism more robust to significantly improve accuracy. The exemplary embodiments described herein further provide tighter accuracy requirements without seeking bias to allow the use of thin springs and envelope variations. The exemplary embodiments described herein further improve the robustness of the gear train installation in order to meet product life requirements, especially when the position sensor needs to be used for high speed rotating applications with higher equipment life requirements.

In some embodiments, the gear reduction system described herein comprises a combination of a high reduction planetary gear stage and an added anti-backlash gear pair. The deceleration is based on having an output gear (e.g., second gear 110,210,310) with N teeth and a fixed gear (e.g., fourth gear 117,217,317) with N-1 teeth having a non-standard pitch circle diameter modified to be equal to the output gear (e.g., fifth gear 122,222,322), wherein the output gear has N teeth, and wherein N is an integer greater than or equal to two. The planet gears (e.g., third gear 112,212,312) orbit around and mesh with both the fixed gear and the output gear. When the planetary gear is operating in orbit, it forces the teeth of both the fixed gear and the output gear to align at the point of engagement. Due to the mismatch in the number of teeth, the output gear is increased by one tooth relative to the fixed gear for each orbit of the planetary gear. The input to this gear stage is the rotation of the planet carrier (e.g., carrier housing 111,211, 311).

Although the present disclosure describes features of the gear reduction system with reference to an input shaft and sensing device, the gear reduction system disclosed herein may be applied to any suitable mechanical system, electromechanical system, sensor, detector, gauge, instrument, or application requiring maximum gear reduction and accuracy, and minimum package size and cost.

Fig. 1A illustrates an exemplary top view 180A of an exemplary gear reduction system 100 according to some exemplary embodiments described herein. In some embodiments, the gear reduction system 100 may be a dual-stage, dual-shaft, single-plane, planetary gear reduction system with a compact anti-backlash transmission. In some embodiments, the gear reduction system 100 may include or may be referred to as a gear train. In some embodiments, the maximum diameter of the gear reduction system 100 is less than about two inches.

As shown in fig. 1A, an exemplary gear reduction system 100 may include a first gear 102 coupled to an input shaft 101. In some embodiments, the first gear 102 may be an input shaft drive gear. The input shaft 101 may be further coupled to a gear 103 and a ball bearing 104. The first gear 102 and the gear 103 may be integral with the input shaft 101. The example gear reduction system 100 may also include a second gear 110 configured to be disposed in meshing engagement with the first gear 102. In some embodiments, the second gear 110 may be a sun gear. The example gear reduction system 100 may also include a carrier housing 111 configured to be fixedly disposed (e.g., welded; attached using an adhesive, a set of fasteners (e.g., screws, retaining pins, bolts), or both; fabricated (e.g., cast, machined, printed) as a single component; or attached using any other suitable technique) within the second gear 110. The example gear reduction system 100 may also include a third gear 112 configured to be disposed within the carrier housing 111. In some embodiments, the third gear 112 may be a planetary gear, an idler gear, or both. The third gear 112 may be mounted to the carriage housing 111 using a retaining pin 113 and one or more ball bearings (such as ball bearing 114). The example gear reduction system 100 may also include a fixed structure 118, which may be partially visible in the example top view 180A. The example gear reduction system 100 may also include a fifth gear 122 coupled to the countershaft 123 and configured to be disposed in meshing engagement with the third gear 112. The fifth gear 122 may be integral with the intermediate shaft 123. In some embodiments, fifth gear 122 may be an opposing gear to fourth gear 117.

Fig. 1B illustrates an exemplary isometric view 180B of an exemplary gear reduction system 100 according to some exemplary embodiments described herein. As shown in fig. 1B, the example gear reduction system 100 may include a first gear 102 coupled to an input shaft 101. Input shaft 101 may be further coupled to ball bearing 104, ball bearing 105, and support structure 107. The wave spring 106 may be disposed between the ball bearing 105 and the support structure 107 to pre-load the ball bearing 105. The example gear reduction system 100 may also include a second gear 110 configured to be disposed in meshing engagement with the first gear 102. The example gear reduction system 100 may also include a carrier housing 111 configured to be fixedly disposed within the second gear 110. The example gear reduction system 100 may also include a third gear 112 configured to be disposed within the carrier housing 111. The third gear 112 may be mounted to the carrier housing 111 using a retaining pin 113, a ball bearing 114, and a ball bearing 115. The example gear reduction system 100 may also include a fifth gear 122 coupled to the countershaft 123 and configured to be disposed in meshing engagement with the third gear 112. The exemplary gear reduction system 100 may also include a sixth gear 124 coupled to the countershaft 123. In some embodiments, the sixth gear 124 may be an output pinion. Sixth gear 124 may be coupled to fifth gear 122 via an intermediate shaft 123. The exemplary gear reduction system 100 may also include a ball bearing 125 coupled to the intermediate shaft 123.

Fig. 1C illustrates an exemplary cross-sectional isometric view 180C of an exemplary gear reduction system 100 according to some exemplary embodiments described herein. As shown in fig. 1C, the example gear reduction system 100 may include a first gear 102 coupled to an input shaft 101. Input shaft 101 may be further coupled to ball bearing 104 and ball bearing 105. The wave spring 106 may be provided on the ball bearing 105 to pre-load the ball bearing 105. The example gear reduction system 100 may also include a second gear 110 configured to be disposed in meshing engagement with the first gear 102. The example gear reduction system 100 may also include a carrier housing 111 configured to be fixedly disposed within the second gear 110. The example gear reduction system 100 may also include a third gear 112 configured to be disposed within the carrier housing 111. The third gear 112 may be mounted to the carrier housing 111 using a retaining pin 113, a ball bearing 114, and a ball bearing 115. The wave spring may be preloaded with the ball bearing 114 and may be disposed between the ball bearing 114 and the carriage housing 111. Another wave spring may be preloaded with the ball bearing 115 and may be disposed between the ball bearing 115 and the carriage housing 111. The example gear reduction system 100 may also include a stationary structure 118. The example gear reduction system 100 may also include a fourth gear 117 coupled to the fixed structure 118 and configured to be disposed in meshing engagement with the third gear 112. The third gear 112 may be further configured to rotate about a fourth gear 117. In some embodiments, fourth gear 117 may be a stationary gear. In some embodiments, fourth gear 117 may have one less tooth than fifth gear 122. The example gear reduction system 100 may also include a carrier shaft 120. The example gear reduction system 100 may also include a ball bearing 119 coupled to the carrier shaft 120. The example gear reduction system 100 may also include a ball bearing 121 coupled to the carrier shaft 120. The example gear reduction system 100 may also include a fifth gear 122 coupled to the countershaft 123 and configured to be disposed in meshing engagement with the third gear 112. The intermediate shaft 123 may be coupled to the ball bearing 121. The exemplary gear reduction system 100 may also include a sixth gear 124 coupled to the countershaft 123. Sixth gear 124 may be coupled to fifth gear 122 via an intermediate shaft 123. The exemplary gear reduction system 100 may also include a ball bearing 125 coupled to the intermediate shaft 123.

Fig. 1D illustrates an exemplary cross-sectional isometric view 180D of an exemplary gear reduction system 100 according to some exemplary embodiments described herein. As shown in fig. 1D, the example gear reduction system 100 may include a first gear 102 coupled to an input shaft 101. Input shaft 101 may be further coupled to ball bearing 104 and ball bearing 105. The wave spring 106 may be provided on the ball bearing 105 to pre-load the ball bearing 105. The retaining ring 108 may couple the support structure 107 to the input shaft 101. Ball bearing 104 and retaining structure 109 may couple input shaft 101 to frame 132. The example gear reduction system 100 may also include a second gear 110 configured to be disposed in meshing engagement with the first gear 102. The example gear reduction system 100 may also include a carrier housing 111 configured to be fixedly disposed within the second gear 110. The example gear reduction system 100 may also include a third gear 112 configured to be disposed within the carrier housing 111. The example gear reduction system 100 may also include a fourth gear 117 coupled to the fixed structure 118 and configured to be disposed in meshing engagement with the third gear 112. The fourth gear 117 may be integral with the fixed structure 118. The securing structure 118 may be fixedly disposed (e.g., attached using a set of fasteners (e.g., screws, retaining pins, bolts), adhesive, or both; welded; or attached using any other suitable technique) to the frame 132. The third gear 112 may be further configured to rotate about a fourth gear 117. The example gear reduction system 100 may also include a carrier shaft 120. Ball bearings 119 may be coupled to frame 132, carriage shaft 120, and fixed structure 118. The example gear reduction system 100 may also include a fifth gear 122 coupled to the countershaft 123 and configured to be disposed in meshing engagement with the third gear 112. The exemplary gear reduction system 100 may also include a sixth gear 124 coupled to the countershaft 123. Sixth gear 124 may be coupled to fifth gear 122 via an intermediate shaft 123. The exemplary gear reduction system 100 may also include a ball bearing 125 coupled to the intermediate shaft 123. The example gear reduction system 100 may also include a seventh gear 126 coupled to a sensing device 130 by a retaining ring 128. In some implementations, the sensing device 130 can be a rotational position sensing device. The sixth gear 124 may be configured to be disposed in meshing engagement with the seventh gear 126. The example gear reduction system 100 may also include an anti-backlash gear 127 coupled to the seventh gear 126 by a torsion spring and a retaining ring 128. The anti-backlash gear 127 may be configured to be disposed in meshing engagement with the sixth gear 124 to provide a compact anti-backlash transmission.

Fig. 1E illustrates an exemplary top view 180E of the exemplary gear reduction system 100 according to some exemplary embodiments described herein. As shown in fig. 1E, the exemplary gear reduction system 100 may include a first gear 102 coupled to an input shaft 101. The input shaft 101 may be further coupled to a gear 103 and a ball bearing 104. The example gear reduction system 100 may also include a second gear 110 configured to be disposed in meshing engagement with the first gear 102. The example gear reduction system 100 may also include a carrier housing 111 configured to be fixedly disposed within the second gear 110. The example gear reduction system 100 may also include a third gear 112 configured to be disposed within the carrier housing 111. The third gear 112 may be mounted to the carriage housing 111 using a retaining pin 113 and one or more ball bearings (such as ball bearing 114). The example gear reduction system 100 may also include a fixed structure 118, which may be partially visible in the example top view 180E. The example gear reduction system 100 may also include a fifth gear 122 coupled to the countershaft 123 and configured to be disposed in meshing engagement with the third gear 112. The exemplary gear reduction system 100 may also include a sixth gear 124 coupled to the countershaft 123. Sixth gear 124 may be coupled to fifth gear 122 via an intermediate shaft 123. The example gear reduction system 100 may also include an anti-backlash gear 127A coupled to a seventh gear (e.g., a seventh gear disposed below the anti-backlash gear 127A and thus not visible in the example top view 180E) by a torsion spring 129A and a retaining ring 128A. The example gear reduction system 100 may also include an anti-backlash gear 127B coupled to a seventh gear (e.g., a seventh gear disposed below the anti-backlash gear 127B and thus not visible in the example top view 180E) by a torsion spring 129B and a retaining ring 128B. The anti-backlash gear 127A and the anti-backlash gear 127B may be configured to be disposed in meshing engagement with the sixth gear 124 to provide a compact anti-backlash transmission.

In some embodiments, as shown in fig. 1A-1E, the gear reduction system 100 may provide a dual stage gear reduction. For example, first gear 102 and second gear 110 may be configured to form a first gear reduction stage. Second gear 110, third gear 112, fourth gear 117, fifth gear 122, and sixth gear 124 may be configured to form a second gear reduction stage that is different from the first gear reduction stage. In some embodiments, the sixth gear 124, the seventh gear 126, and the anti-backlash gear 127 may be configured to form a third gear reduction stage that is different from the first gear reduction stage and the second gear reduction stage.

In some embodiments, as shown in fig. 1B and 1C, the gear reduction system 100 may provide a dual-axis gear reduction. For example, the first gear 102, the input shaft 101, and the gear 103 may be configured to be disposed along the first rotation shaft 141. The second gear 110, the fourth gear 117, the fifth gear 122, and the sixth gear 124 may be configured to be disposed along a second rotation axis 142 different from the first rotation axis 141. In some embodiments, the third gear 112 may be configured to be disposed along a third rotation axis 143 different from the first and second rotation axes 141 and 142.

In some embodiments, as shown in fig. 1D, the gear reduction system 100 may provide a single plane gear reduction. For example, first gear 102, second gear 110, third gear 112, fourth gear 117, and fifth gear 122 may be configured to be disposed along a first gear interaction plane 151. In some embodiments, the sixth gear 124, the seventh gear 126, and the anti-backlash gear 127 can be configured to be disposed along a second gear interaction plane 152 that is different from the first gear interaction plane 151.

Fig. 2A illustrates an exemplary isometric view 280A of an exemplary gear reduction system 200 according to some exemplary embodiments described herein. In some embodiments, the gear reduction system 200 may be a dual-stage, dual-shaft, single-plane, planetary gear reduction system with a compact anti-backlash transmission. In some embodiments, the gear reduction system 200 may include or may be referred to as a gear train. In some embodiments, the maximum diameter of the gear reduction system 200 is less than about two inches.

As shown in fig. 2A, an exemplary gear reduction system 200 may include a first gear 202 coupled to an input shaft 201. In some embodiments, the first gear 202 may be an input shaft drive gear. The input shaft 201 may be further coupled to a gear 203. First gear 202 and gear 203 may be integral with input shaft 201. The example gear reduction system 200 may also include a second gear 210 configured to be disposed in meshing engagement with the first gear 202. In some embodiments, the second gear 210 may be a sun gear. The example gear reduction system 200 may also include a carrier housing 211 configured to be fixedly disposed (e.g., welded; attached using an adhesive, a set of fasteners (e.g., screws, retaining pins, bolts), or both; fabricated (e.g., cast, machined, printed) as a single component; or attached using any other suitable technique) within the second gear 210. The example gear reduction system 200 may also include a third gear 212 configured to be disposed within the carrier housing 211. In some embodiments, the third gear 212 may be a planetary gear, an idler gear, or both. The third gear 212 may be mounted to the carriage housing 211 using a retaining pin and one or more ball bearings. The example gear reduction system 200 may also include a fixed structure 218. The securing structure 218 may be fixedly disposed (e.g., attached using a set of fasteners (e.g., screws, retaining pins, bolts), adhesives, or both; welded; or attached using any other suitable technique) to the frame or support structure. The exemplary gear reduction system 200 may also include a sixth gear 224 coupled to the countershaft 223. In some embodiments, the sixth gear 224 may be an output pinion. The example gear reduction system 200 may also include a seventh gear 226A coupled to the sensing device 230A by a retaining ring 228A. In some implementations, the sensing device 230A can be a first rotational position sensing device. The example gear reduction system 200 may also include a seventh gear 226B coupled to the sensing device 230B by a retaining ring 228B. In some implementations, the sensing device 230B can be a second rotational position sensing device. Sixth gear 224 may be configured to be disposed in meshing engagement with seventh gear 226A and seventh gear 226B. The example gear reduction system 200 may also include an anti-backlash gear 227A coupled to (e.g., disposed above) the seventh gear 226A by a torsion spring and a retaining ring 228A. The example gear reduction system 200 may also include an anti-backlash gear 227B coupled to (e.g., disposed above) the seventh gear 226B by a torsion spring and a retaining ring 228B. The anti-backlash gear 227A and the anti-backlash gear 227B may be configured to be disposed in meshing engagement with the sixth gear 224 to provide a compact anti-backlash transmission.

Fig. 2B illustrates an exemplary cross-sectional isometric view 280B of an exemplary gear reduction system 200 according to some exemplary embodiments described herein. As shown in fig. 2B, exemplary gear reduction system 200 may include a first gear 202 coupled to an input shaft 201. The example gear reduction system 200 may also include a second gear 210 configured to be disposed in meshing engagement with the first gear 202. The example gear reduction system 200 may also include a carrier housing 211 configured to be fixedly disposed within the second gear 210. The example gear reduction system 200 may also include a third gear 212 configured to be disposed within the carrier housing 211. The third gear 212 may be mounted to the carrier housing 211 using a retaining pin 213, a ball bearing 214, and a ball bearing 215. The wave spring may be preloaded with the ball bearing 214 and may be disposed between the ball bearing 214 and the carriage housing 211. Another wave spring may be preloaded with the ball bearing 215 and may be disposed between the ball bearing 215 and the carriage housing 211. The example gear reduction system 200 may also include a fixed structure 218. The example gear reduction system 200 may also include a fourth gear 217 coupled to the fixed structure 218 and configured to be disposed in meshing engagement with the third gear 212. The fourth gear 217 may be integral with the fixed structure 218. The third gear 212 may be further configured to rotate about the fourth gear 217. In some embodiments, the fourth gear 217 may be a stationary gear. In some embodiments, fourth gear 217 may have one less tooth than fifth gear 222. The example gear reduction system 200 may also include a carrier shaft 220. The bracket axle 220 includes a frame bearing location 220A. The example gear reduction system 200 may also include a ball bearing 221A coupled to the first portion of the carrier shaft 220. The example gear reduction system 200 may also include a ball bearing 221B coupled to the second portion of the carrier shaft 220. The exemplary gear reduction system 200 may also include a fifth gear 222 coupled to the countershaft 223 and configured to be disposed in meshing engagement with the third gear 212. The fifth gear 222 may be integral with the intermediate shaft 223. In some embodiments, fifth gear 222 may be an opposing gear to fourth gear 217. A first portion of the intermediate shaft 223 may be coupled to the ball bearing 221A and a second portion of the intermediate shaft 223 may be coupled to the ball bearing 221B. The intermediate shaft 223 includes a plate bearing location 223A. The exemplary gear reduction system 200 may also include a sixth gear 224 coupled to the countershaft 223. Sixth gear 224 may be coupled to fifth gear 222 via an intermediate shaft 223. The example gear reduction system 200 may also include a seventh gear 226B coupled to the sensing device 230B by a retaining ring. Sixth gear 224 may be configured to be disposed in meshing engagement with seventh gear 226B. The example gear reduction system 200 may also include an anti-backlash gear 227B coupled to the seventh gear 226B by a torsion spring and a retaining ring. The anti-backlash gear 227B may be configured to be disposed in meshing engagement with the sixth gear 224 to provide a compact anti-backlash transmission.

In some embodiments, as shown in fig. 2A and 2B, the gear reduction system 200 may provide a two-stage gear reduction. For example, first gear 202 and second gear 210 may be configured to form a first gear reduction stage. Second gear 210, third gear 212, fourth gear 217, fifth gear 222, and sixth gear 224 may be configured to form a second gear reduction stage that is different from the first gear reduction stage. In some embodiments, sixth gear 224, seventh gear 226A, seventh gear 226B, anti-backlash gear 227A, and anti-backlash gear 227B may be configured to form a third gear reduction stage that is different from the first and second gear reduction stages.

In some embodiments, as shown in fig. 2A and 2B, the gear reduction system 200 may provide a dual-axis gear reduction. For example, the first gear 202, the input shaft 201, and the gear 203 may be configured to be disposed along the first rotation axis 241. The second gear 210, the fourth gear 217, the fifth gear 222, and the sixth gear 224 may be configured to be disposed along a second rotation axis 242 different from the first rotation axis 241. In some embodiments, the third gear 212 may be configured to be disposed along a third rotation axis 243 different from the first and second rotation axes 241 and 242. In some embodiments, the seventh gear 226A, the anti-backlash gear 227A, and the sensing device 230A may be configured to be disposed along a fourth rotation axis 244A different from the first, second, and third rotation axes 241, 242, 243. In some embodiments, the seventh gear 226B, the anti-backlash gear 227B, and the sensing device 230B may be configured to be disposed along a fifth rotation axis 244B different from the first, second, third, and fourth rotation axes 241, 242, 243, and 244A.

In some embodiments, as shown in fig. 2B, the gear reduction system 200 may provide a single plane gear reduction. For example, first gear 202, second gear 210, third gear 212, fourth gear 217, and fifth gear 222 may be configured to be disposed along a first gear interaction plane 251. In some embodiments, sixth gear 224, seventh gear 226A, seventh gear 226B, anti-backlash gear 227A, and anti-backlash gear 227B may be configured to be disposed along a second gear interaction plane 252 that is different from first gear interaction plane 251.

Fig. 3A illustrates an exemplary isometric view 380A of an exemplary gear reduction system 300 according to some exemplary embodiments described herein. In some embodiments, the gear reduction system 300 may be a dual-stage, dual-shaft, single-plane, planetary gear reduction system with a compact anti-backlash transmission. In some embodiments, the gear reduction system 300 may include or may be referred to as a gear train. In some embodiments, the maximum diameter of the gear reduction system 300 is less than about two inches.

As shown in fig. 3A, an exemplary gear reduction system 300 may include an input shaft 301 coupled to a first gear (e.g., first gear 302 shown in fig. 3B) and a gear 303. The first gear 302 and the gear 303 may be integral with the input shaft 301. The example gear reduction system 300 may also include a second gear 310 configured to be disposed in meshing engagement with the first gear coupled to the input shaft 301. In some embodiments, the second gear 310 may be a sun gear. The example gear reduction system 300 may also include a carrier housing 311 configured to be fixedly disposed (e.g., manufactured (e.g., cast, machined, printed) as a single component, welded, attached using an adhesive, a set of fasteners (e.g., screws, retaining pins, bolts), or both, manufactured (e.g., cast, machined, printed) as a single component, or attached using any other suitable technique) within the second gear 310. The second gear 310 may be integral with the carrier housing 311. The example gear reduction system 300 may also include a third gear 312 configured to be disposed within the carrier housing 311. In some embodiments, the third gear 312 may be a planetary gear, an idler gear, or both. The third gear 312 may be mounted to the carrier housing 311 using a retaining pin and one or more ball bearings. The exemplary gear reduction system 300 may also include a stationary structure 318. The securing structure 318 may be fixedly disposed (e.g., attached using a set of fasteners (e.g., screws, retaining pins, bolts), adhesives, or both; welded; or attached using any other suitable technique) to the frame or support structure. The exemplary gear reduction system 300 may also include a sixth gear 324 coupled to a countershaft (e.g., countershaft 323 shown in fig. 3B). Sixth gear 324 may be fixedly disposed to intermediate shaft 323. In some embodiments, the sixth gear 324 may be an output pinion. Exemplary gear reduction system 300 may also include ball bearings 325 coupled to sixth gear 324 and a gear shaft (e.g., gear shaft 320 shown in fig. 3B). The ball bearing 325 may be a plate bearing. The example gear reduction system 300 may also include a seventh gear 326A coupled to the sensing device 330A by a retaining ring 328A. In some implementations, the sensing device 330A can be a first rotational position sensing device. The example gear reduction system 300 may also include a seventh gear 326B coupled to the sensing device 330B by a retaining ring 328B. In some implementations, the sensing device 330B can be a second rotational position sensing device. Sixth gear 324 may be configured to be disposed in meshing engagement with seventh gear 326A and seventh gear 326B. The example gear reduction system 300 may also include an anti-backlash gear 327A coupled to (e.g., disposed above) the seventh gear 326A by a torsion spring and a retaining ring 328A. The example gear reduction system 300 may also include an anti-backlash gear 327B coupled to (e.g., disposed above) the seventh gear 326B by a torsion spring and a retaining ring 328B. The anti-backlash gear 327A and 327B may be configured to be disposed in meshing engagement with the sixth gear 324 to provide a compact anti-backlash transmission.

Fig. 3B illustrates an exemplary cutaway isometric view 380B of an exemplary gear reduction system 300, according to some exemplary embodiments described herein. As shown in fig. 3B, the example gear reduction system 300 may include a first gear 302 coupled to an input shaft 301. In some embodiments, the first gear 302 may be an input shaft drive gear. The example gear reduction system 300 may also include a second gear 310 configured to be disposed in meshing engagement with the first gear 302. The example gear reduction system 300 may also include a carrier housing 311 configured to be fixedly disposed within the second gear 310. The example gear reduction system 300 may also include a third gear 312 configured to be disposed within the carrier housing 311. The third gear 312 may be mounted to the carrier housing 311 using a retaining pin 313, a ball bearing 314, and a ball bearing 315. The wave spring may be preloaded with the ball bearing 314 and may be disposed between the ball bearing 314 and the carriage housing 311. Another wave spring may be preloaded with the ball bearing 315 and may be disposed between the ball bearing 315 and the carriage housing 311. The exemplary gear reduction system 300 may also include a stationary structure 318. The example gear reduction system 300 may also include a fourth gear 317 coupled to the fixed structure 318 and configured to be disposed in meshing engagement with the third gear 312. The fourth gear 317 may be integral with the fixed structure 318. The third gear 312 may be further configured to rotate about a fourth gear 317. In some embodiments, fourth gear 317 may be a stationary gear. In some embodiments, fourth gear 317 may have one less tooth than fifth gear 322. The example gear reduction system 300 may also include a gear shaft 320. The example gear reduction system 300 may also include a ball bearing 319 coupled to a first portion of the gear shaft 320. Ball bearing 319 can be a frame bearing. A wave spring may be provided on the ball bearing 319 to pre-load the ball bearing 319. The example gear reduction system 300 may also include a ball bearing 321 coupled to a second portion of the gear shaft 320. A wave spring may be provided on the ball bearing 321 to pre-load the ball bearing 321. The example gear reduction system 300 may also include a ball bearing 335 coupled to a portion of the carrier housing 311. Ball bearings 321 and ball bearings 335 may support the carrier assembly and have a relatively high load rating. Exemplary gear reduction system 300 may also include a ball bearing 325 coupled to sixth gear 324 and to the third portion of gear shaft 320. A wave spring may be provided on the ball bearing 325 to pre-load the ball bearing 325. The example gear reduction system 300 may also include a fifth gear 322 coupled to the gear shaft 320 and configured to be disposed in meshing engagement with the third gear 312. The fifth gear 322 may be integrated with the gear shaft 320. In some embodiments, fifth gear 322 may be an opposing gear to fourth gear 317. The example gear reduction system 300 may also include an anti-backlash gear 333 coupled to the fifth gear 322 by an anti-backlash spring and 332 a retaining ring 334. The anti-backlash gear 333 may be configured to be disposed in meshing engagement with the third gear 312 to provide a compact anti-backlash transmission. The example gear reduction system 300 may also include a sixth gear 324 coupled to the gear shaft 320. The sixth gear 324 may be coupled to the fifth gear 322 via a gear shaft 320. The example gear reduction system 300 may also include a seventh gear 326B coupled to the sensing device 330B by a retaining ring. Sixth gear 324 may be configured to be disposed in meshing engagement with seventh gear 326B. The example gear reduction system 300 may also include an anti-backlash gear 327B coupled to the seventh gear 326B by a torsion spring and a retaining ring. The anti-backlash gear 327B may be configured to be disposed in meshing engagement with the sixth gear 324 to provide a compact anti-backlash transmission.

In some embodiments, gear reduction system 300 may provide a variable center-to-center distance between third gear 312 and fifth gear 322. For example, the gear reduction system 300 may include a spring (not shown) and spring-load the retaining pin 313 by mechanically coupling the spring to the retaining pin 313. In some embodiments, the gear reduction system 300 may spring load the retaining pin 313 without the anti-backlash gear 333. For example, the gear reduction system 300 may include a spring for spring-loading the retaining pin 313, but not the anti-backlash gear 333.

In some embodiments, the gear reduction system 300 may provide indexing based on differences between portions of the fourth gear 317, the fifth gear 322, and the third gear 312 (such as differences in pitch circle diameter, number of teeth, tooth profile, and combinations thereof). In some embodiments, the fourth gear 317 and the fifth gear 322 may have the same pitch circle diameter but have different numbers of teeth. For example, the pitch diameter of the fourth gear 317 may be the same as the pitch diameter of the fifth gear 322, but the fourth gear 317 may have one tooth less or one tooth more than the fifth gear 322. Thus, as the third gear 312 orbits around the fourth gear 317 and the fifth gear 322, the third gear 312 forces the teeth into alignment regardless of the position at which the third gear 312 is engaged, thereby indexing the third gear 312 by one tooth per orbit. In some embodiments, the fourth gear 317 and the fifth gear 322 may have different pitch circle diameters, different tooth profiles (e.g., incomplete tooth profiles), or both. For example, fourth gear 317 and fifth gear 322 may have different pitch circle diameters and different tooth profiles (e.g., one or both of fourth gear 317 and fifth gear 322 may have non-standard tooth profiles). In some embodiments, the portions of the third gear 312 configured to be disposed in meshing engagement with the fourth gear 317 and the fifth gear 322 may have different pitch circle diameters, different numbers of teeth, different tooth profiles, or a combination thereof. For example, the third gear 312 may have an upper portion configured to be disposed in meshing engagement with the fifth gear 322 and a lower portion configured to be disposed in meshing engagement with the fourth gear 317. In an exemplary example, the upper portion of the third gear 312 may have the same pitch circle diameter, but a different number of teeth, as compared to the bottom portion of the third gear 312. In another illustrative example, the upper portion of the third gear 312 may have the same number of teeth, but different pitch circle diameters, as compared to the bottom portion of the third gear 312. In yet another exemplary example, the upper portion of the third gear 312 may have a different number of teeth and a different pitch diameter than the bottom portion of the third gear 312.

Although the anti-backlash gear 333 is shown in fig. 3B as being coupled to the fifth gear 322 by an anti-backlash spring 332 and a retaining ring 334 (e.g., the anti-backlash gear 333 is shown spring-loaded relative to the fifth gear 322 in fig. 3B), in other embodiments, the gear reduction system 300 may instead provide a compact anti-backlash transmission via an anti-backlash gear (e.g., an anti-backlash gear similar in pitch circle diameter to the anti-backlash gear 333) that is coupled to the fourth gear 317 by an anti-backlash spring and a retaining ring (e.g., the anti-backlash gear may be spring-loaded relative to the fourth gear 317). In some embodiments, an anti-backlash spring may be disposed between the anti-backlash gear 333 and the ball bearing 319, such as between the anti-backlash gear 333 and the extrusion on the inner surface of the housing 318. In still other embodiments, gear reduction system 300 may instead provide a compact anti-backlash transmission via two anti-backlash gears: an anti-backlash gear 333 coupled to the fifth gear and spring-loaded relative to the fifth gear 322; and an anti-backlash gear coupled to fourth gear 317 and spring-loaded relative to fourth gear 317.

In some embodiments, gear reduction system 300 may instead provide a compact anti-backlash transmission by splitting third gear 312 into two separate gears (an upper third gear and a lower third gear), where one gear functions as an idler gear and the other gear functions as an anti-backlash gear. For example: removable anti-backlash gear 333, anti-backlash spring 332, and retaining ring 334; the thickness of the fifth gear 322 may be increased (e.g., doubled); the upper third gear may be configured to be disposed to mesh with only the fifth gear 322 and to function as an anti-backlash gear; and the lower third gear may be configured to be disposed to mesh with the fourth gear 317 and the fifth gear 322 and to function as an idle gear. In another example: removable anti-backlash gear 333, anti-backlash spring 332, and retaining ring 334; the thickness of the fourth gear 317 may be increased (e.g., doubled); the lower third gear may be configured to be disposed to mesh with only the fourth gear 317 and to function as an anti-backlash gear; and the upper third gear may be configured to be disposed to mesh with the fourth gear 317 and the fifth gear 322 and to function as an idle gear.

In some embodiments, as shown in fig. 3A and 3B, the gear reduction system 300 may provide a two-stage gear reduction. For example, the first gear 302 and the second gear 310 may be configured to form a first gear reduction stage. Second gear 310, third gear 312, fourth gear 317, fifth gear 322, anti-backlash gear 333, and sixth gear 324 may be configured to form a second gear reduction stage different from the first gear reduction stage. In some embodiments, sixth gear 324, seventh gear 326A, seventh gear 326B, anti-backlash gear 327A, and anti-backlash gear 327B may be configured to form a third gear reduction stage that is different from the first gear reduction stage and the second gear reduction stage.

In some embodiments, as shown in fig. 3A and 3B, the gear reduction system 300 may provide a dual-axis gear reduction. For example, the first gear 302, the input shaft 301, and the gear 303 may be configured to be disposed along the first rotation shaft 341. The second gear 310, the fourth gear 317, the fifth gear 322, the anti-backlash gear 333, and the sixth gear 324 may be configured to be disposed along a second rotation axis 342 different from the first rotation axis 341. In some embodiments, the third gear 312 may be configured to be disposed along a third rotation axis 343 different from the first and second rotation axes 341 and 342. In some embodiments, seventh gear 326A, anti-backlash gear 327A, and sensing device 330A may be configured to be disposed along a fourth axis of rotation 344A that is different from first axis of rotation 341, second axis of rotation 342, and third axis of rotation 343. In some embodiments, seventh gear 326B, anti-backlash gear 327B, and sensing device 330B may be configured to be disposed along a fifth axis of rotation 344B that is different from first axis of rotation 341, second axis of rotation 342, third axis of rotation 343, and fourth axis of rotation 344A.

In some embodiments, as shown in fig. 3B, the gear reduction system 300 may provide a single plane gear reduction. For example, the first gear 302 and the second gear 310 may be configured to be disposed along a first gear interaction plane 351. In some embodiments, sixth gear 324, seventh gear 326A, seventh gear 326B, anti-backlash gear 327A, and anti-backlash gear 327B may be configured to be disposed along a second gear interaction plane 352 that is different from first gear interaction plane 351. In some embodiments, third gear 312, fourth gear 317, fifth gear 322, and anti-backlash gear 333 may be configured to be disposed along a third gear interaction plane 353 that is different from second gear interaction plane 352. In some embodiments, as shown in fig. 3B, third gear interaction plane 353 can be different than first gear interaction plane 351. In other embodiments, third gear interaction plane 353 may be the same as or substantially similar to first gear interaction plane 351.

Fig. 4 illustrates an example exploded view 480 of an example anti-backlash mechanism 400, according to some example embodiments described herein. The example anti-backlash mechanism 400 may include a seventh gear 426 coupled to a sensing device 430 by a retaining ring 428. The example anti-backlash mechanism 400 may also include an anti-backlash gear 427 coupled to the seventh gear 426 via a torsion spring 429 and a retaining ring 428. In some embodiments, the torsion spring 429 may instead be a compression spring. The seventh gear 426 and the anti-backlash gear 427 may be configured to be disposed in meshing engagement with a sixth gear (not shown) to provide a compact anti-backlash transmission. In some implementations, the sensing device 430 can be a rotational position sensing device. In some embodiments, seventh gear 426, anti-backlash gear 427, and sensing device 430 can be configured to be disposed along rotational axis 444.

As shown in fig. 4, a seventh gear 426 (e.g., a driven gear) is rigidly attached to the input shaft of the sensing device 430. The anti-backlash gear 427 is torsionally spring loaded (e.g., by a torsion spring 429) with respect to the seventh gear 426. The spring load causes the anti-backlash gear 427 to rotate relative to the seventh gear 426 until the drive gear (e.g., sixth gears 124,224,324) teeth are sandwiched between the seventh gear 426 and the anti-backlash gear 427, thereby taking up all of the backlash. As long as the torque to be transmitted is less than the torque exerted by the anti-backlash spring, there will be no lost motion when the direction of rotation is reversed.

In some embodiments, as shown, although the gears are described with reference to fig. 1-4 as straight cut gears, one or more of the gears described with reference to fig. 1-4 may be helical gears.

In some embodiments, the components described with reference to fig. 1-4 may include stainless steel, aluminum, other metals, or combinations (e.g., alloys) thereof. In some embodiments, the components described with reference to fig. 1-4 may comprise plastic, nylon, acetyl, polycarbonate, polyphenylene sulfide, polyurethane, or combinations thereof. In some embodiments, the securing structure (e.g., securing structure 118,218,318) may include a mounting structure (e.g., threaded, non-threaded) configured to receive and support a fastener (e.g., a socket head stainless steel screw, other screw, bolt, clamp, etc.) to attach the securing structure to a frame (e.g., frame 132).

Having described specific components and structures of exemplary devices involved in the present disclosure, an exemplary process for providing a gear reduction system is described below in conjunction with FIG. 5.

Fig. 5 illustrates an example flow chart 500 incorporating example operations for providing a gear reduction system, according to some example embodiments described herein. In some embodiments, the gear reduction system described with reference to fig. 5 may be included in a dual-stage, dual-shaft, single-plane, planetary gear reduction system (such as gear reduction system 100, 200, or 300) with a compact anti-backlash transmission.

As shown in operation 502, the example flowchart 500 may begin by providing a first gear (e.g., the first gear 102,202,302) coupled to an input shaft (e.g., the input shaft 101,201, 301). As shown in operation 504, the example flowchart 500 may continue with mounting a second gear (e.g., the second gears 110,210,310) to the first gear, wherein the second gear is in mesh with the first gear. The example flowchart 500 may continue with installing a carrier housing (e.g., carrier housing 111,211,311) within the second gear, as illustrated by operation 506. The example flowchart 500 may continue with the installation of a third gear (e.g., the third gears 112,212,312) within the carrier housing, as indicated by operation 508. As shown in operation 510, exemplary flowchart 500 may continue with mounting a fourth gear (e.g., fourth gears 117,217,317) to the third gear, wherein the fourth gear is in mesh with the third gear, and wherein the third gear is rotatable about the fourth gear. The example flowchart 500 may continue with mounting a fifth gear (e.g., the fifth gears 122,222,322) to the third gear, wherein the fifth gear is in mesh with the third gear, as illustrated by operation 512. The second gear, the fourth gear, the anti-backlash gear, and the fifth gear may be disposed along a common rotational axis (e.g., the second rotational axis 142,242,342). The first, second, third, fourth, anti-backlash, and fifth gears may be disposed along a common gear interaction plane (e.g., first gear interaction plane 151,251, 351).

Optionally (not shown in fig. 5 for simplicity), the example flowchart 500 may continue with mounting a sixth gear (e.g., sixth gears 124,224,324) to a fifth gear, wherein the sixth gear is coupled to the fifth gear. Optionally, the example flowchart 500 may continue with mounting a seventh gear (e.g., seventh gear 126,226A,226B,326A,326B,426) to the sixth gear, wherein the seventh gear is in mesh with the sixth gear, and wherein the seventh gear is coupled to the sensing device (e.g., sensing device 130,230A,230B,330A,330B, 430). Optionally, exemplary flowchart 500 may continue with mounting an anti-backlash gear (e.g., anti-backlash gears 127A,127B,227A,227B,327A,327B,427) to a seventh gear, wherein the anti-backlash gear is coupled to the seventh gear, and wherein the anti-backlash gear meshes with the sixth gear to provide a compact anti-backlash transmission. Optionally, exemplary flowchart 500 may continue with mounting an anti-backlash gear (e.g., anti-backlash gear 333) to a fifth gear (e.g., fifth gear 322), wherein the anti-backlash gear meshes with the third gear (e.g., third gear 312) to provide a compact anti-backlash transmission.

In some implementations, operations 502, 504, 506, 508, 510, and 512 may not necessarily occur in the order depicted in fig. 5. In some embodiments, one or more of the operations depicted in fig. 5 may occur substantially simultaneously. In some embodiments, one or more additional operations may be involved before, after, or between any of the operations shown in fig. 5.

As described above, fig. 5 illustrates an exemplary flowchart describing operations performed in accordance with an exemplary embodiment of the present disclosure. It will be understood that each block of the flowchart, and combinations of blocks in the flowchart, can be implemented by various means, such as hardware, firmware, one or more processors, circuitry associated with execution of software including one or more computer program instructions, or combinations thereof. For example, one or more of the above-described processes can be performed by a material handling device (e.g., one or more robotic arms, servo motors, motion controllers, other material handling devices and structures, and combinations thereof) and computer program instructions residing on a non-transitory computer readable storage memory. In this regard, the computer program instructions which embody the procedures described above may be stored by a memory of a device employing embodiments of the present disclosure and executed by a processor of the device. It will be understood that any such computer program instructions may be loaded onto a computer or other programmable apparatus (e.g., hardware) to produce a machine, such that the resulting computer or other programmable apparatus provides for implementation of the functions specified in the flowchart block or blocks. When executed, the instructions stored in the computer-readable storage memory produce an article of manufacture configured to implement the various functions specified in the flowchart block or blocks. Further, executing a computer or other processing circuitry to perform various functions transforms the computer or other processing circuitry into a particular machine configured to perform example embodiments of the present disclosure.

Accordingly, flow diagram blocks are described that support combinations of means for performing the specified functions and combinations of operations for performing the specified functions. It will also be understood that one or more flow diagram blocks and combinations of flow diagram blocks may be implemented by special purpose hardware-based computer systems which perform the specified functions or combinations of special purpose hardware which execute computer instructions.

In some exemplary embodiments, certain operations disclosed herein may be modified or further amplified as described below. Furthermore, in some embodiments, additional optional operations may also be included. It is to be understood that each of the modifications, optional additions or amplifications described herein may be included in the operations disclosed herein, alone or in combination with any other operations described herein, such as the features and structures described with reference to fig. 1-4 and 6-7.

The foregoing method descriptions and process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by those skilled in the art, the order of steps in the above embodiments may be performed in any order. Words such as "after," "then," "next," and the like are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Furthermore, for example, any reference to claim elements in the singular using the articles "a," "an," or "the" should not be construed as limiting the element to the singular and in some cases, can be construed in the plural.

Fig. 6 illustrates an example resolver sensing element measurement 600 including a sensing element output curve 602, according to some example embodiments described herein. As shown in fig. 6, the resolver sensing element provides two outputs (sine and cosine) that are resolved into an angular output (in degrees). The actual sensor output shown in fig. 6 provides an 216.86:1 gear reduction between the input shaft and the resolver sensing element, providing a 360 degree resolver output for each 216.86 resolution of the input shaft.

Fig. 7A and 7B show exemplary error measurements without and with anti-backlash mechanisms on the planetary gear stages, respectively. FIG. 7A illustrates an exemplary error measurement 700 without an anti-backlash mechanism on a planetary gear stage, similar to the gear reduction system 200 shown in FIG. 2. Fig. 7B illustrates an exemplary error measurement 720 with an anti-backlash mechanism (e.g., including anti-backlash gear 333 and related components) on a planetary gear stage, similar to gear reduction system 300 shown in fig. 3. As shown in fig. 7A and 7B, the anti-backlash mechanism on the planetary gear stage greatly reduces errors and hysteresis in the sensing element output.

As described above with reference to fig. 1-7, exemplary embodiments of the present disclosure thus provide a compact gear reduction system. Accordingly, the gear reduction system disclosed herein can easily and cost effectively meet all transmission requirements and also minimize the overall size of the gear reduction system.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof can be made by one skilled in the art without departing from the teachings of the disclosure. The embodiments described herein are merely representative and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments resulting from the incorporation, integration, and/or omission of features of one or more embodiments are also within the scope of the present disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is instead defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each claim is incorporated into the specification as a further disclosure, and a claim is one or more embodiments of the present disclosure. Moreover, any of the above advantages and features may be related to particular embodiments, but the application of such issued claims should not be limited to methods and structures accomplishing any or all of the above advantages or having any or all of the above features.

Further, the section headings used herein are for consistency with the recommendations of 37c.f.r. § 1.77 or to provide organizational cues. These headings should not limit or characterize the disclosure as set forth in any claims that may issue from this disclosure. For example, a description of a technology in the "background" should not be read as an admission that certain technology is prior art to any disclosure in this disclosure. Neither should the "summary" be considered a limiting characterization of the disclosure set forth in the published claims. Furthermore, any reference in this disclosure to "disclosure" or "embodiments" in the singular should not be used to prove that there is only one point of novelty in this disclosure. Embodiments of the disclosure may be set forth according to the limitations of the various claims issuing from this disclosure, and such claims accordingly define the disclosure protected thereby, and equivalents thereof. In all cases, the scope of these claims should be considered in light of the present disclosure in light of the advantages of the claims themselves, and should not be limited by the headings set forth herein.

Moreover, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other devices or components that are shown or discussed as being coupled or communicating with each other may be indirectly coupled through some intermediate device or component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the scope disclosed herein.

Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which these embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although the drawings show only certain components of the devices and systems described herein, it should be understood that various other components may be used in conjunction with the components and structures disclosed herein. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. For example, various elements or components may be combined, rearranged or integrated into another system, or certain features may be omitted, or not implemented. Further, the steps of any of the methods described above may not necessarily occur in the order depicted in the figures, and in some cases, one or more of the depicted steps may occur substantially simultaneously, or additional steps may be involved. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.