Hardened slot walls in a skew shifting continuous variable planetary system
A continuous variable planetary (CVP) system comprises a C2 carrier having a pattern of slots, the slots having one or more slot walls; a C1 carrier, at least one of the C2 carrier or C1 carrier being rotatable relative to the other; at least three planetary assemblies coupled between the C2 carrier and the C1 carrier, each planetary assembly including a planet, a planet axle, and an end cap on at least one end of the planet axle, the end cap disposed within the slot, rotation of C2 carrier relative to the C1 carrier inducing a skew condition in the planet axle and thereby inducing a tilt condition on the planet axle; and a protective layer affixed against at least one of the one or more slot walls, the protective layer including one or more protective layer attachment features configured to attach to one or more slot wall attachment features.
1 . A carrier of a continuous variable planetary (CVP) system, the CVP system including at least one planet assembly having a planet, a planet axle about which the planet rotates, and an end cap on one end of the planet axle, the carrier comprising:
a slot including one or more slot walls, at least a portion of at least one of the one or more slot walls having a contour, the one or more slot walls having one or more slot wall attachment features, the slot configured to receive the end cap and to allow the end cap to move therein as the planet axle skews and tilts under operating conditions; and
a protective layer conforming to the contour of the at least a portion of the at least one of the one or more slot walls, the protective layer including one or more protective layer attachment features configured to attach to the one or more slot wall attachment features to secure the protective layer against the at least a portion of the at least one of the one or more slot walls within the slot, the protective layer configured to protect the at least one of the one or more slot walls from damage caused by movement of the end cap within the slot as the planet axle skews and tilts under the operating conditions.
2 . The carrier of claim 1 , wherein the protective layer is metallic.
3 . The carrier of claim 1 , wherein the protective layer is made from a ferrous alloy.
4 . The carrier of claim 1 , wherein the protective layer is made from steel.
5 . The carrier of claim 1 , wherein the protective layer is made from carbon steel.
6 . The carrier of claim 1 , wherein the carrier is rotatable.
7 . The carrier of claim 1 , wherein the carrier is non-rotatable.
8 . The carrier of claim 1 , wherein the at least one of the one or more slot walls is flat.
9 . The carrier of claim 1 , wherein the at least one of the one or more slot walls is curved.
10 . The carrier of claim 1 , wherein the one or more protective layer attachment features comprise one or more tabs, and the one or more slot wall attachment features comprise one or more pockets.
11 . The carrier of claim 10 , wherein the one or more tabs include bent portions.
12 . The carrier of claim 10 , wherein the one or more tabs includes curved portions.
13 . The carrier of claim 10 , wherein the one or more pockets include a pocket at a bottom of the at least one of the one or more slot walls.
14 . The carrier of claim 10 , wherein the one or more pockets include an open pocket through to a back side of the carrier.
15 . The carrier of claim 1 , wherein the carrier comprises magnesium.
16 . The carrier of claim 1 , wherein the protective layer comprises a metallic layer with a thickness of between 0.05 mm and 0.3 mm.
17 . The carrier of claim 1 , wherein the at least one of the one or more slot walls includes only a rear slot wall.
18 . The carrier of claim 1 , wherein the at least one of the one or more slot walls includes only a front slot wall.
19 . The carrier of claim 1 , wherein the one or more slot wall attachment features comprises a clip.
20 . The carrier of claim 1 , wherein the protective layer is manufactured with pliant materials capable of being conformed to the contour of the at least a portion of the at least one of the one or more slot walls.
21 . A method comprising:
obtaining a carrier for a continuous variable planetary (CVP) system, the CVP system including at least one planet assembly having a planet, a planet axle about which the planet rotates, and an end cap on one end of the planet axle, the carrier comprising a slot including one or more slot walls, at least a portion of at least one of the one or more slot walls having a contour, the one or more slot walls having one or more slot wall attachment features, the slot configured to receive the end cap and to allow the end cap to move therein as the planet axle skews and tilts under operating conditions; and
installing a protective layer conforming to the contour of the at least a portion of the at least one of the one or more slot walls, the protective layer including one or more protective layer attachment features, the installing including using the one or more protective layer attachment features to attach to the one or more slot wall attachment features to secure the protective layer against the at least a portion of the at least one of the one or more slot walls within the slot, the protective layer configured to protect the at least one of the one or more slot walls from damage caused by movement of the end cap within the slot as the planet axle skews and tilts under the operating conditions.
22 . The method of claim 21 , wherein the one or more protective layer attachment features comprise one or more tabs, the one or more slot wall attachment features comprise one or more pockets, and the installing includes inserting the one or more tabs into the one or more pockets.
23 . The method of claim 22 , wherein the one or more tabs include bent portions.
24 . The method of claim 22 , wherein the one or more tabs includes curved portions.
25 . The method of claim 22 , wherein the one or more pockets include a pocket at a bottom of the at least one of the one or more slot walls.
26 . The method of claim 22 , wherein the one or more pockets include an open pocket through to a back side of the carrier.
27 . The method of claim 21 , wherein the at least one of the one or more slot walls includes only a rear slot wall, and the installing includes installing the protective layer conforming to the contour of the rear slot wall.
28 . The method of claim 21 , wherein the at least one of the one or more slot walls includes only a front slot wall, and the installing includes installing the protective layer conforming to the contour of the front slot wall.
29 . The method of claim 21 , wherein the one or more slot wall attachment features comprises a clip.