Actuating Mechanism for a Switch Mode CVT

Norbert Mongeon, Deanna Souza, and Michael Sweeney

Advisor: Professor Holly K. Ault
Mechanical Engineering Department

Abstract

With greater energy storage and power density than electric and hydraulic systems, a
flywheel kinetic energy recovery system may prove to be a viable solution for increasing efficiency in
passenger vehicles. A Switch Mode Continuously Variable Transmission (SM CVT) connects a
high-speed flywheel to the drivetrain with a high-speed clutch operating at a given duty cycle to
output a specific torque. Previous research has been limited by the efficiency and wear of the
clutch actuation system. The main goal of this investigation was to create a new mechanism for
controlling the clutchs high-speed duty cycle with better efficiency, wear characteristics, and
reliability. An actuation method derived from variable valve timing technology was selected. This
mechanism uses an eccentric cam to drive a set of linear cams at high speed to engage the clutch.
Each translating roller follower has an internal spring system to output the desired clamping force.
Duty cycle is varied by changing the position of the eccentric camshaft. The device performed to
expectations, but further research is needed as a full transmission system.

Dynamic Force Analysis

Dynamic forces were calculated using MathCAD and compared to
dynamic simulations in CREO. The results matched very closely and
were used to compute stresses of various components and determining
the gearing of the cam shaft. The spikes in the MathCAD analysis are
contributed to compressing the Belleville spring systems and were not
simulated in CREO.

load application time at 10,000 Hz

Vibrational torque transducer
Measures acceleration of camshaft

Testing Results
The graphs below show the load cell force plots for a
10%, 50% and 90% duty cycle.

An eccentric cam drives linear cams in a reciprocating motion.

Calculated torque on eccentric due to springs and inertia (left) compared

to simulated torque due to inertial forces (right)

Linear cams translate roller followers and close the clutch by

compressing a Belleville spring systems. The followers are returned to
low dwell with a wave spring. Load cells measure the closure force.

Achieved closure force of

250 pounds, 200 pounds
below design spec.
The engagement time
between low dwell and high
dwell is 0.977 milliseconds
at 50% duty cycle.
Achieved duty cycles from
0% to 100% in 10%
intervals

Stress Analysis

Custom 5-6-7 Polynomial

Cycle frequency of 20Hz
Duty cycle adjustable from 0%-100%
Optimized 0.48 radius of curvature
Rise length accounts for 21% of cycle
Rise height of 0.063
Clutch air gap of 0.025
Spring compression of 0.038
Closure force of 456 lbf

Load cells
Measure force, duty cycle, and

Calculated inertial and spring forces (left) compared to simulated inertial

forces (right)

Mechanism Operation

Linear Cam Design

Testing Setup

Analysis performed
Tearout from cam holder
Tearout on eccentric strap tabs
Tearout on leadscrew tabs
Von Mises on clevis pin
Von Mises on camshaft
Leadscrew thread analysis
All components exhibited a safety
factor greater than 2

Cycle frequency of 20.227

Hz with a designed
frequency of 20.233 Hz.
Ringing in Springs and load
cells is visible at a
frequency of 550 Hz

Camshaft free body diagram

Manufacturing
29 machined parts were made in Washburn totaling
45+ hours of machine run time on CNC machines
180+ parts were assembled into the prototype
A testing hood was built for safety

Camshaft accelerations
exceeded the limit of the
vibrational torque
transducer

Recommendations and References

Further work on this project could include adding a rotating clutch and a Kinetic Energy
Recovery System flywheel to test for efficiency in addition to counteracting vibrations.
Van de Ven, J.D., & Demetriou, M. A. (2011). Switch-Mode Continuously Variable Transmission: Modeling and Optimization. Journal of Dynamic Systems,
Measurement and Control, 133, 031008-1 031008-7. Retrieved from http://dynamicsystems.asmedigitalcollection.asme.org
Cusack, J.C. (2013). Switch-Mode Continuously Variable Transmission. Prototype Design and Testing. Worcester Polytechnic Institute, Worcester.