WO2013116877A2 - Stair lift drive system - Google Patents

Stair lift drive system Download PDF

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Publication number
WO2013116877A2
WO2013116877A2 PCT/US2013/026380 US2013026380W WO2013116877A2 WO 2013116877 A2 WO2013116877 A2 WO 2013116877A2 US 2013026380 W US2013026380 W US 2013026380W WO 2013116877 A2 WO2013116877 A2 WO 2013116877A2
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WO
WIPO (PCT)
Prior art keywords
axis
pinion
bearing
rack
bearing surface
Prior art date
Application number
PCT/US2013/026380
Other languages
French (fr)
Other versions
WO2013116877A3 (en
Inventor
John Cross
Original Assignee
John Cross
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by John Cross filed Critical John Cross
Publication of WO2013116877A2 publication Critical patent/WO2013116877A2/en
Publication of WO2013116877A3 publication Critical patent/WO2013116877A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
    • B66B9/00—Kinds or types of lifts in, or associated with, buildings or other structures
    • B66B9/06—Kinds or types of lifts in, or associated with, buildings or other structures inclined, e.g. serving blast furnaces
    • B66B9/08—Kinds or types of lifts in, or associated with, buildings or other structures inclined, e.g. serving blast furnaces associated with stairways, e.g. for transporting disabled persons
    • B66B9/0807—Driving mechanisms
    • B66B9/0815—Rack and pinion, friction rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
    • B66B9/00—Kinds or types of lifts in, or associated with, buildings or other structures
    • B66B9/06—Kinds or types of lifts in, or associated with, buildings or other structures inclined, e.g. serving blast furnaces
    • B66B9/08—Kinds or types of lifts in, or associated with, buildings or other structures inclined, e.g. serving blast furnaces associated with stairways, e.g. for transporting disabled persons
    • B66B9/0846—Guide rail

Definitions

  • This invention generally relates to the field of stair lifts, and to systems for the movement people from one place to another and other linear translation devices. Generally these devices move linearly either fully horizontal or on an incline up to fully vertical. Particularly this device relates to the field of stair lifts used to move one person up one flight of stairs on a seated conveyance.
  • the straight lift is usually designed as a motorized carriage with a seat attached.
  • the carriage rides on a fixed rail attached to the wall or the stair treads.
  • This rail contains a gear rack running the entire length of the rail.
  • the carriage contains a motor and gearbox with a drive gear that mates with the rack on the rail.
  • the motor rotates the drive gear interfacing with the rack causing the carriage to move along the rail.
  • Rollers are also mounted to the carriage that function to maintain the orientation between the carriage and the rack while allowing movement along the rail.
  • the curved stair lift functions similarly to the straight lift except the rail is usually made of tubes to allow custom curves to be made. This allows the stair lift to be designed to fit many different configurations of staircases.
  • the design of the carriage, along with the drive gear and rack, are very similar to the straight lift.
  • a drive system includes a motor, having a motor output configured to rotate about a first axis of rotation and at least one set of gears coupled to the motor output.
  • the assembly further includes a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation so as to mesh with rack teeth of a rack and move the pinion relative to the rack in a first direction.
  • a first bearing is coupled to the pinion and has a first bearing surface that rotates with the pinion about the second axis, wherein the first bearing surface is configured to rotate along a rack bearing surface in a second longitudinal direction that is substantially parallel to the first longitudinal direction.
  • An assembly includes as integrated carriage and rail.
  • the integrated carriage includes a motor, having a motor output configured to rotate about a first axis of rotation, at least one set of gears coupled to the motor output, a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation, and a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis.
  • the rail includes a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail and a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
  • An integrated carriage assembly comprises a motor, the motor having a motor output configured to rotate about a first axis of rotation, a gearbox mounted to the motor, at least one set of gears rotatably fixed directly to the housing, a first gear of the at least one set of gears coupled to the motor output and configured to rotate about the first axis, and a second gear of the at least one set of gears configured to rotate about a second axis that is perpendicular to the first axis, a pinion having pinion teeth, the pinion coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about the second axis, and a first set of bearings, rotatably fixed to the motor; and a second set of bearings, rotatably fixed to the gearbox.
  • a stair lift assembly includes seat configured to at least in part support the weight of an adult human user.
  • the assembly further includes an integrated carriage, coupled to the seat and including a motor, having a motor output configured to rotate about a first axis of rotation, at least one set of gears coupled to the motor output, a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation; a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis.
  • the assembly also includes a rail configured to guide motion of the carriage and including a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail, and a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
  • Fig. 1 is a schematic side view of a stair lift assembly
  • Fig. 2A is a schematic cross-sectional side view of a portion of the stair lift assembly shown in Fig. 1, as seen from the perspective of line D shown in Fig. 1, according to a first embodiment;
  • FIG. 2B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 2A;
  • FIG. 3 A is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1-2B;
  • Fig. 3B is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1-3 A, as seen from the perspective of line U shown in Fig. 1;
  • Fig. 4A is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1-3B, as seen from the perspective of line D shown in Fig. 1;
  • FIG. 4B is a schematic top view of a portion of the stair lift assembly shown in Figs. 1-4A;
  • FIG. 5 A- is a perspective view of a portion of the stair lift assembly shown in Figs. 1-4B; [0020] Fig. 5B- is a side view of a portion of the stair lift assembly shown in Figs. 1-
  • Fig. 5C- is a top view of a portion of the stair lift assembly shown in Figs. 1-5B;
  • Fig. 5D is a perspecitve view of a portion of the stair lift assembly shown in Figs. 1-5C;
  • Fig. 6A is a cross-sectional view of a portion of the stair lift assembly shown in Figs. 1-5D based on line 6A shown in Fig. 5C;
  • Fig. 6B is a cross-sectional view of a portion of the stair lift assembly shown in Figs. 1-5D, based on line 6B shown in Fig. 5C;
  • Fig. 7A is a schematic cross-sectional side view of a portion of the stair lift assembly shown in Fig. I, as seen from the perspective of line U shown in Fig. I, according to a second embodiment;
  • FIG. 7B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A;
  • FIG. 8A is a schematic perspective view of a portion of the stair lift assembly shown in Figs. I, 7A, B;
  • Fig. 8B is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1, 7A-8A, as seen from the perspective of line U shown in Fig. i ;
  • Fig. 9A is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1, 7A-8B, as seen from the perspective of line U shown in Fig. i ;
  • Fig. 9B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A-9A;
  • Fig. 10A- is a top view of a portion of the stair lift assembly shown in Figs. 1,
  • Fig. 10B- is a side view of a portion of the stair lift assembly shown in Figs. 1, 7A-10A;
  • Fig. IOC- is a side view of a portion of the stair lift assembly shown in Figs. 1, 7A-10B;
  • Fig. 10D- is a perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A-10C.
  • a stair lift assembly 10 such as a drive system or integrated carriage and rail assembly, can include a rail 20, 20', an integrated carriage assembly 40, 40' that rides along the rail, and a seat 100, mounted to the integrated carriage assembly.
  • the rail 20, 20' extends in a direction, for example diagonally along a stairway SW between a first height FH and a second height SH, such as a first floor and a second floor.
  • the stair lift assembly 10 is configured to be mounted relative to, that is, to or near, a stairway, for example a straight stairway (i.e., one without a landing or a turn).
  • the stair lift assembly 10 may be used on non-straight stairways. For example, for stairways with a landing or a turn, multiple stair lift assemblies 10 may be used to travel between the first height and the second height.
  • the stair lift assembly 10 may also be configured to move its integrated carriage assembly 40, 40' along different angles, from fully horizontal up to fully vertical.
  • Stair lift assembly 10 may be described in relation to a three dimensional coordinate system that includes a longitudinal axis L that extends parallel to a length defined by the rail 20, 20' such that axis L intersects the lines defined by the first and second heights FH, SH. Longitudinal axis L is perpendicular to both transverse axis T and a lateral axis A, which are each also is perpendicular to each other. Stair lift assembly 10 may also be described in relation to direction G which represents the gravitational force of the weight of the integrated carriage assembly 40 against the rail 20.
  • Direction G may intersect or be askew to axis T.
  • Stair lift assembly 10 is shown throughout the drawings as two embodiments.
  • the first embodiment shown in Figs. 1-6B, has a rail 20 with a recess 25 that extends along axis L with an opening 25a defined along axis T (that is, on the top side of rail 20).
  • the second embodiment shown in Figs. 1, 7A-10D, has a recess 25' that extends vertically and defines a vertical opening 25a' defined along axis L (that is, on the side of the rail).
  • Each of the embodiments shown in Figs. 2A-10D, respectively, correspond to different bearing
  • rail 20 has a rail body 20a that defines at least one recess, such as recess 25.
  • Recess 25 may include a lower portion 25b having a depth that is configured to fit at least a portion of the gearbox 42 of the integrated carriage assembly (described in greater detail below).
  • Rail 20 includes rack 22 that is configured to mesh with the pinion 60 of the integrated carriage assembly 40.
  • Rack 22 may extend the length of rail 20 parallel axis L and includes teeth 24 that extend upward along the axis T from axis L.
  • a rack bearing surface 28 also extends parallel to the longitudinal axis, such that the rack bearing surface 28 and the rack 22 extend parallel to one another.
  • Rack bearing surface 28 is shown in relation to the first embodiment as part of rail body 20a. However, as explained in detail in relation to the second embodiment, rack bearing surface 28 and rack 22 may be formed integrally and mounted to the rail 20.
  • the rack bearing surface 28 may be substantially flat and smooth and configured to accommodate a bearing 61 on the integrated carriage assembly 40.
  • Figs. 2A-4A depict rack bearing surface 28 as part of the body 20a of rail 20.
  • Rack 22 may be formed separately and then fixed to rail 20.
  • Bearing surface 28 partially defines a channel 25c.
  • Channel 25c may further be defined by a bearing surface 30 that extends parallel to axis L and bearing surface 28.
  • Channel 25c is parallel to and opposes a channel 25d within rail body 20a.
  • Channel 25d is in part defined by bearing surfaces 34, 36 that, like surfaces 28, 30, extend parallel to each other and axis L and are substantially flat and smooth.
  • Channels 25c, 25d accommodate bearings of the integrated carriage assembly 40, such as bearings 61, 62, as described in more detail below.
  • bearing 61 is configured to rotate against surfaces 28, 30, while bearing 62 is configured to rotate against surfaces 34, 36.
  • Rail body 20a also defines bearing surfaces 32, 37, which each, respectively, extend upward parallel to axis T, from surfaces 34, 36 and extend longitudinally parallel to axis L. As described in detail below, bearings 64, 63, respectively, are configured to rotate against surfaces 32, 37. Surfaces 32,37 are illustrated in Figure 3B as inward facing edges of rail 20, and the present invention encompasses other structure.
  • Rack bearing surface 28 may be formed separately from or integrally with either the rail 20 and the rack 22.
  • rack bearing surface 28 may be formed from extruded aluminum, powdered metal, or other suitable material.
  • rack bearing surface 28 may be formed integrally with an a rail 20, such as an extruded aluminum rail.
  • rack 22 and rack bearing surface 28 may be formed integrally from powdered metal.
  • the integrally formed structure may have discrete segments that are fixed to the rail 20.
  • integrated carriage assembly 40 and the rail 20 are separate components that need not be secured to one another until the rail 20 is secured to the stairway, integrated carriage assembly 40 will be described in its secured state on 20 and in relation to the axes L, A, T used to describe the rail 20.
  • Integrated carriage assembly 40 includes a motor 44 and a gearbox 42.
  • Gearbox 42 includes a set of gears 50 enclosed in the gearbox 42.
  • Motor 44 includes a motor output 46 configured to rotate about a motor output axis M that is parallel to the axis L.
  • Motor output 46 is coupled to a worm 50a that also rotates about output axis M.
  • Worm 50a is in meshed communication with a worm gear 50b that rotates about a pinion axis P.
  • Axis P is perpendicular to axis M and parallel to the lateral axis A.
  • Shaft 52 is fixed to the worm gear 50b at a first end 52a of the shaft 52.
  • Shaft 52 extends from the worm gear 50b along axis P to a second end 52b and is configured to rotate about axis P as motor 44 drives the motor output 46.
  • Shaft 52 is supported by a set of shaft bearings 54 disposed within the gearbox 42.
  • Second end of shaft 52b is fixed to the pinion 60, such that as motor 44 drives motor output 46 about axis M, worm 50a also rotates about axis M, and worm gear 50b, shaft 52, and pinion 60 all rotate about axis P.
  • pinion 60 and shaft 52 may be formed integrally as a single piece.
  • Pinion 60, bearing 61 and shaft 52 may also be formed integrally as a single piece.
  • Worm 50a and worm gear 50b of the set of gears 50 may be configured to provide gear reduction of the motor so as to reduce the speed at which the motor output 46 rotates while increasing the torque at which the output rotates.
  • gear configurations may be used to modify the speed and torque of the motor output 46.
  • the embodiment shown, including worm 50a and worm gear 50b may be described as single pass gears. Single pass gears are generally cheaper and easier to assemble. However, it will be appreciated that double pass gears, as well as higher order pass gears may be used. Embodiments with double pass and higher order pass gears may further employ a worm in place of a pinion and a rack configured to mesh with the worm.
  • bearings such as bearings 61, 62, 63, 64 - ride in and guide assembly 40 relative to rail 20 (described in part above).
  • Bearings rotatably coupled to the gearbox 42 and motor 44 function to guide the integrated carriage assembly 40 within the at least one recess 25 of the rail 20. Some bearings may also support the weight of the integrated carriage assembly 40 and chair 100 against the rail 20, 20'.
  • Bearing 61 including its bearing surface 61a, may be secured to shaft 52 of gearbox 42. Specifically, bearing 61 may be secured to shaft 52 such that pinion 60 and bearing
  • Bearing 61 rotate about the pinion axis (parallel to axis A).
  • Bearing 61 may be fixedly attached to or integrally formed with shaft 52 such that bearing 61, shaft 52, and pinion 60 are all configured to rotate at the same angular velocity.
  • bearing 61 may be rotatably attached to shaft 52 such that bearing 61 freely rotates independently from the rotation of shaft 52 and pinion 60.
  • Bearing 61 may be fixedly or rotatably attached directly to pinion 60 instead of shaft 52.
  • Bearing 61 may be configured to have a diameter that is substantially equal or equal to the pitch diameter of the pinion.
  • rack 22 and rack bearing surface 28 may be configured to correspond to the pinion 60 and bearing 61, such that pinion 60 and bearing 61 rotate at the same angular velocity and rotational speed.
  • bearing 61 including bearing surface 61a, rotates within channel 25c, such that bearing surface 61a rotates along surfaces 28, 30, along the pinion axis (parallel to axis A).
  • bearing 61 may be weight bearing, such that bearing 61 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
  • Bearing 62 which includes a bearing surface 62a, is rotatably secured to gearbox 42 on the opposite side of the gearbox 42 from bearing 61.
  • bearing 62 including bearing surface 62a, rotates within channel 25d, such that bearing surface 62a rotates along surfaces 34, 36, along an axis of rotation that is parallel to or identical to the pinion axis (and axis A).
  • bearing 62 may be weight bearing, such that bearing 62 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20. Bearings 61, 62 may rotate about the same axis.
  • Bearing 63 which includes a bearing surface 63a, is rotatably secured to gearbox 42. As described above, bearing 63, including bearing surface 63 a, rotates along surface 37 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
  • Bearing 64 which includes a bearing surface 64a, is rotatably secured to gearbox 42 on the opposite side of gearbox 42 from bearing 63. As described above, bearing 64, including bearing surface 64a, rotates along surface 32 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
  • Bearing 65 which includes a bearing surface 65a, is rotatably secured to motor
  • bearing 65 including bearing surface 65a, including bearing surface 65a, rotates within channel
  • bearing 63 may be weight bearing, such that bearing 63 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
  • Bearing 66 which includes a bearing surface 66a, is rotatably secured to motor 44 on the opposite side of the motor 44 from bearing 65 and on the opposite end of the integrated carriage assembly 40 from bearing 62.
  • bearing 66 including bearing surface 66a, within channel 25d, such that bearing surface 66a rotates along surfaces 34, 36, about an axis that is parallel to the pinion axis (and axis A).
  • Bearings 65, 66 may rotate about the same axis.
  • bearings 61, 62, 65 when bearing surface 66a contacts bearing surface 34, bearing 66 may be weight bearing, such that bearing 66 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
  • Bearing 67 which includes a bearing surface 67a, is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40 from bearing 63. Like bearing 63, bearing 67, including bearing surface 63 a, rotates along surface 37 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
  • Bearing 68 which includes a bearing surface 68a, is rotatably secured to motor 44 on the opposite side of the motor 44 from bearing 67 and on the opposite end of the integrated carriage assembly 40 from bearing 64. Like bearing 64, bearing 68, including bearing surface 68a, rotates along surface 32 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
  • rail 20 forms an upwardly open C-shape, with recess 25 providing space for integrated carriage assembly 40 to pass through, a rack surface that extends from a lower surface of the floor of rack 20 to which rack 22 is affixed, a pair of inwardly opening channels 25c and 25d to receive and guide horizontally oriented bearings 61 and 62 of assembly 40, and a pair of inwardly facing edges 32 and 37 to receive and guide vertically oriented bearings 63 and 64 of assembly 40.
  • the second embodiment of stair lift assembly 10 shown in Figs. 1, 7A-10D includes rail 20' having a rail body 20a' that defines at least one recess, such as recess 25'.
  • Recess 25' may include a lower portion 25b' having a depth that is configured to fit at least a portion of a gearbox 42 of the integrated carriage assembly described in greater detail below.
  • Rail 20' includes a rack 22' that is configured to mesh with a pinion 60 of the integrated carriage assembly 40'.
  • Rack 22' may extend the length of rail 20' parallel axis L.
  • Rack 22' includes teeth 24' that extend outward along the axis A from axis L.
  • a rack bearing surface 28' also extends parallel to the longitudinal axis such that the rack bearing surface 28' and the rack 22' extend parallel to one another.
  • the rack bearing surface 28' may be substantially flat and smooth and configured to accommodate a bearing 61 ' on the integrated carriage assembly.
  • the rack 22' and rack bearing surface 28' may be formed integrally to provide increased manufacturing accuracy. Increased manufacturing accuracy reduces the noise created as the pinion 60 and bearing 62' rotate along the rack 22' and rack bearing surface 28'.
  • Individual segments 27 include portions of the rack 22' and rack bearing surface 28' that have been integrally formed.
  • An exemplary segment 27 is shown in Fig. 9D with pinion 60.
  • Segments 27 may be separately secured to the rail 20' during installation of the stair lift assembly 10.
  • rail body 20a' may define a recess 21, such as a dovetail shaped recess configured to fit a lower portion of segments 27, such as a dovetail shaped lower portion.
  • Recess 21 may be part of recess 25' or may be separate from recess 25'.
  • recess 21 may in part be defined by a bottom portion 21a of the rail body 20a', such as a relatively flat bottom portion that extends the approximate length of the rail 20' parallel to the longitudinal and lateral axis, as well as rack bearing surface 28'.
  • the recess 21 may further be defined by side portions 21b of the rail 20 that extend out from the bottom portion 21a parallel to the lateral axis.
  • Top portions 21c such as diagonally shaped top portions extend laterally and transversely toward each other.
  • Segments 27 may each include a corresponding bottom surface 27a, side portions 27b, and top portions 27c that slidably fit within recess 21, secured by top portion 21c extending over top portion 27c.
  • rack and rack bearing surface segments 27 may be slid into recess 21 to form the rack 22' and rack bearing surface 28'.
  • Segments 27 may have a length that is a fraction of the total length of the rail 20'.
  • segments 27 may be approximately 6 to 8 inches in length.
  • Other embodiments of the recess 21 and segment 27 may have different cross sectional configurations.
  • side portions 21b, 27b and top portions 21c, 27c may be asymmetrical or symmetrical, respectively.
  • rack 22 may have a lower portion with a dovetail configuration (not shown) that corresponds to a dovetail-shaped recess in rail body 20a (not shown).
  • Rack 22 may also be partitioned into segments (not shown).
  • rack 22 (or portions thereof) may be slid into the dovetail shaped recess.
  • other cross- sectional configurations of the rail body 20a and rack 22 may be used.
  • recess 25' may include two channels 25c', 25d'.
  • Channels 25c', 25d' may be at least partially defined by bearing surfaces, such as bearing surfaces 28', 30', 32', 34', 36'. Bearing surfaces 28', 30', 32', 34', 36' extend parallel to axis L and are substantially flat and smooth. Channels 25c', 25d' accommodate bearings of the integrated carriage assembly 40', such as bearings 61 ', 62', 63', 64', as described in more detail below. For example, as shown in Fig. 8B, bearing surface 30' may extend parallel to and opposing rack bearing surface 28' along the length of the rail 20'. Bearing surface 32' also extends along the length of the rail, between and perpendicular to surfaces 28', 30'.
  • surfaces 28', 30', 32' form channel 25c' in which bearings 6 , 64' (shown in Fig. 9 A) rotate.
  • bearing 61 ' is configured to rotate against surfaces 28', 30', while bearing 64' is configured to rotate against surface 32'.
  • Bearing surfaces 34', 36' also extend along the length of the rail, parallel to surfaces 28', 30' and axis L so as to form channel 25d' that accommodates the rotation of bearing 62'.
  • channels 25c', 25d' may be configured such that bearings 61 ', 62' may rotate about the same axis of rotation or may rotate about different axis that are parallel and disposed the same distance along the lateral axis from the longitudinal axis.
  • Channel 25d' is depicted in Fig 8A with a curved surface extending in between surfaces 34', 36'.
  • Alternate configurations may include a flat, smooth surface that extends between surfaces 34', 36', such as surface 32' of channel 25c'.
  • Bearing surface 37' may also extend along the length of the rail 20' and parallel to the axis A, so as to be perpendicular to bearing surfaces 28', 30', 32', 34'. Bearing surface 37' may in part define recess 25b'. As shown in Fig. 9A, bearing surface 37' is configured to contact bearing 63 ' .
  • gears 50a, 50b of integrated carriage assembly 40 described in relation to Figs. 6A, 6B of the first embodiment are substantially the same as those in integrated carriage assembly 40' (shifted shifted 90° about the L axis).
  • motor output 46 is configured to rotate about a motor output axis that is parallel to the axis L.
  • Motor output 46 is coupled to a worm 50a that also rotates about the motor output axis.
  • Worm 50a is in meshed communication with a worm gear 50b that rotates about a pinion axis that is perpendicular to the motor output axis and parallel to transverse axis T
  • Shaft 52 extends from the worm gear 50b along the pinion axis to a second end
  • pinion 60 and shaft 52 may be formed integrally as a single piece.
  • Pinion 60, bearing 61 ' and shaft 52 may also be formed integrally as a single piece.
  • Bearings such as bearings 61 ', 62', 63', 64', in part described above, may be rotatably coupled to gearbox 42 and motor 44'. Bearings rotatably coupled to the gearbox 42 and motor 44' function to guide the integrated carriage assembly 40' within the at least one recess 25' of the rail 20'. Some bearings may also support the weight of the integrated carriage assembly 40' and chair 100 against the rail 20'.
  • Bearing 6 including its bearing surface 61a', may be secured to shaft 52 of gearbox 42.
  • bearing 61 ' may be secured to shaft 52 such that pinion 60 and bearing 61 ' rotate about the pinion axis (parallel to axis T).
  • Bearing 61 ' may be fixedly attached to or integrally formed with shaft 52 such that bearing 6 , shaft 52, and pinion 60 are all configured to rotate at the same angular velocity.
  • bearing 61 ' may be rotatably attached to shaft 52 such that bearing 61 ' freely rotates independently from the rotation of shaft 52 and pinion 60.
  • Bearing 61 ' may be fixedly or rotatably attached directly to pinion 60 instead of shaft 52.
  • Bearing 61 ' may be configured to have a diameter that is substantially equal or equal to the pitch diameter of the pinion.
  • rack 22' and rack bearing surface 28' may be configured to correspond to the pinion 60 and bearing 61 ', such that pinion 60 and bearing 61 ' rotate at the same angular velocity and rotational speed.
  • bearing 61 ' including bearing surface 61a', rotates within channel 25c', such that bearing surface 61a' rotates along surfaces 28', 30', along the pinion axis (parallel to axis T).
  • Bearing 62' which includes a bearing surface 62a', is rotatably secured to gearbox 42 on the opposite side of the gearbox 42 from bearing 61 '. As described above, bearing 62', including bearing surface 62a', rotates within channel 25d', such that bearing surface 62a' rotates along surfaces 34', 36', along an axis of rotation that is parallel to or identical to the pinion axis (and axis T).
  • Bearing 63' which includes a bearing surface 63a', is rotatably secured to gearbox 42. As described above, bearing 63 ', including bearing surface 63a', rotates along surface 37' about an axis of rotation that is perpendicular to the pinion axis (and axis T).
  • Bearing 64' which includes a bearing surface 64a', is rotatably secured to gearbox 42. As described above, bearing 64', including bearing surface 64a', rotates along surface 32', within channel 25 d' about an axis of rotation that is perpendicular to the pinion axis (and axis T). When bearing surface 64a' contacts bearing surface 32', bearing 64' may be weight bearing, such that bearing 64' supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
  • Bearing 65' which includes a bearing surface 65a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 61 '. Like bearing 61 ', bearing 65', including bearing surface 65a', rotates within channel 25c', such that bearing surface 65a' rotates along surfaces 28', 30', along the pinion axis (parallel to axis T).
  • Bearing 66' which includes a bearing surface 66a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 64'.
  • bearing 66' including bearing surface 66a', rotates along surface 32' about an axis of rotation that is perpendicular to the pinion axis (and axis T).
  • bearing 66' may be weight bearing, such that bearing 66' supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
  • Bearing 67' which includes a bearing surface 67a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 63'. Like bearing 63 ', bearing 67', including bearing surface 63a', rotates along surface 37' about an axis of rotation that is perpendicular to the pinion axis (and axis T).
  • Bearing 68' which includes a bearing surface 68a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 62' and the opposite side of the motor from bearing 65'. Like bearing 62', bearing 68', including bearing surface 68a', rotates within channel 25d', such that bearing surface 68a' rotates along surfaces 34', 36', along an axis of rotation that is parallel to the pinion axis (and axis T).
  • chair 100 and bearings such as bearings 61-68, 6 ⁇ -68' may all be mounted directly to the integrated carriage assembly 40, 40'
  • integrated carriage assembly 40, 40' may have a lower profile configuration relative to the rail compared to a configuration with bearings mounted to a housing to encloses the gearbox and motor.
  • gearbox 42 and motor 44 may be configured to at least partially fit within recess 25 such that at least a portion of the rail and at least a portion of the gearbox 42 and/or motor 44 overlap in relation to axis T (in the first embodiment) or the A axis
  • gearbox 42 and motor 44 are moveably nested within recess 25, 25' of rail body 20a, 20a'.
  • gearbox 42 and motor 44 provide structural support to the carriage assembly.
  • gearbox 42 and motor 44 are configured to bear the weight of the chair 100 against the rail 20, 20'.
  • the bearings may be made from high molecular weight plastic, self-lubricating materials, bearing materials, or any other suitable material. While bearings 61-68, 61 '-68' are described herein as rotating about axes that are parallel to either axis A or axis T, other axial rotations are contemplated.
  • any of bearings 61-68, 61 '-68' may be configured so as to rotate about an axis that is not parallel to axis A or axis T, such as an axis that is at a 45° to both axis A and axis T.
  • Chair 100 may have multiple configurations. In the embodiments shown in Figs. 1, 2A, 7A, Chair 100 includes a seat 102 that extends in a plane perpendicular to the gravitational force G. Back support 104 extends up from the seat 102 in a direction opposite to force G. Foot rest 106 extends in a plane that is parallel to the plane of the seat and down from the seat in direction G. Chair 100 is configured to accommodate a person using the stair lift assembly. For example, chair 100 may be configured to accommodate a person having a body weight of 80 to 300 pounds. Alternatively, chair 100 may be configured to accommodate a wider weight range.
  • first and second embodiments may be modified for different applications.
  • first and second embodiments are described in relation to a stairway, wherein the first and second heights FH, SH are different
  • stair lift assembly 10 may be used in applications where first and second heights are substantially similar.
  • stair lift assembly 10 may move substantially horizontally in relation to the first height.

Abstract

A drive system for a stair lift includes a motor, having a motor output configured to rotate about a first axis of rotation and at least one set of gears coupled to the motor output. The assembly further includes a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation so as to mesh with rack teeth of a rack and move the pinion relative to the rack in a first direction. A first bearing is coupled to the pinion and has a first bearing surface that rotates with the pinion about the second axis, wherein the first bearing surface is configured to rotate along a rack bearing surface in a second longitudinal direction that is substantially parallel to the first longitudinal direction.

Description

STAIR LIFT DRIVE SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Number 61/599,569, filed February 16, 2012, the disclosure of which is hereby incorporated by reference in its entirety as if set forth herein at length.
TECHNICAL FIELD
[0002] This invention generally relates to the field of stair lifts, and to systems for the movement people from one place to another and other linear translation devices. Generally these devices move linearly either fully horizontal or on an incline up to fully vertical. Particularly this device relates to the field of stair lifts used to move one person up one flight of stairs on a seated conveyance.
BACKGROUND
[0003] Motorized devices have been developed to lift and lower an individual up and down a flight of stairs. These devices are divided into two basic categories. The straight stair lift and the curved stair lift.
[0004] The straight lift is usually designed as a motorized carriage with a seat attached. The carriage rides on a fixed rail attached to the wall or the stair treads. This rail contains a gear rack running the entire length of the rail. The carriage contains a motor and gearbox with a drive gear that mates with the rack on the rail. The motor rotates the drive gear interfacing with the rack causing the carriage to move along the rail. Rollers are also mounted to the carriage that function to maintain the orientation between the carriage and the rack while allowing movement along the rail.
[0005] The curved stair lift functions similarly to the straight lift except the rail is usually made of tubes to allow custom curves to be made. This allows the stair lift to be designed to fit many different configurations of staircases. The design of the carriage, along with the drive gear and rack, are very similar to the straight lift.
[0006] Current state of the art motorized carriages typically feature a motor and gearbox mounted into a frame that is separate from the motor and gearbox. This frame also contains guide rollers to allow the frame to move along a guide rail. The guide rollers and the frame together control the orientation of the drive pinion, attached to the gearbox output shaft, to the rack, which is attached to the guide rail. SUMMARY
[0007] A drive system includes a motor, having a motor output configured to rotate about a first axis of rotation and at least one set of gears coupled to the motor output. The assembly further includes a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation so as to mesh with rack teeth of a rack and move the pinion relative to the rack in a first direction. A first bearing is coupled to the pinion and has a first bearing surface that rotates with the pinion about the second axis, wherein the first bearing surface is configured to rotate along a rack bearing surface in a second longitudinal direction that is substantially parallel to the first longitudinal direction.
[0008] An assembly includes as integrated carriage and rail. The integrated carriage includes a motor, having a motor output configured to rotate about a first axis of rotation, at least one set of gears coupled to the motor output, a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation, and a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis. The rail includes a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail and a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
[0009] An integrated carriage assembly comprises a motor, the motor having a motor output configured to rotate about a first axis of rotation, a gearbox mounted to the motor, at least one set of gears rotatably fixed directly to the housing, a first gear of the at least one set of gears coupled to the motor output and configured to rotate about the first axis, and a second gear of the at least one set of gears configured to rotate about a second axis that is perpendicular to the first axis, a pinion having pinion teeth, the pinion coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about the second axis, and a first set of bearings, rotatably fixed to the motor; and a second set of bearings, rotatably fixed to the gearbox.
[0010] A stair lift assembly includes seat configured to at least in part support the weight of an adult human user. The assembly further includes an integrated carriage, coupled to the seat and including a motor, having a motor output configured to rotate about a first axis of rotation, at least one set of gears coupled to the motor output, a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation; a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis. The assembly also includes a rail configured to guide motion of the carriage and including a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail, and a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing summary, as well as the following detailed description of the various embodiments of the application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the various embodiments of the disclosure, reference is made to the drawings. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities illustrated in the drawings, in which:
[0012] Fig. 1 is a schematic side view of a stair lift assembly;
[0013] Fig. 2A is a schematic cross-sectional side view of a portion of the stair lift assembly shown in Fig. 1, as seen from the perspective of line D shown in Fig. 1, according to a first embodiment;
[0014] Fig. 2B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 2A;
[0015] Fig. 3 A is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1-2B;
[0016] Fig. 3B is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1-3 A, as seen from the perspective of line U shown in Fig. 1;
[0017] Fig. 4A is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1-3B, as seen from the perspective of line D shown in Fig. 1;
[0018] Fig. 4B is a schematic top view of a portion of the stair lift assembly shown in Figs. 1-4A;
[0019] Fig. 5 A- is a perspective view of a portion of the stair lift assembly shown in Figs. 1-4B; [0020] Fig. 5B- is a side view of a portion of the stair lift assembly shown in Figs. 1-
5A;
[0021] Fig. 5C- is a top view of a portion of the stair lift assembly shown in Figs. 1-5B;
[0022] Fig. 5D is a perspecitve view of a portion of the stair lift assembly shown in Figs. 1-5C;
[0023] Fig. 6A is a cross-sectional view of a portion of the stair lift assembly shown in Figs. 1-5D based on line 6A shown in Fig. 5C;
[0024] Fig. 6B is a cross-sectional view of a portion of the stair lift assembly shown in Figs. 1-5D, based on line 6B shown in Fig. 5C;
[0025] Fig. 7A is a schematic cross-sectional side view of a portion of the stair lift assembly shown in Fig. I, as seen from the perspective of line U shown in Fig. I, according to a second embodiment;
[0026] Fig. 7B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A;
[0027] Fig. 8A is a schematic perspective view of a portion of the stair lift assembly shown in Figs. I, 7A, B;
[0028] Fig. 8B is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1, 7A-8A, as seen from the perspective of line U shown in Fig. i ;
[0029] Fig. 9A is a schematic side view cross-sectional side view of a portion of the stair lift assembly shown in Figs. 1, 7A-8B, as seen from the perspective of line U shown in Fig. i ;
[0030] Fig. 9B is a schematic perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A-9A;
[0031] Fig. 10A- is a top view of a portion of the stair lift assembly shown in Figs. 1,
7A-9B;
[0032] Fig. 10B- is a side view of a portion of the stair lift assembly shown in Figs. 1, 7A-10A;
[0033] Fig. IOC- is a side view of a portion of the stair lift assembly shown in Figs. 1, 7A-10B; and
[0034] Fig. 10D- is a perspective view of a portion of the stair lift assembly shown in Figs. 1, 7A-10C. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0035] Referring to Fig. 1, a stair lift assembly 10, such as a drive system or integrated carriage and rail assembly, can include a rail 20, 20', an integrated carriage assembly 40, 40' that rides along the rail, and a seat 100, mounted to the integrated carriage assembly. As shown in the illustrated embodiments, the rail 20, 20' extends in a direction, for example diagonally along a stairway SW between a first height FH and a second height SH, such as a first floor and a second floor. The stair lift assembly 10 is configured to be mounted relative to, that is, to or near, a stairway, for example a straight stairway (i.e., one without a landing or a turn).
[0036] In another embodiment the stair lift assembly 10 may be used on non-straight stairways. For example, for stairways with a landing or a turn, multiple stair lift assemblies 10 may be used to travel between the first height and the second height. The stair lift assembly 10 may also be configured to move its integrated carriage assembly 40, 40' along different angles, from fully horizontal up to fully vertical.
[0037] Stair lift assembly 10 may be described in relation to a three dimensional coordinate system that includes a longitudinal axis L that extends parallel to a length defined by the rail 20, 20' such that axis L intersects the lines defined by the first and second heights FH, SH. Longitudinal axis L is perpendicular to both transverse axis T and a lateral axis A, which are each also is perpendicular to each other. Stair lift assembly 10 may also be described in relation to direction G which represents the gravitational force of the weight of the integrated carriage assembly 40 against the rail 20. Direction G may intersect or be askew to axis T.
[0038] Stair lift assembly 10 is shown throughout the drawings as two embodiments. The first embodiment, shown in Figs. 1-6B, has a rail 20 with a recess 25 that extends along axis L with an opening 25a defined along axis T (that is, on the top side of rail 20). The second embodiment, shown in Figs. 1, 7A-10D, has a recess 25' that extends vertically and defines a vertical opening 25a' defined along axis L (that is, on the side of the rail). Each of the embodiments shown in Figs. 2A-10D, respectively, correspond to different bearing
configurations on the rail 20, 20' and integrated carriage assembly 40, 40' (explained in more detail below).
[0039] According to the first embodiment, rail 20 has a rail body 20a that defines at least one recess, such as recess 25. Recess 25 may include a lower portion 25b having a depth that is configured to fit at least a portion of the gearbox 42 of the integrated carriage assembly (described in greater detail below). [0040] Rail 20 includes rack 22 that is configured to mesh with the pinion 60 of the integrated carriage assembly 40. Rack 22 may extend the length of rail 20 parallel axis L and includes teeth 24 that extend upward along the axis T from axis L.
[0041] A rack bearing surface 28 also extends parallel to the longitudinal axis, such that the rack bearing surface 28 and the rack 22 extend parallel to one another. Rack bearing surface 28 is shown in relation to the first embodiment as part of rail body 20a. However, as explained in detail in relation to the second embodiment, rack bearing surface 28 and rack 22 may be formed integrally and mounted to the rail 20. The rack bearing surface 28 may be substantially flat and smooth and configured to accommodate a bearing 61 on the integrated carriage assembly 40. Figs. 2A-4A depict rack bearing surface 28 as part of the body 20a of rail 20. Rack 22 may be formed separately and then fixed to rail 20.
[0042] Bearing surface 28 partially defines a channel 25c. Channel 25c may further be defined by a bearing surface 30 that extends parallel to axis L and bearing surface 28. Channel 25c is parallel to and opposes a channel 25d within rail body 20a. Channel 25d is in part defined by bearing surfaces 34, 36 that, like surfaces 28, 30, extend parallel to each other and axis L and are substantially flat and smooth. Channels 25c, 25d accommodate bearings of the integrated carriage assembly 40, such as bearings 61, 62, as described in more detail below. For example, as shown in Fig. 4A, bearing 61 is configured to rotate against surfaces 28, 30, while bearing 62 is configured to rotate against surfaces 34, 36.
[0043] Rail body 20a also defines bearing surfaces 32, 37, which each, respectively, extend upward parallel to axis T, from surfaces 34, 36 and extend longitudinally parallel to axis L. As described in detail below, bearings 64, 63, respectively, are configured to rotate against surfaces 32, 37. Surfaces 32,37 are illustrated in Figure 3B as inward facing edges of rail 20, and the present invention encompasses other structure.
[0044] Rack bearing surface 28 may be formed separately from or integrally with either the rail 20 and the rack 22. For example, rack bearing surface 28 may be formed from extruded aluminum, powdered metal, or other suitable material. In some embodiments, rack bearing surface 28 may be formed integrally with an a rail 20, such as an extruded aluminum rail.
Alternatively, rack 22 and rack bearing surface 28 may be formed integrally from powdered metal. In configurations where rack 22 and rack bearing surface 28 are integrally formed, the integrally formed structure may have discrete segments that are fixed to the rail 20.
[0045] While the integrated carriage assembly 40 and the rail 20 are separate components that need not be secured to one another until the rail 20 is secured to the stairway, integrated carriage assembly 40 will be described in its secured state on 20 and in relation to the axes L, A, T used to describe the rail 20.
[0046] Integrated carriage assembly 40 includes a motor 44 and a gearbox 42. Gearbox 42 includes a set of gears 50 enclosed in the gearbox 42. Motor 44 includes a motor output 46 configured to rotate about a motor output axis M that is parallel to the axis L. Motor output 46 is coupled to a worm 50a that also rotates about output axis M. Worm 50a is in meshed communication with a worm gear 50b that rotates about a pinion axis P. Axis P is perpendicular to axis M and parallel to the lateral axis A. Shaft 52 is fixed to the worm gear 50b at a first end 52a of the shaft 52. Shaft 52 extends from the worm gear 50b along axis P to a second end 52b and is configured to rotate about axis P as motor 44 drives the motor output 46. Shaft 52 is supported by a set of shaft bearings 54 disposed within the gearbox 42. Second end of shaft 52b is fixed to the pinion 60, such that as motor 44 drives motor output 46 about axis M, worm 50a also rotates about axis M, and worm gear 50b, shaft 52, and pinion 60 all rotate about axis P. Alternatively, pinion 60 and shaft 52 may be formed integrally as a single piece. Pinion 60, bearing 61 and shaft 52 may also be formed integrally as a single piece. As described above, actuation of pinion 60 moves the integrated carriage assembly 40 relative to the rail 20'. Worm 50a and worm gear 50b of the set of gears 50 may be configured to provide gear reduction of the motor so as to reduce the speed at which the motor output 46 rotates while increasing the torque at which the output rotates.
[0047] In some embodiments (not shown), other gear configurations may be used to modify the speed and torque of the motor output 46. For example, the embodiment shown, including worm 50a and worm gear 50b may be described as single pass gears. Single pass gears are generally cheaper and easier to assemble. However, it will be appreciated that double pass gears, as well as higher order pass gears may be used. Embodiments with double pass and higher order pass gears may further employ a worm in place of a pinion and a rack configured to mesh with the worm.
[0048] As motor 44 actuates pinion 60 along rack 22, bearings, such as bearings 61, 62, 63, 64 - ride in and guide assembly 40 relative to rail 20 (described in part above). Bearings rotatably coupled to the gearbox 42 and motor 44 function to guide the integrated carriage assembly 40 within the at least one recess 25 of the rail 20. Some bearings may also support the weight of the integrated carriage assembly 40 and chair 100 against the rail 20, 20'.
[0049] Bearing 61, including its bearing surface 61a, may be secured to shaft 52 of gearbox 42. Specifically, bearing 61 may be secured to shaft 52 such that pinion 60 and bearing
61 rotate about the pinion axis (parallel to axis A). Bearing 61 may be fixedly attached to or integrally formed with shaft 52 such that bearing 61, shaft 52, and pinion 60 are all configured to rotate at the same angular velocity. Alternatively, bearing 61 may be rotatably attached to shaft 52 such that bearing 61 freely rotates independently from the rotation of shaft 52 and pinion 60. Bearing 61 may be fixedly or rotatably attached directly to pinion 60 instead of shaft 52.
Bearing 61 may be configured to have a diameter that is substantially equal or equal to the pitch diameter of the pinion. When bearing 61 has a diameter that is substantially equal or equal to the pitch diameter of the pinion, rack 22 and rack bearing surface 28 may be configured to correspond to the pinion 60 and bearing 61, such that pinion 60 and bearing 61 rotate at the same angular velocity and rotational speed. As described above, during operation, bearing 61, including bearing surface 61a, rotates within channel 25c, such that bearing surface 61a rotates along surfaces 28, 30, along the pinion axis (parallel to axis A). When bearing surface 61a contacts bearing surface 34, bearing 61 may be weight bearing, such that bearing 61 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
[0050] Bearing 62, which includes a bearing surface 62a, is rotatably secured to gearbox 42 on the opposite side of the gearbox 42 from bearing 61. As described above, bearing 62, including bearing surface 62a, rotates within channel 25d, such that bearing surface 62a rotates along surfaces 34, 36, along an axis of rotation that is parallel to or identical to the pinion axis (and axis A). Like bearing 61, when bearing surface 62a contacts bearing surface 34, bearing 62 may be weight bearing, such that bearing 62 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20. Bearings 61, 62 may rotate about the same axis.
[0051] Bearing 63, which includes a bearing surface 63a, is rotatably secured to gearbox 42. As described above, bearing 63, including bearing surface 63 a, rotates along surface 37 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
[0052] Bearing 64, which includes a bearing surface 64a, is rotatably secured to gearbox 42 on the opposite side of gearbox 42 from bearing 63. As described above, bearing 64, including bearing surface 64a, rotates along surface 32 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
[0053] Bearing 65, which includes a bearing surface 65a, is rotatably secured to motor
44 on the opposite end of the integrated carriage assembly 40 from bearing 61. Like bearing 61, bearing 65, including bearing surface 65a, including bearing surface 65a, rotates within channel
25c, such that bearing surface 65a rotates along surfaces 28, 30, about an axis that is parallel to the pinion axis (and axis A). Like bearings 61, 62, when bearing surface 63a contacts bearing surface 34, bearing 63 may be weight bearing, such that bearing 63 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
[0054] Bearing 66, which includes a bearing surface 66a, is rotatably secured to motor 44 on the opposite side of the motor 44 from bearing 65 and on the opposite end of the integrated carriage assembly 40 from bearing 62. Like bearing 62, bearing 66, including bearing surface 66a, within channel 25d, such that bearing surface 66a rotates along surfaces 34, 36, about an axis that is parallel to the pinion axis (and axis A). Bearings 65, 66 may rotate about the same axis. Like bearings 61, 62, 65, when bearing surface 66a contacts bearing surface 34, bearing 66 may be weight bearing, such that bearing 66 supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
[0055] Bearing 67, which includes a bearing surface 67a, is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40 from bearing 63. Like bearing 63, bearing 67, including bearing surface 63 a, rotates along surface 37 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T).
[0056] Bearing 68, which includes a bearing surface 68a, is rotatably secured to motor 44 on the opposite side of the motor 44 from bearing 67 and on the opposite end of the integrated carriage assembly 40 from bearing 64. Like bearing 64, bearing 68, including bearing surface 68a, rotates along surface 32 about an axis of rotation that is perpendicular to the pinion axis (parallel to axis T). Thus, rail 20 forms an upwardly open C-shape, with recess 25 providing space for integrated carriage assembly 40 to pass through, a rack surface that extends from a lower surface of the floor of rack 20 to which rack 22 is affixed, a pair of inwardly opening channels 25c and 25d to receive and guide horizontally oriented bearings 61 and 62 of assembly 40, and a pair of inwardly facing edges 32 and 37 to receive and guide vertically oriented bearings 63 and 64 of assembly 40.
[0057] The second embodiment of stair lift assembly 10 shown in Figs. 1, 7A-10D includes rail 20' having a rail body 20a' that defines at least one recess, such as recess 25'. Recess 25' may include a lower portion 25b' having a depth that is configured to fit at least a portion of a gearbox 42 of the integrated carriage assembly described in greater detail below.
[0058] Rail 20' includes a rack 22' that is configured to mesh with a pinion 60 of the integrated carriage assembly 40'. Rack 22' may extend the length of rail 20' parallel axis L. Rack 22' includes teeth 24' that extend outward along the axis A from axis L.
[0059] A rack bearing surface 28' also extends parallel to the longitudinal axis such that the rack bearing surface 28' and the rack 22' extend parallel to one another. The rack bearing surface 28' may be substantially flat and smooth and configured to accommodate a bearing 61 ' on the integrated carriage assembly.
[0060] The rack 22' and rack bearing surface 28' may be formed integrally to provide increased manufacturing accuracy. Increased manufacturing accuracy reduces the noise created as the pinion 60 and bearing 62' rotate along the rack 22' and rack bearing surface 28'.
Additionally, increased manufacturing accuracy also increases the strength and durability of the rack 22' and rack bearing surface 28'.
[0061] Individual segments 27 include portions of the rack 22' and rack bearing surface 28' that have been integrally formed. An exemplary segment 27 is shown in Fig. 9D with pinion 60. Segments 27 may be separately secured to the rail 20' during installation of the stair lift assembly 10. For example, as shown in Fig. 8B, rail body 20a' may define a recess 21, such as a dovetail shaped recess configured to fit a lower portion of segments 27, such as a dovetail shaped lower portion. Recess 21 may be part of recess 25' or may be separate from recess 25'. In the embodiment shown, recess 21 may in part be defined by a bottom portion 21a of the rail body 20a', such as a relatively flat bottom portion that extends the approximate length of the rail 20' parallel to the longitudinal and lateral axis, as well as rack bearing surface 28'. The recess 21 may further be defined by side portions 21b of the rail 20 that extend out from the bottom portion 21a parallel to the lateral axis. Top portions 21c, such as diagonally shaped top portions extend laterally and transversely toward each other. Segments 27 may each include a corresponding bottom surface 27a, side portions 27b, and top portions 27c that slidably fit within recess 21, secured by top portion 21c extending over top portion 27c. During assembly, after rail 20' is secured to the stairway, rack and rack bearing surface segments 27 may be slid into recess 21 to form the rack 22' and rack bearing surface 28'. Segments 27 may have a length that is a fraction of the total length of the rail 20'. For example, segments 27 may be approximately 6 to 8 inches in length. Other embodiments of the recess 21 and segment 27 (not shown) may have different cross sectional configurations. For example, side portions 21b, 27b and top portions 21c, 27c, may be asymmetrical or symmetrical, respectively.
[0062] The dovetailed configuration described above in relation to rail 20' may also be applied to rail 20. For example, rack 22 may have a lower portion with a dovetail configuration (not shown) that corresponds to a dovetail-shaped recess in rail body 20a (not shown). Rack 22 may also be partitioned into segments (not shown). After rail 20 is secured to the stairway, rack 22 (or portions thereof) may be slid into the dovetail shaped recess. Alternatively, other cross- sectional configurations of the rail body 20a and rack 22 may be used. [0063] Returning to the second embodiment, as shown in Figs. 8B, 9A, recess 25' may include two channels 25c', 25d'. Channels 25c', 25d' may be at least partially defined by bearing surfaces, such as bearing surfaces 28', 30', 32', 34', 36'. Bearing surfaces 28', 30', 32', 34', 36' extend parallel to axis L and are substantially flat and smooth. Channels 25c', 25d' accommodate bearings of the integrated carriage assembly 40', such as bearings 61 ', 62', 63', 64', as described in more detail below. For example, as shown in Fig. 8B, bearing surface 30' may extend parallel to and opposing rack bearing surface 28' along the length of the rail 20'. Bearing surface 32' also extends along the length of the rail, between and perpendicular to surfaces 28', 30'. Together, surfaces 28', 30', 32' form channel 25c' in which bearings 6 , 64' (shown in Fig. 9 A) rotate. As described in detail below, bearing 61 ' is configured to rotate against surfaces 28', 30', while bearing 64' is configured to rotate against surface 32'.
[0064] Bearing surfaces 34', 36' also extend along the length of the rail, parallel to surfaces 28', 30' and axis L so as to form channel 25d' that accommodates the rotation of bearing 62'. As described in detail below, channels 25c', 25d' may be configured such that bearings 61 ', 62' may rotate about the same axis of rotation or may rotate about different axis that are parallel and disposed the same distance along the lateral axis from the longitudinal axis. Channel 25d' is depicted in Fig 8A with a curved surface extending in between surfaces 34', 36'. Alternate configurations may include a flat, smooth surface that extends between surfaces 34', 36', such as surface 32' of channel 25c'.
[0065] Bearing surface 37' may also extend along the length of the rail 20' and parallel to the axis A, so as to be perpendicular to bearing surfaces 28', 30', 32', 34'. Bearing surface 37' may in part define recess 25b'. As shown in Fig. 9A, bearing surface 37' is configured to contact bearing 63 ' .
[0066] While set of gears 50 is not shown in relation to cross-sectional views of integrated carriage assembly 40', the gears 50a, 50b of integrated carriage assembly 40 described in relation to Figs. 6A, 6B of the first embodiment are substantially the same as those in integrated carriage assembly 40' (shifted shifted 90° about the L axis). Specifically, in integrated carriage assembly 40' motor output 46 is configured to rotate about a motor output axis that is parallel to the axis L. Motor output 46 is coupled to a worm 50a that also rotates about the motor output axis. Worm 50a is in meshed communication with a worm gear 50b that rotates about a pinion axis that is perpendicular to the motor output axis and parallel to transverse axis T
(because carriage assembly 40 is shifted 90° from what is shown in the cross sectional views in
Figs. 6A, 6B). Shaft 52 extends from the worm gear 50b along the pinion axis to a second end
52b and is configured to rotate about the pinion axis as motor 44 drives the motor output 46. As motor 44 drives motor output 46 about the motor axis, pinion 60 rotates about the pinion axis. As indicated in relation to the first embodiment, pinion 60 and shaft 52 may be formed integrally as a single piece. Pinion 60, bearing 61 ' and shaft 52 may also be formed integrally as a single piece.
[0067] Bearings, such as bearings 61 ', 62', 63', 64', in part described above, may be rotatably coupled to gearbox 42 and motor 44'. Bearings rotatably coupled to the gearbox 42 and motor 44' function to guide the integrated carriage assembly 40' within the at least one recess 25' of the rail 20'. Some bearings may also support the weight of the integrated carriage assembly 40' and chair 100 against the rail 20'.
[0068] Bearing 6 , including its bearing surface 61a', may be secured to shaft 52 of gearbox 42. Specifically, bearing 61 ' may be secured to shaft 52 such that pinion 60 and bearing 61 ' rotate about the pinion axis (parallel to axis T). Bearing 61 ' may be fixedly attached to or integrally formed with shaft 52 such that bearing 6 , shaft 52, and pinion 60 are all configured to rotate at the same angular velocity. Alternatively, bearing 61 ' may be rotatably attached to shaft 52 such that bearing 61 ' freely rotates independently from the rotation of shaft 52 and pinion 60. Bearing 61 ' may be fixedly or rotatably attached directly to pinion 60 instead of shaft 52. Bearing 61 ' may be configured to have a diameter that is substantially equal or equal to the pitch diameter of the pinion. When bearing 61 ' has a diameter that is substantially equal or equal to the pitch diameter of the pinion, rack 22' and rack bearing surface 28' may be configured to correspond to the pinion 60 and bearing 61 ', such that pinion 60 and bearing 61 ' rotate at the same angular velocity and rotational speed. As described above, during operation, bearing 61 ', including bearing surface 61a', rotates within channel 25c', such that bearing surface 61a' rotates along surfaces 28', 30', along the pinion axis (parallel to axis T).
[0069] Bearing 62', which includes a bearing surface 62a', is rotatably secured to gearbox 42 on the opposite side of the gearbox 42 from bearing 61 '. As described above, bearing 62', including bearing surface 62a', rotates within channel 25d', such that bearing surface 62a' rotates along surfaces 34', 36', along an axis of rotation that is parallel to or identical to the pinion axis (and axis T).
[0070] Bearing 63', which includes a bearing surface 63a', is rotatably secured to gearbox 42. As described above, bearing 63 ', including bearing surface 63a', rotates along surface 37' about an axis of rotation that is perpendicular to the pinion axis (and axis T).
[0071] Bearing 64', which includes a bearing surface 64a', is rotatably secured to gearbox 42. As described above, bearing 64', including bearing surface 64a', rotates along surface 32', within channel 25 d' about an axis of rotation that is perpendicular to the pinion axis (and axis T). When bearing surface 64a' contacts bearing surface 32', bearing 64' may be weight bearing, such that bearing 64' supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
[0072] Bearing 65', which includes a bearing surface 65a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 61 '. Like bearing 61 ', bearing 65', including bearing surface 65a', rotates within channel 25c', such that bearing surface 65a' rotates along surfaces 28', 30', along the pinion axis (parallel to axis T).
[0073] Bearing 66', which includes a bearing surface 66a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 64'. Like bearing 64', bearing 66', including bearing surface 66a', rotates along surface 32' about an axis of rotation that is perpendicular to the pinion axis (and axis T). Like bearing 64', when bearing surface 66a' contacts bearing surface 32', bearing 66' may be weight bearing, such that bearing 66' supports at least part of the gravitational force of the chair 100 and integrated carriage assembly against the rail 20.
[0074] Bearing 67', which includes a bearing surface 67a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 63'. Like bearing 63 ', bearing 67', including bearing surface 63a', rotates along surface 37' about an axis of rotation that is perpendicular to the pinion axis (and axis T).
[0075] Bearing 68', which includes a bearing surface 68a', is rotatably secured to motor 44 on the opposite end of the integrated carriage assembly 40' from bearing 62' and the opposite side of the motor from bearing 65'. Like bearing 62', bearing 68', including bearing surface 68a', rotates within channel 25d', such that bearing surface 68a' rotates along surfaces 34', 36', along an axis of rotation that is parallel to the pinion axis (and axis T).
[0076] For the two embodiments described in relation to the figures, chair 100 and bearings, such as bearings 61-68, 6Γ-68' may all be mounted directly to the integrated carriage assembly 40, 40' By mounting chair 100 and bearings 61-68, 6Γ-68' directly to the gearbox 42 and motor 44, respectively, integrated carriage assembly 40, 40' may have a lower profile configuration relative to the rail compared to a configuration with bearings mounted to a housing to encloses the gearbox and motor. Specifically, by mounting bearings 61-68, 6Γ-68' to gearbox 42 and motor 44, respectively, gearbox 42 and motor 44 may be configured to at least partially fit within recess 25 such that at least a portion of the rail and at least a portion of the gearbox 42 and/or motor 44 overlap in relation to axis T (in the first embodiment) or the A axis
(in the second embodiment) such that gearbox 42 and motor 44 are moveably nested within recess 25, 25' of rail body 20a, 20a'. By mounting of the chair 100 and bearings 61-68, 6Γ-68' to the gearbox 42 and motor 44, respectively, gearbox 42 and motor 44 provide structural support to the carriage assembly. Specifically, gearbox 42 and motor 44 are configured to bear the weight of the chair 100 against the rail 20, 20'. The bearings may be made from high molecular weight plastic, self-lubricating materials, bearing materials, or any other suitable material. While bearings 61-68, 61 '-68' are described herein as rotating about axes that are parallel to either axis A or axis T, other axial rotations are contemplated. For example, any of bearings 61-68, 61 '-68' may be configured so as to rotate about an axis that is not parallel to axis A or axis T, such as an axis that is at a 45° to both axis A and axis T.
[0077] Chair 100 may have multiple configurations. In the embodiments shown in Figs. 1, 2A, 7A, Chair 100 includes a seat 102 that extends in a plane perpendicular to the gravitational force G. Back support 104 extends up from the seat 102 in a direction opposite to force G. Foot rest 106 extends in a plane that is parallel to the plane of the seat and down from the seat in direction G. Chair 100 is configured to accommodate a person using the stair lift assembly. For example, chair 100 may be configured to accommodate a person having a body weight of 80 to 300 pounds. Alternatively, chair 100 may be configured to accommodate a wider weight range.
[0078] The forgoing descriptions are not intended to be limiting in terms of its exact configuration. The stair lift assembly 10 described in relation to the first and second
embodiments may be modified for different applications. For example, while the first and second embodiments are described in relation to a stairway, wherein the first and second heights FH, SH are different, stair lift assembly 10 may be used in applications where first and second heights are substantially similar. Specifically, stair lift assembly 10 may move substantially horizontally in relation to the first height.

Claims

What is Claimed:
1. A drive system comprising:
an integrated carriage system having:
a motor having a motor output configured to rotate about a first axis of rotation; at least one set of gears coupled to the motor output;
a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation so as to mesh with rack teeth of a rack and move the pinion relative to the rack in a first direction; and
a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis, wherein the first bearing surface is configured to rotate along a rack bearing surface in a second longitudinal direction that is substantially parallel to the first longitudinal direction.
2. The drive system of claim I, further comprising the rack and the rack bearing surface.
3. The drive system of claim 1 , further comprising a rail that includes the rack and the rack bearing surface.
4. The drive system of claim I, wherein the pinion has a pitch diameter and the first bearing surface has a diameter and the pitch diameter and the diameter are approximately equal.
5. The drive system of claim 4, wherein the pinion and first bearing surface are configured to rotate at the same angular velocity.
6. The drive system of claim 5, the integrated carriage assembly further comprising a second bearing having a second bearing surface.
7. The drive system of claim 6, wherein the second bearing surface is configured to rotate about a third axis.
8. The drive system of claim 7, wherein the second axis is substantially collinear with the third axis.
9. The drive system of claim 6, the integrated carriage assembly further comprising a third bearing having a third bearing surface that is configured to rotate about a fourth axis.
10. The drive system of claim 9, wherein the second axis is substantially perpendicular to the fourth axis.
1 1. The drive system of claim 1 , wherein the first axis and the second axis are substantially perpendicular.
12. An integrated carriage and rail assembly comprising:
an integrated carriage including:
a motor, having a motor output configured to rotate about a first axis of rotation;
at least one set of gears coupled to the motor output;
a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation; and
a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis;
a rail capable of being affixed relative to stairs, the rail including:
a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail;
a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
13. The integrated carriage and rail assembly of claim 12, wherein the pinion has a pitch diameter and the first bearing surface has a diameter and the pitch diameter and the diameter are approximately equal.
14. The integrated carriage and rail assembly of claim 12, further comprising a second bearing having a second bearing surface.
15. The integrated carriage and rail assembly of claim 14, wherein the second bearing surface is configured to rotate about a third axis that is substantially collinear with the second axis.
16. The integrated carriage and rail assembly of claim 14, further comprising a third bearing having a third bearing surface that is configured to rotate about a fourth axis that is substantially perpendicular to the second axis.
17. The integrated carriage and rail assembly of claim 12, wherein the first axis and the second axis are substantially perpendicular.
18. The integrated carriage and rail assembly of claim 12, wherein the rack bearing surface is flat.
19. A drive system comprising:
an integrated carriage assembly including:
a motor, the motor having a motor output configured to rotate about a first axis of rotation;
a gearbox mounted to the motor;
at least one set of gears rotatably fixed directly to the housing, a first gear of the at least one set of gears coupled to the motor output and configured to rotate about the first axis, and a second gear of the at least one set of gears configured to rotate about a second axis that is perpendicular to the first axis;
a pinion having pinion teeth, the pinion coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about the second axis; and
a first set of bearings, rotatably fixed to the motor; and
a second set of bearings, rotatably fixed to the gearbox.
20. The drive system of claim 19, wherein the pinion has a pitch diameter and at least one of the second set of bearings has a bearing surface diameter that is approximately equal to the pitch diameter.
21. The drive system of claim 20, wherein the pinion and first bearing surface are configured to rotate at the same angular velocity.
22. The drive system of claim 20, further including a rail having a length along the first axis and a height along a third axis, the third axis being perpendicular to the first axis and the third axis, the rail further including a rail body that defines a recess that extends within the length and height of the rail, the gearbox and motor being at least partially disposed within the recess.
23. The drive system of claim 20, further including a rail having a length along the first axis and a width along a third axis, the third axis being perpendicular to the first axis and the third axis, the rail further including a rail body that defines a recess that extends within the length and width of the rail, the gearbox and motor being at least partially disposed within the recess.
24. The drive system of claim 20, further including a seat having a weight that is at least partially supported by the gearbox and motor.
25. A stair lift assembly comprising:
a seat configured to at least in part support the weight of an adult human user; an integrated carriage, coupled to the seat and including:
a motor, having a motor output configured to rotate about a first axis of rotation;
at least one set of gears coupled to the motor output;
a pinion having pinion teeth and coupled to the at least one set of gears and configured to be driven by the motor so as to rotate about a second axis of rotation; and
a first bearing coupled to the pinion and having a first bearing surface that rotates with the pinion about the second axis;
a rail configured to be affixed relative to stairs to guide motion of the carriage and including:
a rack having rack teeth that are configured to mesh with the pinion teeth of the pinion such that as the pinion rotates about the second axis, the pinion moves in a first direction relative to the rack such that the carriage also moves in the first direction relative to the rail; and
a rack bearing surface extending substantially parallel to the rack such that as the first bearing rotates about the second axis, the first bearing moves in a second direction relative to the rack that is substantially parallel to the first direction.
26. The stair lift assembly of claim 25, wherein the pinion has a pitch diameter and the first bearing surface has a diameter and the pitch diameter and the diameter are approximately equal.
27. The stair lift assembly of claim 25, the integrated carriage further comprising a second bearing having a second bearing surface, wherein the second bearing surface is configured to rotate about a third axis.
28. The stair lift assembly of claim 25, wherein the second axis is substantially perpendicular to the third axis.
PCT/US2013/026380 2012-02-02 2013-02-15 Stair lift drive system WO2013116877A2 (en)

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US201261599569P 2012-02-02 2012-02-02
US61/599,569 2012-02-02

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Publication number Priority date Publication date Assignee Title
JP5837663B1 (en) * 2014-09-19 2015-12-24 シンテックス株式会社 Stair lift system and stair lift
CN107324184A (en) * 2017-07-08 2017-11-07 李习勇 A kind of inexpensive corridor apparatus for ride instead of walk
US20220259011A1 (en) * 2019-07-09 2022-08-18 Stannah Stairlifts Limited Improvements in or relating to stairlifts

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US5230405A (en) * 1991-11-13 1993-07-27 Michael Roman Bruno Stairway chairlift device
US20060288515A1 (en) * 2004-03-02 2006-12-28 Hutton Kenneth M Sootblower frame assembly
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Publication number Priority date Publication date Assignee Title
DE2901422A1 (en) * 1979-01-15 1980-07-31 Franz Anker Home lift for invalids - travels up and overhangs stairs and is supported from wall
US5230405A (en) * 1991-11-13 1993-07-27 Michael Roman Bruno Stairway chairlift device
US20060288515A1 (en) * 2004-03-02 2006-12-28 Hutton Kenneth M Sootblower frame assembly
US7281607B1 (en) * 2005-03-10 2007-10-16 King Tool & Manufacturing Company, Inc. Elevating device

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5837663B1 (en) * 2014-09-19 2015-12-24 シンテックス株式会社 Stair lift system and stair lift
CN107324184A (en) * 2017-07-08 2017-11-07 李习勇 A kind of inexpensive corridor apparatus for ride instead of walk
US20220259011A1 (en) * 2019-07-09 2022-08-18 Stannah Stairlifts Limited Improvements in or relating to stairlifts

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