Zhejiang Sankai Mechanical and Electrical Co., Ltd

Variator

What is Variator

 

 

A variator itself is the main driving part of a continually variable transmission (CVT). Where a gearbox has gears, each with a fixed gear radio, a CVT smoothly transitions through its gearing range.The variator is a small, metal component that acts as the driving force between your car's engine and its transmission. It changes gears by spinning slightly faster or slower than other components in order to keep them matched up with each other.

 

Advantages of Variator

Fuel Efficiency

Unlike typical automatics, the CVT can change the gear ratio forever to maintain the engine running at peak efficiency. On the whole, the more gears offered in a typical automatic transmission, the better engine power is optimized. Even the most advanced traditional transmissions are topping out at 10 gears, while the CVT has an infinite quantity of combinations leading to much better gas economy.

Much Less Weight

While it's not an universal truth, normally CVT transmissions are typically more lightweight and smaller sized than a conventional automatic transmission. CVTs occupy much less room and also weigh less than their conventional equivalents.

 

 

 

Easier, Not as Expensive Design

Conventional automatic transmissions are extremely complicated and also can have hundreds of moving parts. CVTs contain a much simpler design which means that they are less complicated, much faster to assemble, and cost much less resources to make.

 

 

Velvety Performance

Considering that they are not bound by a static setup, a CVT has the capability to adapt to your driving demands as well as the roadway conditions. There is no ‘hunting for gears' in a CVT, the onboard computer system remains in the perfect/exact spot for effectiveness and power. Regardless of the circumstance, driving is smooth and constant because it doesn't actually ‘shift'.

Why Choose US

 

 

Our Factory
Zhejiang Sankai Machine and Electric Co.,Ltd is an integrative and professional manufacturer of power transmission device, which specialize in scientific research, production and marketing.

 

Innovation
Adopting advanced detecting equipment and means, company establishes a quality control system that is in accordance with 1S0900 I: 2015. Products are sold all over the country, exporting to Southeast Asia, Europe, America and other regions. Sankai will continue, as we always do, to strive to become a leader of power transmission industry.

 

Our Products
Our company specialize in High Precision Planetary Gearbox, NMRV series Worm Gearbox, UDL series Stepless Speed Variator, SRC series Helical Gearbox, SKM series Helical-Hypoid Gearbox, Precision Gearbox for Robot Arm and PC Helical Gear Unit.

 

Quality services
Sincerely Sankai determine to provide service of better quality, in-time and fast reply to our clients. And Sankai is looking forward to cooperating with domestic and foreign friends and grow together with our hard work and professionalism.

 

Stepless Speed Variators

 

Features of Variator

●The voice is low, and there is no vibration when running.
●High efficiency, can rotate in both directions.
●High adjustment accuracy: up to 0.5-1 revolution.
●Speed regulating handwheels can be installed on both sides of the motor as needed.
●Gear housing material: aluminum alloy.
●Gear housing coating: RAL5010 blue or silver epoxy paint.
●There are a total of 12 models to choose from, with power from 0.18kW to 7.5kW.
●Fully enclosed mechanical speed change, which can be applied to wet, dusty and slightly corrosive working environment.
●Strong combination ability, can be combined with various types of reducers to achieve low speed, large torque gauge speed effect.

 

Parts of a Variator

Slider: It is a metallic cylinder on which the variator rests and fixes it for its correct operation.
Pulley: Part in contact with the scooter drive belt.
Masses or rollers: Counterweights responsible for the operation and opening of the variator. The lighter the weight, the later the opening and the higher the acceleration. The heavier the weight, the earlier the opening and the higher the top speed.
Ramp or bell: Internal part of the drive on which the masses or rollers slide, depending on the type of drive.
Grease only on certain models: Only conventional drives use grease to lubricate and reduce friction between the pin and drive.
In any type of variator, we will find that the pulley is in direct contact with the belt and this is delimited by a semi-pulley that guides it.

Automatic Speed Variator

 

The Difference Between CVT and Stepped Transmission

 

 

Continuously variable transmission and has the distinction of class type is, its transmission ratio is not constant, but a series of continuous values, for example, from 3.455 to 0.85 has been changed.
CVT has the advantages of simple structure, smaller volume than traditional transmission, many gears it is neither a manual transmission, no planetary gear set automatic transmission is complex, it brought from the wheel and metal to realize stepless change ratio on the Lord, the main.
The principle is the same with the common gearbox size groups of gear does not have a control in the next, the formation of different ratio, like bicycle pedal diameter wheel and chain drives the wheels to rotate at different speeds. Due to different strength of the thrust of each gear is not one, the transmission output speed changes, so do not divide class slow rotation.
CVT uses the drive belt and variable width ratchet for power transmission, namely when the ratchet wheel change groove width corresponding elbow, change the drive wheel and the driven wheel transmission contact radius of belt transmission, the transmission belt generally with the rubber belt, metal belt and the metal chain. CVT is the real stepless, it has the advantages of light weight, small size, less parts, operating efficiency compared with AT has higher, low fuel consumption.
CVT transmission system, the traditional gear by a pair of pulleys and a steel belt replaced, each block is V structure is composed of two conical disc, engine shaft is connected through a small pulley, steel belt drive pulley. The trick in this special pulley: drive pulley structures CVT strange activity, divided into halves, can be close to or separate relative. Conical disk can be tightened or opening in the thrust hydraulic, extrusion chain steel sheet in order to regulate V groove width.
When the cone disc to the medial mobile tighten, chain steel piece in extrusion cone disc to center outside of the direction of movement (centrifugal direction), contrary to the center, power transmission.

 

The Working Principle of Stepless Speed Variator
Stepless Speed Variators
Automatic Speed Variator
Stepless Speed Variators
Automatic Speed Variator

No specific gear, which operate on similar automatic gearbox, gear jump process but the ratio changes were different from automatic gearbox, but a continuous, so the continuous and smooth power transmission. The CVT technology is continuously variable transmission technique, it uses the drive belt and variable diameter main, from the wheel matched to transfer power, continuously changing transmission ratio can be achieved, so as to get the best match of transmission and engine condition. CVT common hydraulic mechanical stepless speed changer and the metal belt cvt.
V type rubber belt, metal belt, multi disc, ball, roller rotating and other structures, mostly using roller transmission power metal band and variable radius. Through the change the active roller and the passive roller radius, to change gear ratio. The theory on the efficiency of the transmission is very high, but must be based on the power transfer load case. Because it is the use of friction between the strip and roller to transmit power, so the working condition of steel strip and roller is very harsh.
In order to effectively transfer the power, allowing no slippage between strip and roller, and the heat was generated a lot, if slippage might be made internal parts burned or serious loss. In order to increase the static friction force, the most direct way is added between the strip and roller pressure. But the friction increases, power transmission loss will increase, intangible or increase fuel consumption. And strip strength is also a key. So the CVT gearbox with high efficiency and energy saving advantage of comfort, etc.. Drawback is that the CVT gearbox generally can't bear large torque. Otherwise is to compensate for higher fuel consumption.
Stepless speed regulator and has the distinction of class type is, its transmission ratio is not constant, but a series of continuous values, for example, from 3.455 to 0.85 has been changed. CVT has the advantages of simple structure, smaller volume than traditional transmission, many gears it is neither a manual transmission, no planetary gear set automatic transmission is complex, it brought from the wheel and metal to realize stepless change ratio on the Lord, the main.
The principle is the same with the common gearbox size groups of gear does not have a control in the next, the formation of different ratio, like bicycle pedal diameter wheel and chain drives the wheels to rotate at different speeds. Due to different strength of the thrust of each gear is not one, the transmission output speed changes, so do not divide class slow rotation.
CVT uses the drive belt and variable width ratchet for power transmission, namely when the ratchet wheel change groove width corresponding elbow, change the drive wheel and the driven wheel transmission contact radius of belt transmission, the transmission belt generally with the rubber belt, metal belt and the metal chain. CVT is the real stepless, it has the advantages of light weight, small size, less parts, operating efficiency compared with AT has higher, low fuel consumption. But the disadvantage of CVT is obvious, is the drive belt is easily damaged, can not bear the heavy load, only used in the 1 liter or so low power and low torque motors, so in possession of automatic transmission rate is about 4% below. In recent years, to study the major car companies, the situation has improved. CVT will be the development direction of automatic transmission.
CVT transmission system, the traditional gear by a pair of pulleys and a steel belt replaced, each block is V structure is composed of two conical disc, engine shaft is connected through a small pulley, steel belt drive pulley. The trick in this special pulley: drive pulley structures CVT strange activity, divided into halves, can be close to or separate relative. Conical disk can be tightened or opening in the thrust hydraulic, extrusion chain steel sheet in order to regulate V groove width. When the cone disc to the medial mobile tighten, chain steel piece in extrusion cone disc to center outside of the direction of movement (centrifugal direction), contrary to the center, power transmission

 

Stepless Speed Variators

 

Precautions for Using Variator

●Gear gearbox under normal operating conditions and wear,tooth surface showing uniform wear, requirements along the direction of tooth wear should not exceed the original tooth long thirty percent; tooth thickness should not exceed 0.40; the tooth surface of gear meshing area of not less than 2/3; operation of the gear meshing clearance in general should be 0.15-0.26mm, uselimit is 0.80mm; engaging gear meshing clearance should be 0.10-0.15mm, available for the 0.60mm. dial indicator or soft metalfriction measurement using limit. If more than the gap, should bereplaced in pairs.
●Gear tooth broken tooth broken, is mainly due to the gear meshing clearance meshing parts do not meet the requirements,improper or work under shock load caused by large. If the tooth edge slightly broken is not more than 2mm, continue to use theavailable oilstone grinding; if more than the scope or more than 3tiny broken, it should be replaced in pairs.
●A constant mesh gear face wear bevel face constant meshshould be.10-0.30mm of the axial clearance, to ensure that the gear in good operation, if the tooth abrasion, grinding can berepaired, but the grinding amount should not exceed.50mm.
●A constant mesh gear axle neck, the needle roller bearing andseat hole wear into the gear seat hole and needle roller bearing and shaft neck three gap should be 0.01-0.08mm with, or should be replaced.

 

How to Replace the Components of the Variator

To perform the maintenance of the variator, it is necessary to have the necessary tools and tools.
How to change the rollers?
To change the rollers, just remove the bell and the old masses and put the new ones in their place. Remember that you can play with adjusting the weight of the rollers to obtain the result that best suits your needs.
Once the rollers have been replaced, they need an adaptation period (between 200 and 300km) where the rollers will wear out in order to be properly coupled to the variator.

How to change a bushing?
To change the variator bushing, it is necessary to heat the body with a heat gun up to approximately 160ºC. Once hot, proceed to remove the worn bushing with caution and always wearing gloves to avoid burns.
Heat the variator body to 160ºC again and insert the new bushing in its place. Once in place, allow the variator to cool down so that the bushing is securely in place.
Never use lubricants, grease or sharp objects to service the variator.

Stepless Speed Variators

 

How Often Should Service a Variator

 

As with other components, the maintenance of the variator will have to be in accordance with the conditions and treatment given to the motorcycle. If we do a sporty driving, we enter a circuit with the bike and the weight of which must pull the bike is high, it is more likely that maintenance should be performed before if the scooter is used for urban use or highways.
For this same reason, we recommend that the variator be serviced every oil change (approximately every 4,000 km, depending on the model of the motorcycle).

 

The rollers
They are the element that suffers more wear compared to the rest. It is very easy to identify when we must replace the rollers of the variator, since when riding the bike we will notice that the bike revs up but lacks thrust or that the power has decreased.
In a visual inspection, we will observe that the end of the rollers has been flattened by the friction with the bell of the variator, leaving the hole located at the end of the roller out of sight. In this way, by looking at the wear indicator, we will know the remaining life of our rollers.

 

Wear-indicator
Under normal conditions, it is estimated that the rollers should be changed approximately every 2 oil changes of our scooter.
Attention: Placing rollers of a length that does not correspond does not exempt us from the maintenance of this component. This will only result in a loss of top speed.

 

The bushing
It is the element that withstands the most friction and in turn ensures the correct operation of the variator.
To identify if the bushing of our variator must be replaced, we must pay attention to the tolerance or clearance between the slider and the bushing. If it is greater than 0.2mm, the bushing must be replaced by a new one.
It is estimated that the bushing should be changed approximately every 4 oil changes (about 16,000km).

 

The slider
The slider should only be replaced by a new one if the outer walls of the slider are damaged. To do this, carry out a visual inspection of the condition of the slider or check the tolerance between the slider and the new bushing.

 

The belt
Inspecting the tension of the drive belt will indicate belt wear. This is especially important on the ranges, as it can withstand more power than the standard belt.
If a is fitted, the belt must always be replaced with the original or with the same specifications as indicated by the manufacturer.

 

 
FAQ
 
 

Q: What is a speed variator?

A: Speed variators are electronic devices that allow speed and torque of three-phase induction motors to be varied. The speed variator developed by SUPSONIK, S.L. Is a voltage and frequency converter that generates a nearly constant rotational magnetic flow in the air gap of the induction motor.

Q: How does a mechanical speed variator work?

A: The mechanical variable speed transmission system is based on the transfer of power, by friction, beetween a moving part (moved by the control speed), drive and driven shafts.

Q: What is the mechanism of a variator?

A: The variator has a driving cone, which is rotated manually by means of a handle (via an additional gear transmission), and a driven cone to which the rotation is transmitted. A belt made of elastic material is wrapped over the two cones and transfers mechanical energy as a result of frictional forces.

Q: What does a high speed variator do?

A: A variator is the front, or driven part of the CVT. This is the part that controls the progression of the variator (forcing the gearing ratio down, meaning higher speed).

Q: How do you know if your variator is bad?

A: The variator rollers will also wear with time and develop flat spots – at which point they must also be replaced. Worn rollers will adversely affect performance and cause jerky acceleration. A rattling sound coming from your scooter is also often a sign that they need replacing.

Q: How does a variator work?

A: As the variator slides closer to the front pulley it applies pressure to the drive belt that sits in between the angled faces of the front pulley half and the variator so that it forces the belt out to a higher gear ratio. This is the basic operation of the front pulley.

Q: How does a mechanical motorcycle speedometer work?

A: When the engine turns over, the driveshaft turns to make the wheels spin round. The speedometer cable, powered by the driveshaft, turns as well. The cable spins a magnet around at the same speed inside the speed cup. The magnet rotates continually in the same direction (in this case, counter-clockwise).

Q: What are variator rollers?

A: In this type of variator, the rollers move longitudinally (rolling) to open or close the variator and transfer the motor power to the drive system. The rollers run on ramps located inside the variator.

Q: What is the difference between variator roller and slider?

A: Roller weights are cylindrical, or round if you look at them from the side. Slider weights have their own unique shape that is designed in an effort to improve performance and reduce wear. Rollers are easily installed. You simply place them in the grooves in your variator so that they will roll along the ramp.

Q: What does changing variator weights do?

A: By changing your CVT stock rollers to a lighter weight, you can increase acceleration off the mark, and by adding weight, you can increase top speed.

Q: What do lighter variator rollers do?

A: Ok, we all know that lighter rollers allow your engine to rev harder and vice versa, and that if the variator is working well it should hold the engine at a constant rpm dictated largely by the weight of the rollers.

Q: Does a variator increase top speed?

A: So with a performance variator it will allow the bike to increase its speed in a shorter time and increase its top speed, this is also more efficent and stops the engine for screaming at high RPM without getting any faster.

Q: Can you mix variator rollers?

A: I always mix rollers to get the preferred weight. Mixing for example 3x4gram and 3x7gram will cause no problem. It will act just the same as 6x5,5gram. The heavyer once will perhaps wear out a little bit faster/earlier.

Q: Should you grease variator rollers?

A: Rollers are NOT to be greased and doing so will absolutely give you ZERO performance gain. Why you think there isn't any grease in your variator? The centrifuginal forces would also throw out all the grease at once.

Q: When should I replace my variator?

A: Variator rollers are consumable items. The rollers have had a long and hard life at 8,000 miles of service. Although its possible your scoot seems to be okay, CVT performance has been compromised over the rollers lifetime. Its prudent to replace the rollers.

Q: How do I choose variator weights?

A: Lighter to accelerate, Heavier to higher top-end. That is, if you choose a weight lighter than the stock one, you can have more initial acceleration; and if you choose a heavier one, you can have higher top-end speed than the original setting.

Q: How long do roller weights last?

A: The variator and rollers will last much longer if it's taken apart about every 1500-2000 miles and cleaned. Rollers get flat spots because they get "stuck" in place from built up grime and belt dust. Take it apart clean all the goo out regularly and it's possible to get 10k out of a set of rollers.

Q: What do heavier variator weights do?

A: The heavier the weights, slower acceleration but lower RPM on top speed. Just my experience, not expert. It's the opposite. Lighter weights result in higher engine RPMS which tends to improve acceleration.

Q: What do lighter variator rollers do?

A: Ok, we all know that lighter rollers allow your engine to rev harder and vice versa, and that if the variator is working well it should hold the engine at a constant rpm dictated largely by the weight of the rollers.

Q: What does changing variator weights do?

A: By changing your CVT stock rollers to a lighter weight, you can increase acceleration off the mark, and by adding weight, you can increase top speed.

As one of the most professional variator manufacturers and suppliers in China, we're featured by quality products and competitive price. Please rest assured to buy variator for sale here from our factory. Contact us for quotation and free sample.

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