High reduction belt-driven linear actuator

A linear actuator system comprising:

• an actuator chassis having a main drive axis;
• a first plurality of sheaves coupled to a first shaft coupled to the actuator chassis, the first plurality of sheaves comprising sheaves having an axis of rotation that is coincident with the first shaft, the sheaves in the first plurality of sheaves having different sheave diameters with respect to one another;
• and
• a second plurality of sheaves coupled respectively to a second shaft coupled to the actuator chassis, the second plurality of sheaves comprising sheaves having an axis of rotation that is coincident with the second shaft, the sheaves in the second plurality of sheaves having different sheave diameters with respect to one another,
• wherein at least one of the first shaft and the second shaft is configured to translate along the main drive axis, wherein the first shaft and the second shaft are oriented perpendicularly to the main drive axis and are offset with respect to one another by a rotation angle about the main drive axis.

A method of driving a belt driven linear actuator system, the method comprising:

• energizing a rotary actuator connected to a redirection sheave to rotate the redirection sheave, the redirection sheave coupled to an actuator chassis, the actuator chassis comprising:
• a first plurality of sheaves coupled to a first shaft coupled to the actuator chassis, the first plurality of sheaves comprising sheaves having an axis of rotation that is coincident with the first shaft, the sheaves in the first plurality of sheaves having different sheave diameters with respect to one another;
• and
• a second plurality of sheaves coupled respectively to a second shaft coupled to the actuator chassis, the second plurality of sheaves comprising sheaves having an axis of rotation that is coincident with the second shaft, the sheaves in the second plurality of sheaves having different sheave diameters with respect to one another,
• wherein at least one of the first shaft and the second shaft is configured to translate along the main drive axis, wherein the first shaft and the second shaft are oriented perpendicularly to the main drive axis and are offset with respect to one another by a rotation angle about the main drive axis.

A method of manufacturing a belt driven linear actuator system, the method comprising:

• movably coupling an actuation shaft to an actuator chassis;
• the actuation shaft movably coupled to the actuator chassis to translate along a main drive axis;
• coupling a first plurality of sheaves to the actuator chassis, the first plurality sheaves coupled to the actuation chassis via a first shaft, the first plurality of sheaves configured to rotate freely about the first shaft, the first shaft rotatably coupled to the actuator chassis and fixed in position with respect to the actuator chassis, wherein the sheaves in the first plurality of sheaves have different sheave diameters with respect to one another;
• and
• coupling a second plurality of sheaves to the actuator chassis, the second plurality of sheaves coupled to the actuation chassis via a second shaft, the second plurality of sheaves configured to rotate freely about second shaft, the second shaft configured to translate along the main drive axis in the actuator chassis to drive the actuation shaft, wherein the sheaves in the second plurality of sheaves have different sheave diameters with respect to one another, and wherein the first shaft and the second shaft are oriented perpendicularly to the main drive axis and are offset with respect to one another by a rotation angle about the main drive axis.