Bionic Bone Reducer Gear Structure for Lightweight Impact Resistance
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Solution Overview
Problem
Current reducers for bionic robots lack an optimization design that balances light weight with high bearing capacity for impact resistance, particularly under dynamic alternating working conditions, and fail to consider both internal matrix support strength and surface contact strength simultaneously.
Innovation Solution
A reducer gear design featuring a reticulated porous base layer with fiber trabeculae and a compact outer contour layer, optimized using 3D printing and finite element methods to distribute material based on load spectra, ensuring lightweight and high impact resistance, and filled with tough and soft materials to enhance support and contact toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a harmonic reducer is used, then the weight is reduced, but the impact resistance and transmission efficiency are seriously deficient
Solution Approach 1:
The gear combines a reticulated porous base layer made of light-weight material (e.g., aluminum alloy or titanium alloy) with a compact outer contour layer made of high-strength material (e.g., steel alloy). This composite structure integrates the advantages of both materials: the porous base provides light weight while the compact outer layer provides high strength and impact resistance, resolving the contradiction between weight reduction and impact resistance improvement.
2Reliability
If a cycloidal reducer is used, then the impact resistance and transmission accuracy are improved, but the weight becomes too heavy
Solution Approach 1:
The gear structure applies local quality by having different structural characteristics in different regions: the outer contour layer (where contact and load transmission occur) has a compact dense structure for high strength, while the inner base layer has a reticulated porous structure for weight reduction. This localized structural differentiation allows the gear to have high impact resistance at critical areas while maintaining overall light weight.
3Reliability
If a planetary gear reducer is used, then the transmission precision and efficiency are improved, but the weight is heavier compared to harmonic reducer
Solution Approach 1:
The gear utilizes porous materials by implementing a reticulated porous base layer structure that significantly reduces the overall weight of the gear compared to solid structures. The porous structure maintains sufficient mechanical properties while reducing mass, enabling the planetary gear reducer to achieve high transmission efficiency with reduced weight, thus resolving the contradiction between transmission efficiency and weight.
4Strength
If existing optimization design methods are used, then the support strength is considered, but the contact strength under dynamic alternating loads is not adequately addressed
Solution Approach 1:
The design methodology applies preliminary action by first determining the thickness distribution of the outer contour layer based on contact strength requirements under dynamic alternating loads, and then optimizing the porous base layer structure based on support strength requirements. This sequential design approach ensures that both contact strength and support strength are adequately addressed, resolving the contradiction between these two strength requirements.
Data Source
AI summary
A reducer gear for robot includes an outer contour layer and a reticulated porous base layer cladded by the outer contour layer; the outer contour layer comprises a mounting surface layer, a tooth surface layer, and a connecting surface layer connected between the mounting surface layer and the tooth surface layer and forming a complete gear outer contour together with the mounting surface layer and the tooth surface layer; the mounting surface layer, the tooth surface layer and the connecting surface layer are compact structures; the reticular porous base layer is located in a cavity formed by the outer contour layer, and fiber trabeculae in a porous grid structure are provided in the reticular porous base layer.