Double-Flexspline Harmonic Reducer With Limited Deformation Control
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Solution Overview
Problem
Existing harmonic reducers face challenges with return difference accuracy due to engagement tightness issues between elliptical long shaft teeth and rigid gear teeth, leading to increased production costs and reduced precision life, as well as wear that affects engagement tightness and accuracy.
Innovation Solution
A double-flexspline harmonic reducer with a strong flexspline and a weak flexspline, where the strong flexspline has a flexible thin wall for non-circular elastic deformation, and a deformation stopper limits the deformation of the strong flexspline, allowing for adjustable deformation and improved engagement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the engagement tightness between the elliptical long shaft teeth and the rigid gear teeth is increased to reduce return difference, then the transmission precision is improved, but the assembly difficulty increases and the rotation becomes difficult
Solution Approach 1:
The patent replaces the traditional rigid wheel with a strong flexspline that can elastically deform. This inversion of the rigid component into a flexible one allows the system to achieve tight engagement through controlled elastic deformation rather than through rigid precision fitting, thereby reducing assembly difficulty while maintaining transmission precision.
Solution Approach 2:
The patent introduces a deformation stopper that limits the deformation amount of the strong flexspline. By controlling the deformation parameter within a specific range, the system achieves optimal engagement tightness without excessive assembly force, resolving the contradiction between precision and assembly ease.
2Manufacturing precision
If the production accuracy requirements of the harmonic reducer are increased to improve engagement accuracy, then the transmission precision is improved, but the production cost increases
Solution Approach 1:
The patent utilizes elastic deformation parameters of the strong flexspline to achieve engagement accuracy. Instead of relying on high-precision rigid component fabrication, the system achieves accurate engagement through controlled elastic deformation, allowing the use of cheaper materials and processing techniques while maintaining high engagement accuracy.
Solution Approach 2:
The strong flexspline with its flexible thin wall structure enables the system to achieve precision through elastic deformation rather than rigid precision manufacturing. This flexible component approach allows for lower manufacturing costs while maintaining high engagement accuracy.
3Manufacturing precision
If the flexspline and rigid wheel are designed for accurate engagement to improve transmission precision, then the return difference is reduced, but the component wear increases during operation
Solution Approach 1:
The patent controls the deformation amount of the strong flexspline within a specific range using a deformation stopper. This controlled deformation ensures accurate engagement while distributing contact stresses more evenly, reducing localized wear and improving component reliability during operation.
Solution Approach 2:
The elastic deformation capability of the strong flexspline acts as a cushioning mechanism that absorbs shock and reduces impact loads during engagement. This beforehand cushioning effect protects the components from excessive wear while maintaining accurate engagement.
4Manufacturing precision
If the deformation amount of the strong flexspline is increased to improve engagement, then the transmission accuracy is improved, but the material fatigue increases
Solution Approach 1:
The patent optimizes the deformation amount of the strong flexspline by introducing a deformation stopper that limits the deformation within a specific range. This controlled deformation parameter achieves the necessary transmission accuracy while keeping the deformation within safe limits to avoid excessive material fatigue and extend component life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the tolerance to machining tolerances, reduces material fatigue, and extends the precision life of the reducer while allowing the use of cheaper materials and processing techniques, achieving high-precision transmission with reduced costs.
Implementation Method 1
the contact part of the strong flexspline and the weak flexspline is subjected to the radial pressure of the weak flexspline to generate a non-circular elastic deformation
Data Source
AI summary
The present application discloses a double-flexspline harmonic reducer, comprising a strong flexspline (3) , a weak flexspline (2), a wave generator (1), and a deformation stopper (4) of the strong flexspline; the strong flexspline and the weak flexspline are coaxially fixed axially and radially, the strong flexspline and the weak flexspline are respectively provided with teeth that can engage with each other; the number of teeth of the strong flexspline and the weak flexspline are different; the wave generator is used to make the weak flexspline to undergo non-circular elastic deformation and partially engage with the strong flexspline; the contact part of the strong flexspline and the weak flexspline is subjected to the radial pressure of the weak flexspline to generate a non-circular elastic deformation, a flexible tubular wall of the strong flexspline has a toothless surface, and a limiting contact surface is processed on the toothless surface.