Duplex Gear Alignment and Laser Welding for Precision Robot Reducers
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Solution Overview
Problem
Current machining processes for high-precision reducers in bionic robots face challenges in aligning and welding duplex gears, leading to reduced precision, transmission system sticking, and shortened service life due to phase angle errors and random errors in gear alignment, which cannot be effectively addressed by traditional gear aligning tools or machines.
Innovation Solution
A machining device comprising a laser welding device, rotary mechanism, and rotary platform that allows for simultaneous alignment and welding of multiple sets of duplex gears, eliminating phase angle errors and ensuring precise alignment and fixation through fine-pitch high tooth profiles and nitrided tooth surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional gear aligning tools are used to align and weld duplex gears separately, then each gear can be machined individually, but the phase angle errors accumulate and degradation gear precision by at least one precision level
Solution Approach 1:
The patent merges multiple gear alignment and welding operations into a single unified process. The dual clamping mechanism simultaneously clamps both gears in a set, and the laser welding device simultaneously welds both gears to the rotating frame, eliminating sequential operations and their associated error accumulations.
Solution Approach 2:
The patent replaces traditional mechanical alignment tools with a laser-based system. The laser welding device uses optical fields instead of mechanical contact to align and fix the gears, achieving higher precision by avoiding mechanical tolerance accumulations.
2Ease of manufacture
If gear shaping is used for single clamping duplex gears machining, then the machining can be performed, but the precision is low and the efficiency is low with high cost
Solution Approach 1:
The patent replaces traditional mechanical gear shaping with laser welding technology. The laser welding device uses optical energy to melt and fuse the gears to the rotating frame, achieving precise positioning without the low precision and high cost associated with mechanical gear shaping.
3Manufacturing precision
If special gear aligning machine is used to measure and align gears according to space coordinate values, then alignment can be performed, but errors still exist due to tooth thickness tolerance and precision decreases
Solution Approach 1:
The patent replaces complex mechanical measurement and alignment systems with a simplified laser-based system. The laser welding device inherently provides alignment through its optical axis, eliminating the need for complex coordinate measurement and reducing both device complexity and alignment errors.
4Speed
If multi-stage planetary tandem transmission is adopted to meet speed ratio requirements, then the speed ratio can be achieved, but the rotation precision is greatly decreased
Solution Approach 1:
The patent uses differential planetary transmission with duplex gears instead of multi-stage planetary tandem. By combining multiple functions into a single stage with precisely aligned duplex gears, it achieves both the required speed ratio and maintains high rotation precision without the cumulative errors of multi-stage systems.
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
The solution enables precise alignment and welding of multiple duplex gears simultaneously, improving rotation precision, load-bearing capacity, and reliability of the reducer, while avoiding the issues of gear sticking and reduced service life associated with traditional methods.
Implementation Method 1
a laser welding device (1), a laser rotary support (2), a rotary mechanism (3) and a rotary platform (4); the rotary mechanism (3) is installed with a reducer body (5)
Implementation Method 2
fine-pitch high tooth profiles and nitrided tooth surfaces
Data Source
AI summary
A machining device for duplex gear of high-precision reducer for robot includes a laser welding device, a laser rotary support, a rotary mechanism and a rotary platform, the rotary mechanism being installed with a reducer body, wherein a center of a central gear is fixedly connected with a rotating shaft; sets of duplex gears are evenly disposed around the central gear; the gear of each set of duplex gear which is connected with the central gear are connected to an output gear ring from outside; a fixed gear ring is disposed above the output gear ring; a rotating frame is disposed at ends, close to the top of the reducer, of rotating shafts of the sets of duplex gears and the rotating shaft of the central gear.