Flexspline Annular Flange Design for Hollow Diameter Expansion
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Solution Overview
Problem
Existing wave gear devices face limitations in increasing the hollow diameter without simultaneously increasing the outer diameter, particularly in cup-type and 'silk hat'-type designs.
Innovation Solution
A flexspline with a radially flexible cylindrical body, a disc-shaped diaphragm, and a unique annular flange structure that allows for a reduced outer diameter while enabling a larger hollow diameter, featuring a first annular part bent at a right angle and a second annular part protruding inwardly, allowing the flange to be positioned within the diaphragm region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cup-type flexspline with an attachment flange is used, then the structure provides stable mounting, but the hollow diameter cannot be increased due to the flange blocking the center opening
Solution Approach 1:
The attachment flange is bent at a right angle to extend axially from the diaphragm, moving the mounting interface from the radial plane to the axial direction. This dimensional repositioning allows the hollow diameter to be increased without the flange blocking the center opening, while maintaining stable mounting through the axially extended flange structure.
2Volume of moving object
If a 'silk hat'-type flexspline without a blocking flange is used, then the hollow diameter can be increased, but the outer diameter increases due to the outward extension of the attachment flange
Solution Approach 1:
Instead of extending the attachment flange radially outward which increases outer diameter, the flange is bent to extend axially from the diaphragm. This repositions the mounting function to the axial dimension, allowing the hollow diameter to be increased while the outer diameter remains controlled by the diaphragm's radial extent.
Solution Approach 2:
The diaphragm is designed as a flexible disc-shaped component that can bend to form the axially extended flange structure. This flexible film approach allows the attachment flange to be formed from the diaphragm material itself, enabling the hollow diameter to match the diaphragm's outer diameter without adding radial protrusion.
3Reliability
If the attachment flange is made rigid and disc-shaped, then secure coupling is achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The attachment flange is merged with the diaphragm as a single integrated component rather than being a separate piece. The flange is formed by bending the diaphragm material itself, eliminating the need for additional fastening components and reducing assembly steps while maintaining secure coupling through the rigid bent flange structure.
Solution Approach 2:
The diaphragm serves dual functions as both the flexible membrane for wave gear operation and the material source for the rigid attachment flange. This single-component design reduces structural complexity while achieving reliable coupling through the bent flange portion.
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 configuration allows for a significant reduction in outer diameter while enabling a larger hollow diameter, making it possible to create a large-hollow-diameter wave gear device with minimal increase in outer diameter.
Implementation Method 1
a radially flexible cylindrical body (31)
Implementation Method 2
a disc-shaped diaphragm (32) continuous with one open end (31a) of the cylindrical body (31), the disc-shaped diaphragm bending and extending outward in a radial direction
Data Source
AI summary
In a flexspline of a wave gear device, an annular flange thereof is constructed from a first annular part bent at a right angle from an outer peripheral edge of a diaphragm, and a second annular part caused to inwardly protrude at a uniform width from a leading end of the first annular part. It is possible for the annular flange to be disposed within the region where the diaphragm is formed, as viewed in the direction of an axis of the device. An outer diameter can be reduced to a greater extent than with a “silk hat”-shaped flexspline; and when a hollow wave gear device is manufactured, a hollow diameter can be more readily increased than in a case where a cup-shaped flexspline is used.