Two-Stage Gear Reducer Gap Layout for Smoother Actuator Torque
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Solution Overview
Problem
Conventional gear devices with two-stage speed reducers for electric actuators suffer from poor product efficiency and uneven output torque due to significant input shaft loss and torque variation, which are exacerbated by the use of high reduction ratios, leading to inefficiencies and motor capacity issues.
Innovation Solution
A gear device with a two-stage speed reduction unit, where the first reduction unit has a larger gap and backlash than the second, and is housed in a case with controlled lubrication, allowing for reduced metal contact resistance and unevenness, and includes a partitioned lubrication system to manage lubricant levels effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-stage speed reducer with high reduction ratio is used, then the motor capacity can be reduced, but the product efficiency deteriorates due to significant input shaft loss and torque variation
Solution Approach 1:
The patent applies different gap values to different reduction stages: the first reduction unit has a first gap between the external gear and pin, while the second reduction unit has a second gap that is smaller than the first gap. This local differentiation allows the first stage to handle torque variation more effectively while the second stage maintains higher efficiency, resolving the contradiction between motor capacity reduction and product efficiency maintenance.
2Manufacturing precision
If the gap between external gear and pin is reduced, then the manufacturing precision improves, but the resistance caused by metal contact increases
Solution Approach 1:
The patent specifies different gap values for different reduction units: the first gap in the first reduction unit is larger than the second gap in the second reduction unit. This local quality approach allows each stage to have optimized gap values suitable for its specific function, reducing metal contact resistance where needed while maintaining precision where critical.
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 configuration improves overall efficiency and maintains motor capacity by reducing resistance and unevenness in output torque, enabling smaller motor designs and broader installation orientations.
Implementation Method 1
A space in the case is filled with lubricant when a rotation axis of the electric motor is horizontal
Data Source
AI summary
A gear device according to the disclosure includes an internal gear having a pin groove, a pin rotatably supported by the pin groove, an external gear oscillatorily rotating while its external tooth is engaging with the pin, and a speed reduction unit. The speed reduction unit decelerates a rotational driving force of an electric motor and transmits the decelerated rotational driving force to a rotating drive unit. The speed reducer includes a first reduction unit disposed on the input side and a second reduction unit disposed coaxially with the first reduction unit on the output side. A gap is formed between the external gear and the pin when the center of the pin groove, the center of the pin, and the tooth bottom of the external gear are aligned. The first gap in the first reduction unit is larger than the second gap in the second reduction unit.