Harmonic Drive Carrier With Integrated Wave Generator for High Gear Ratios
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Solution Overview
Problem
Existing actuation systems, such as those in aircrafts for moving control surfaces or rotating components like compressors, require high gear ratios but often use complex geartrains with numerous moving parts.
Innovation Solution
A harmonic drive with a balanced epicyclic geartrain incorporating a carrier with an integrated wave generator, featuring a carrier with forward and aft bearings, clips to prevent lateral movement, and a flex spline aligned with a circular spline, along with a sun gear, ring gear, and planet gears to achieve high gear ratios with reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If complex geartrains with larger number of moving parts are used to achieve high gear ratio, then the gear ratio requirement is met, but the device complexity increases
Solution Approach 1:
The wave generator is integrated directly into the carrier structure, merging two previously separate components into one unified element. This reduces the total number of moving parts while maintaining the high gear ratio functionality through the harmonic drive mechanism combined with the epicyclic geartrain.
Solution Approach 2:
The carrier serves multiple functions: it supports the planet gears, provides structural integrity for the epicyclic geartrain, and integrates the wave generator functionality. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity while achieving the required gear ratio.
2Power
If complex geartrains with larger number of moving parts are used to achieve high gear ratio, then the gear ratio requirement is met, but the size of the mechanism increases
Solution Approach 1:
By merging the wave generator into the carrier, the overall size of the mechanism is reduced compared to having separate components. The integrated structure eliminates the need for additional mounting spaces and reduces the total volume occupied by the geartrain assembly.
Solution Approach 2:
The harmonic drive mechanism with integrated wave generator and carrier is designed to be compact, allowing the entire assembly to fit within a smaller overall envelope. The nested arrangement of components within the carrier structure minimizes the external dimensions while maintaining the high gear ratio capability.
3Power
If complex geartrains with larger number of moving parts are used to achieve high gear ratio, then the gear ratio requirement is met, but the part count increases
Solution Approach 1:
The integration of the wave generator into the carrier merges two distinct parts into one, directly reducing the part count. This unified structure maintains all necessary functional elements while eliminating the need for separate manufacturing and assembly of individual wave generator and carrier components.
Solution Approach 2:
The carrier is designed as a multi-functional component that performs gear support, structural framing, and wave generator integration. This universality reduces the total number of parts needed, as one component fulfills multiple roles that would traditionally require separate dedicated parts.
Data Source
AI summary
A harmonic drive having a housing with an outer shell defining an inner surface; an epicyclic geartrain within the housing; the geartrain includes a carrier; the carrier defines a center passage and an outer surface, and wherein the center passage of the carrier receives an input shaft; the outer surface of the carrier defines a wave generator portion that defines a wave generator; the harmonic drive has an output shaft that has an output shaft forward portion and an output shaft aft portion; the output shaft aft portion is within the housing and surrounds the carrier; the output shaft forward portion extends through a forward end of the housing; a flex spline is defined by the output shaft aft portion; the flex spline is aligned with the wave generator; a circular spline is defined along the inner surface of the housing; the circular spline is aligned with the flex spline.