Plastic Harmonic Reducer Structure for Lower-Cost Precision Transmission
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Solution Overview
Problem
Harmonic reducers, despite their compactness and high transmission ratio, are limited by high manufacturing costs, which restrict their application in certain industrial sectors where a more cost-effective solution is needed.
Innovation Solution
The essential components of the harmonic reducer, including the circular spline, flexible spline, and wave generator, are manufactured using injection molding of plastic materials to achieve a compact, strong, and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal materials are used for harmonic reducer components, then strength and durability are improved, but manufacturing cost increases
Solution Approach 1:
The patent uses composite plastic materials with glass fiber reinforcement to manufacture harmonic reducer components. This allows achieving metal-like strength and rigidity while significantly reducing manufacturing cost and enabling complex geometric shapes through injection molding
Solution Approach 2:
The patent modifies material parameters by selecting specific plastic materials with appropriate mechanical properties, thermal characteristics, and tribological properties to replace traditional metals while maintaining functional requirements
2Stability of the object's composition
If the flex spline bell is extended in the axial direction to ensure flexibility, then elastic deformation capability is improved, but device volume increases
Solution Approach 1:
The patent employs a thin-walled flex spline structure made of plastic material that achieves the required flexibility through material elasticity and optimized wall thickness distribution, eliminating the need for extended axial dimensions
Solution Approach 2:
The patent compensates for reduced axial dimension by optimizing the radial and circumferential geometry of the flex spline, using advanced molding techniques to create complex three-dimensional tooth profiles that maintain flexibility in a compact form
3Ease of manufacture
If plastic materials are used for harmonic reducer components, then manufacturing cost and weight are reduced, but tribological properties deteriorate
Solution Approach 1:
The patent uses composite plastic materials with glass fiber reinforcement and appropriate additives to enhance wear resistance, friction characteristics, and overall tribological performance while maintaining the cost advantages of plastic manufacturing
Solution Approach 2:
The patent introduces lubricating additives and surface treatment layers as intermediaries between plastic components to reduce friction and wear, compensating for the inherently lower tribological properties of plastic materials
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 approach results in a solid, resistant, and compact harmonic reducer with competitive production costs, enabling precise motion transmission and easy integration into larger structures, while maintaining high transmission ratios and reducing maintenance costs.
Implementation Method 1
the operation of the harmonic reducer is primarily based on the elastic deformation of the flex spline FS in turn induced by the motion and rotation of the wave generator WG
Implementation Method 2
a new and innovative reducer of the harmonic type which is characterized, as illustrated in detail below, to have its essential components which are made by moulding a plastic material
Data Source
AI summary
A harmonic reducer includes an outer shell, a circular spline, a flex spline, a wave generator, and an electric motor. The circular spline, flex spline, and wave generator are housed in the outer shell. The electric motor controls rotation of the wave generator around an axis of the harmonic reducer. The circular spline, the flex spline, and support body of the wave generator are made by injection molding of a plastic material. The circular spline consists of a first fixed circular spline and a second mobile or movable circular spline, integral with a user of the harmonic reducer, each having respective internal toothing. The wave generator has two groups of rotating bearings, arranged in diametrically opposite areas of the wave generator.