Plate Harmonic Reducer With Bar Wave Generator for Thin Coaxial Gearing
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Solution Overview
Problem
Existing harmonic reducers face challenges in design complexity, high manufacturing costs, and difficulty in achieving lightweight, thin, and efficient torque transmission with low noise, due to their intricate structure and elliptical wave generator design.
Innovation Solution
A plate harmonic reducer design featuring a disc-shaped circular spline member, a disc-shaped flex spline member, and a wave generator member with a bar shape, where the first and second toothed gear portions are positioned to overlap vertically, and the wave generator presses the flex spline member to engage the gears, allowing for a coaxial configuration and reduced complexity in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an elliptical wave generator is used in a conventional harmonic reducer, then speed reduction ratio and rotational precision are improved, but design complexity and manufacturing cost increase
Solution Approach 1:
The wave generator is segmented into a circular body with localized pressing protrusions rather than a continuous elliptical shape. This segmentation allows the complex elliptical function to be achieved through simpler discrete pressing elements, reducing design complexity while maintaining precision
Solution Approach 2:
Instead of using an elliptical wave generator to create harmonic motion, the patent inverts the approach by using a circular wave generator with pressing protrusions that actively press the flex spline to create the desired motion. This inversion simplifies the wave generator geometry while achieving the same functional outcome
2Strength
If a cup-shaped flex spline member is used, then structural strength is improved, but the top and bottom width increases making thin harmonic reducers difficult to design
Solution Approach 1:
The pressing protrusions are extracted as separate functional elements from the flex spline member and placed on the wave generator. This extraction allows the flex spline to be redesigned as a thinner plate structure without compromising strength, as the pressing function is now provided by the wave generator's protrusions rather than requiring a deep cup shape
Solution Approach 2:
The patent transitions from a three-dimensional cup-shaped flex spline to a two-dimensional plate-shaped flex spline. This dimensional reduction maintains the necessary structural strength through optimized plate geometry while significantly reducing the top and bottom width, enabling thin harmonic reducer designs
3Device complexity
If the first and second toothed gear portions are positioned to overlap vertically, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The first and second toothed gear portions are merged into a vertically overlapping configuration where they engage through the thickness of the flex spline. This merging simplifies the overall structure by eliminating the need for separate lateral positioning mechanisms, reducing device complexity while the pressing protrusions ensure precise engagement
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 design simplifies the profile design, reduces weight and volume, enhances torque efficiency, and lowers manufacturing costs while maintaining precision and reducing stress concentration, allowing for a compact and efficient power transmission with a consistent bearing life and precision.
Implementation Method 1
the flex spline member is formed of an elastic material... the wave generator member presses at least part of the flex spline member so that at least part of the first toothed gear portion and at least part of the second toothed gear portion are engaged with each other
Data Source
AI summary
Provided is a plate harmonic reducer, and more particularly, a plate harmonic reducer, in which design may be further simplified and a manufacturing cost may be reduced.