Strain Wave Gear Output Flange With Integrated Encoder Mounting
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Solution Overview
Problem
Existing strain wave gears for robot arms are costly, require multiple parts for assembly, and lack rigidity, while encoder setups need manual adjustment and additional components, leading to increased complexity and potential failure.
Innovation Solution
A strain wave gear design with an integrated output flange and encoder, where the inner ring and flex spline are formed as a single unit, reducing parts and assembly complexity, and an encoder setup that eliminates the need for manual adjustment by positioning the encoder reader on the outer ring and track on the inner ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate parts are used for output flange and encoder mounting, then adaptability is improved, but device complexity increases and rigidity decreases
Solution Approach 1:
The output flange and encoder mounting structure are merged into a single integrated component. The output flange includes a mounting surface with mounting holes directly formed on it, eliminating the need for separate encoder mounting brackets or adapters. This integration reduces the total part count and assembly complexity while maintaining the adaptability to mount encoders.
2Ease of repair
If multiple separate parts are assembled, then ease of repair is improved, but assembly time increases and rigidity decreases
Solution Approach 1:
The output flange is designed as an integrated piece with the circular spline and internally toothed gear formed as a single unit. This reduces the number of assembly steps required during manufacturing while maintaining the ability to replace entire modules if repair is needed. The integration eliminates multiple fastening operations and alignment procedures.
3Ease of operation
If encoder read head is placed externally, then ease of operation is improved, but measurement precision decreases due to alignment requirements
Solution Approach 1:
The encoder mounting structure is nested within the output flange itself. The mounting surface and holes are directly formed on the output flange, allowing the encoder to be mounted in a predetermined position with high precision. This eliminates the need for external alignment adjustments while keeping the encoder accessible for operation and maintenance.
4Stability of the object's composition
If integrated design is used, then rigidity increases and assembly time decreases, but manufacturing complexity increases
Solution Approach 1:
The output flange, circular spline, and internally toothed gear are formed as a single integrated component. This integration provides structural rigidity by eliminating joints and connection points that could introduce flexibility or misalignment. The manufacturing is simplified through modular design where the integrated output flange assembly can be produced as a complete unit and then installed as a single module.
Data Source
AI summary
A strain wave gear includes an outer ring and an inner ring rotatably arranged in the outer ring. The inner ring includes an internally toothed gear and a flex spline is arranged in the inner ring and includes a flexible part that includes an external toothed gear. A wave generator is rotatable in relation to the flex spline and is configured to flex the flexible part in a radial direction to partly mesh the external toothed gear with the internally toothed gear causing rotation of the inner ring in relation to the outer ring. A part of the inner ring extends out of the outer ring and includes an outwardly protruding output flange. An encoder reader can be disposed on the outer ring and an encoder track can disposed on the inner ring. A robot joint that includes the strain wave gear is also disclosed.