Wave Gear Device Alignment Using Positioning Jigs
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Solution Overview
Problem
Existing wave gear devices require highly accurate processing of the housing to align the circular spline, flex spline, and wave generator, leading to increased costs and production time due to the need for large reference surfaces, which can result in misalignment and degraded rotational accuracy.
Innovation Solution
A method of producing a wave gear device where the circular spline, flex spline, and wave generator are aligned using a cylindrical housing with a reduced reference surface, allowing for accurate alignment of their central axes and reducing production time by using jigs to position and secure these components relative to each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the housing is highly accurately processed with large reference surfaces to align the circular spline, flex spline, and wave generator, then the alignment accuracy of components is improved, but the cost and production time are increased
Solution Approach 1:
A positioning jig is introduced as an intermediary tool to facilitate accurate positioning of the circular spline, flex spline, and wave generator. The jig includes positioning protrusions that fit into corresponding recesses on the components, enabling precise alignment without requiring extensive machining of the housing. This mediator transfers the positioning function from the housing to a dedicated tool, resolving the contradiction between alignment accuracy and production time.
Solution Approach 2:
The positioning jig is prepared in advance with pre-formed positioning protrusions and reference surfaces. By performing the positioning function beforehand through the jig rather than through housing machining, the method eliminates the need for time-consuming high-precision housing processing while maintaining alignment accuracy. The preliminary preparation of the jig allows for rapid assembly in subsequent production.
2Manufacturing precision
If the housing is highly accurately processed with large reference surfaces, then the alignment accuracy of components is improved, but the processing requirements and cost are increased
Solution Approach 1:
The positioning jig serves as a mediator that assumes the positioning function previously required from the housing. The jig's reference surfaces and positioning protrusions provide the necessary geometric constraints for component alignment, allowing the housing to be manufactured with lower precision requirements. This transfers the manufacturing complexity from the housing to the positioning jig, which can be produced separately with standard precision.
Solution Approach 2:
The positioning function is segmented from the housing and embodied in a separate positioning jig. This segmentation allows the housing to be manufactured independently with reduced precision requirements, while the positioning jig handles the alignment function. The division of functionality resolves the contradiction by enabling the housing to be easier to manufacture while maintaining alignment accuracy through the dedicated positioning tool.
3Measurement precision
If the reference surface area of the housing is increased to improve positioning accuracy, then the alignment precision is improved, but the processing time and cost are increased
Solution Approach 1:
The positioning jig acts as an intermediary that provides concentrated, precise positioning contact points through its protrusions and recesses. Instead of requiring large reference surfaces on the housing, the jig's localized positioning features achieve high positioning accuracy with minimal contact area. This mediator enables accurate positioning without the time-consuming process of creating and machining large reference surfaces on the housing.
Data Source
AI summary
A circular spline is secured to a housing. An output member is positioned relative to the circular spline, an outer race of a bearing is secured to the housing, and an inner race of the bearing is secured to the output member. A flex spline is positioned relative to the circular spline and secured to the output member. A wave generator is positioned relative to the circular spline, and a support member, by which the wave generator is rotatably supported, is secured to the housing.