Wave Generator Plug Structure for Large Hollow Strain Wave Gearing
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Solution Overview
Problem
Increasing the inner diameter of the hollow part in strain wave gearings to enhance the hollow diameter leads to reduced radial thickness and rigidity of the plug, causing deformation during manufacturing and operation, which affects proper meshing between gears under load.
Innovation Solution
A wave generator with a cylindrical rigid plug having a non-circular outer surface and a high-rigidity plug support ring, both made from specific materials, to maintain structural integrity and prevent deformation, allowing for a larger hollow part and improved meshing positions between the externally and internally toothed gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inner diameter of the hollow part in the wave generator is increased to enhance the hollow diameter of the strain wave gearing, then the hollow diameter is improved, but the radial thickness and rigidity of the plug are reduced, causing deformation during manufacturing and operation
Solution Approach 1:
The invention applies composite material construction by combining the plug (made from iron-based material) with a plug support ring (made from high-rigidity material) to create a composite structure. This composite structure maintains the large hollow diameter while compensating for the reduced rigidity of the thinner plug wall through the high-rigidity support ring, thereby preventing deformation during manufacturing and operation
Solution Approach 2:
The wave generator plug is segmented into two functional components: the plug itself (providing the hollow structure) and the plug support ring (providing additional rigidity). This segmentation allows each component to be optimized independently - the plug can have a larger hollow diameter while the support ring provides the necessary structural reinforcement to prevent deformation
2Volume of moving object
If the thickness of the plug in the radial direction is reduced to increase the hollow diameter, then the hollow diameter is improved, but the manufacturing precision is degraded due to deformation during press-fitting of the wave-generator bearing
Solution Approach 1:
The plug support ring is installed on the plug before the wave-generator bearing is press-fitted. This preliminary action provides structural support to the thin-walled plug during the subsequent press-fitting process, preventing deformation of the outer circumferential surface and maintaining manufacturing precision even when the plug thickness is reduced to increase hollow diameter
3Volume of moving object
If the thickness of the plug is reduced to increase the hollow diameter, then the hollow diameter is improved, but the reliability is degraded due to radial deformation under load during operation
Solution Approach 1:
The invention changes the rigidity parameter of the plug structure by adding the high-rigidity plug support ring. This parameter change allows the plug to maintain its shape and prevent radial deformation under operational loads, ensuring reliable gear meshing accuracy while accommodating the reduced thickness necessary for larger hollow diameter
Data Source
AI summary
A wave generator for a strain wave gearing makes a flexible externally toothed gear to flex into an elliptical shape and mesh with rigid internally toothed gears, and makes meshing positions of the flexible externally toothed gear with the both gears to move in a circumferential direction. On the inner side of a rigid plug of the wave generator, a plug support ring is secured and integrated. The rigid plug is formed from an iron-based material, and the plug support ring is formed from a high-rigidity material that is more rigid than the iron-based material. Since deformation of the rigid plug is suppressed, the wave generator provided with a large hollow part can be obtained.