Harmonic Gear

Slide-1
Introduction
Harmonic Drives (HD) were invented in the late 1950 by
C. Walton Musser.
HD have become a primary choice when precise
positional accuracy and repeatability are required.
HD is capable of high gear ratios, zero backlash, and
high torque-to-weight ratios.
HD are very compact with torque-to-weight ratios 50%
smaller and 30% greater efficiencies than other gearing
mechanisms.
Slide-2
Basic Working Principle

All harmonic drives consist
of the same three basic
elements:
A Circular Spline
B Flex Spline
C Wave Generator
Slide-3
Wave Generator
The wave generator (WG) consists of

two parts: (yellow inner ring)
An elliptically shaped steel plug
Ball bearing
The plug is pressed into the bearing
so that the bearing conforms to the
plugs elliptical shape.
The WG is pressed into the flex
spline.
The WG is attached to the drive input
in the most common configuration.
Slide-4
Flex Spline
The flex spline (FS) is a thin walled steel
cylindrical cup.
It has teeth machined into outside upper
rim of the cup.
The FS has a large diameter to allow
radial flexibility while maintaining high
torsional stiffness.
In common configuration rotates in
reverse of the wave generator plug.
The rotating output element in the
common configuration.
Slide-5
Circular Spline
The Circular Spline is a
rigid circular ring with teeth
on the inside edge that mate
with the teeth of the flex
spline (blue outer ring).
It is the non-rotating
element in the common
configuration.
Slide-6
How it works: Reduction

The gear reductions are a
result of the flex spline
having two less teeth than
the circular spline.
Click for
Animation
200
100 : 1
200 202
Notice the negative sign because the flex
spline rotates in reverse of the wave
generator
07/16/15
ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators
Slide-7
How it works: Flexing

The Harmonic Drive
mechanism relies upon the
elastic properties of the the flex
spline material (steel).
The resulting deformation is
well below the endurance limits
of the material, if the peak
torque is kept below the rated
maximum.
This flexing preloads the gears
and helps reduce noise, friction,
and backlash.
Slide-8
How it works: Zero Backlash

Because the flex spline is
preloaded almost zero back
lash is achievable 6,3 or 1 arcsec depending on size and
reduction ratio.
The amount of backlash
between mating teeth remains
constant over the lifetime of
the drive because the
preloading and the relative
motion of the gears.
Click for
Animation
Slide-9
How it works: Efficiency

Standard gear mechanisms
have contact between only a
couple of teeth at any given
time.
The unique design of the
harmonic drive allows for
30% of the teeth to be in
contact at any give time.
Increases torque transfer
efficiency to be between 65%
and 90% highest of any gear
transfer mechanism.
07/16/15
Click for
Animation
Slide-10
Configurations
07/16/15
Slide-11
Major Specifications
There is not limitation of type motor to provide
the input actuation.
Input/output torque requirements
Hollow shaft vs. solid shaft
Input Power
Lubrication types and operating temperatures
Size and Weight
Slide-12
Advantages
Simple construction (3 piece)
Light weight (up to 50% lighter than conventional
reducers)
Compact (single stage, pancake style, coaxial input out
put shafts)
High efficiency in gear ratios between 60:1 to 250:1
efficiencies of 65% to 95% are achievable.
High positional accuracy (0.008)
High torque-to-weight ratio (100:1, 160:1, 200:1)
07/16/15
Slide-13
Advantages cont.
Zero backlash
Infinite lifetime w/ constant performance
Cost effective
Hollow Shaft
Quiet operation because low tooth impact, elliptical
shape keeps gears tight and smooth.
Slide-14
Limitations
Gear reductions below 30:1 are limited because
of the possibility of fatiguing the flexspline.
Restricted to input power levels below 6000W.
Large models experience lower efficiency
High ratio drives are non-backdrivable
Must be careful of operating temperatures, and
lubrication techniques.
Slide-15
Selection
Harmonic Drives have many specifications but the basics
are:
Input/output Torque Ratio
Lubrication Type
Output Rpm
Physical size and weight
Maximum Backlash (6,3,1 arc/sec)
Maximum Transmission Error (6,3,1 arc/sec)
07/16/15
Slide-16
Cost
Harmonic Drives range in cost based on size,
lubrication, and configuration type.
The drive costs a bit more than other reduction
devices, but the savings is made up by being able
to reduce the requirements for the motor and the
savings in size and weight.
Based on the myriad of configuration possibilities
it is recommended to contact a sales rep for actual
pricing.

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Slide-1

Basic Working Principle

The wave generator (WG) consists of

How it works: Reduction

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

How it works: Flexing

How it works: Zero Backlash

How it works: Efficiency

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