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ㆍProduct: Strain wave gearing (or Harmonic drive gear)
ㆍAnalysis Goal: Performance evaluation for strain wave gearing design
Strain wave gearing, also known as harmonic drive gear, is a kind of reduction gear that can achieve a very high reduction ratio in a very small and light structure. It is widely used in compact and high-precision products such as robots. A flexible gear (Flex Spline) is deformed into an elliptical shape by a rapidly rotating body (Wave Generator), causing its teeth to engage with the rigid, internal gear (Circular Spline).
The rapid deformation and gear contact and significant inertial forces are difficult for traditional Finite Element Analysis (FEA) software to simulate. RecurDyn MFBD (Multi Flexible Body Dynamics) technology, which is precisely designed to simulate and analyze this kind of condition, was used to analyze this complex system of strain wave gearing (harmonic drive gear).
Process: Strain wave gearing simulation
① Model the Circular Spline and the Wave Generator as rigid bodies.
② Model the Flex Spline as a flexible body using Full Flex, prestressed in its initial state.
③ Model contact between teeth of Flex Spline and Circular Spline using high-accuracy general purpose algorithm (Geo Contact).
④ Model contact between the Flex Spline and Wave Generator using optimized contact for rigid cylinder shapes (Geo Cylinder).
⑤ Perform simulation the strain wave gearing system
Key Technologies for Analysis: Strain wave gearing / Harmonic Drive Gear
• MFBD solver that can accurately reproduce the high-speed motion and large deformation of the Flex Spline of the strain wave gearing
• High-accuracy, low-computation contact algorithms
- Contact between rigid bodies and flexible bodies
- Efficient contact between a large number of gear teeth - Optimized contact for simple rigid geometry such as cylinders or spheres
• Visualization of contact force distribution and pressure due to contact between gear teeth
Toolkits for Straing wave gearing simulation
• RecurDyn/Professional
• RecurDyn/FFlex
Customer Challenges in strain wave gearing development
• Evaluation of the relationship between design parameters and performance
• Prediction of effect on vibration and transmission error due to dimensional differences within a given tolerance range
• Prediction of effect of applied load and operational speed on the behavior of the Flex Spline
• Identifying the significance of the twist angle of the Flex Spline on performance
• Predicting the reaction force exerted on the Wave Generator
Solutions
• Modeling and Simulation time reduction through MFBD technology
• Reproduction of the Flex Spline behavior using nonlinear flexible body and contact algorithm
• Calculation of stresses in Flex Spline due to deformation and contact
• Simulation of strain wave gearing (harmonic drive gear) considering various design/operating conditions and tolerances
Outcomes
• Evaluate the performance of the new tooth profile and reflect it in the strain wave gearing design.
• Predict the efficiency and error for various design conditions and determine an optimal specification of the harmonic drive gear.
• Reduce time and cost through quantitative performance evaluation using a virtual model
Other Applications
◀ Transmission Simulation Using RecurDyn
ㆍDynamic simulation of transmission with multiple gears
ㆍAnalysis of gears’ dynamic behavior when shifting gear
◀ Analysis of the Reduction Gear Train Which Takes Into Consideration the Viscosity of Lubricating Oil
ㆍVisualization of the lubricating oil spray which was not possible until now
ㆍThe effect of the gear output according to a load of oil viscosity can be designed to be closer to reality.
