The operating characteristics of harmonic reducers under different load conditions vary significantly. When the load is light, the internal flexspline, rigid spline and wave generator bear relatively little stress. The main test is the transmission accuracy of the reducer and the efficiency under low load.
For example, in the transmission of some precision instruments and equipment, light load conditions require harmonic reducers to accurately transmit small movements and torques, and run smoothly without lag. Under heavy load conditions, such as the joint drive of industrial robots or the power transmission of heavy machinery, the flexspline will bear huge periodic alternating stress, which not only places extremely high requirements on the strength and fatigue life of its materials, but may also Excessive deformation leads to a decrease in transmission accuracy, and even failure phenomena such as tooth surface wear and gluing, affecting the reliability and stability of the entire system.
2. Test methods and indicators for reliability verification
For different load conditions, a variety of test methods need to be used to verify the reliability of the harmonic reducer. In terms of light load testing, high-precision torque sensors and angle encoders can be used to measure the output torque fluctuation, backlash, transmission efficiency and other indicators under small torque input. The output torque fluctuation is required to be within a very small range and the backlash is It meets the requirements of precision transmission of equipment, and the transmission efficiency remains at a high level and stable. For heavy-load testing, it is necessary to build a test bench that simulates the actual heavy-load working environment, use a large torque loading device to apply rated and overload torque to the harmonic reducer, and simultaneously monitor key parameters such as temperature rise, vibration, noise, and fatigue life.
For example, through long-term high-torque cyclic loading tests, we can observe whether fatigue cracks appear in the flexspline, measure whether the vibration and noise are within the acceptable range, and whether the temperature rise is too high to affect the normal operation of the reducer, so as to comprehensively judge whether it is in critical condition. reliability under load conditions.
3. Reliability performance under different load conditions
Under light load conditions, high-quality harmonic reducers can usually show good reliability. Their transmission accuracy can be controlled at the arc second level, and the backlash is extremely small. During long-term operation, various performance indicators are stable and can Meet the strict requirements for high-precision transmission such as optical instruments and semiconductor manufacturing equipment.
However, under heavy load conditions, the reliability of harmonic reducers faces greater challenges. When some ordinary models approach or exceed the rated load, the vibration may intensify and the efficiency may drop sharply. As the running time increases, the fatigue damage of the flexspline gradually accumulates and the service life is shortened. However, the specially designed and optimized heavy-duty harmonic reducer, through the use of high-strength flexspline materials, improved tooth design and optimized lubrication system, can maintain the rated load under rated heavy load or even a certain degree of overload conditions. Relatively stable performance effectively extends fatigue life and ensures reliable operation in heavy-duty applications such as industrial automation and aerospace.
4. Measures to improve reliability and future prospects
In order to improve the reliability of harmonic reducer under different load conditions, many aspects can be started. In the design stage, the tooth shape and structural parameters of the flexspline and rigid spline are optimized according to the load requirements, and appropriate materials are selected and strengthened, such as shot peening the flexspline to improve its fatigue strength. During the manufacturing process, the processing accuracy is strictly controlled to ensure that the assembly accuracy and clearance of each component meet the design requirements. At the same time, we constantly improve lubrication technology and select suitable lubricants to improve lubrication effects and reduce wear and heat.
In the future, with the continuous advancement of material science, manufacturing processes and testing technology, harmonic reducers are expected to achieve higher reliability under higher loads and more complex working conditions, such as the development of new materials with higher strength and toughness for use in Flexspline manufacturing uses advanced intelligent manufacturing technology to achieve more precise processing and assembly, and uses big data and artificial intelligence technology to more accurately predict and monitor its reliability, further expanding its application scope in high-end manufacturing and other fields. .
