Speed Reducers for Precision Motion Control Reducer Catalog

Transcription

1 Speed Reducers for Precision Motion Control Reducer Catalog SHD-2SH

2 Excellent Technology for Evolving Industries Harmonic Drive actuators utilize high-precision, zero-backlash Harmonic Drive precision gears and play critical roles in robotics, semiconductor manufacturing equipment, factory automation equipment, medical diagnostics and surgical robotics. Additionally, our products are frequently used in mission-critical spaceflight applications which capture the human spirit. With over 5 years of experience, our expert engineering and production teams continually develop enabling technologies for the evolving motion control market. We are proud of our outstanding engineering capabilities and successful history of providing customer specific solutions to meet their application requirements. Harmonic Drive LLC continues to develop enabling technologies for the evolving motion control market, which drives the pace of global innovation. C. Walton Musser Patented Strain Wave Gearing in

3 Operating Principle of Gears A simple three-element construction combined with the unique operating principle puts extremely high reduction ratio capabilities into a very compact and lightweight package. The high-performance attributes of this gearing technology including, zero-backlash, high-torque-to-weight ratio, compact size, and excellent positional accuracy, are a direct result of the unique operating principles. Wave Generator The Wave Generator is a thin, raced-ball bearing fitted onto an elliptical hub. This serves as a high-efficiency torque converter and is generally mounted onto the input or motor shaft. Flexspline The Flexspline is a non-rigid, thin cylindrical cup with external teeth on the open end of the cup. The Flexspline fits over the Wave Generator and takes on its elliptical shape. The Flexspline is generally used as the output of the gear. Circular Spline The Circular Spline is a rigid ring with internal teeth. It engages the teeth of the Flexspline across the major axis of the Wave Generator ellipse. The Circular Spline has two more teeth than the Flexspline and is generally mounted onto a housing. Circular Spline Wave Generator Flexspline The Flexspline is slightly smaller in diameter than the Circular Spline and usually has two fewer teeth than the Circular Spline. The elliptical shape of the Wave Generator causes the teeth of the Flexspline to engage the Circular Spline at two opposite regions across the major axis of the ellipse. As the Wave Generator rotates the teeth of the Flexspline engage with the Circular Spline at the major axis. For every 18 degree clockwise movement of the Wave Generator, the Flexspline rotates counterclockwise by one tooth in relation to the Circular Spline. Each complete clockwise rotation of the Wave Generator results in the Flexspline moving counterclockwise by two teeth from its original position, relative to the Circular Spline. Normally, this motion is taken out as output. Development of HarmonicDrive Speed Reducers Harmonic Drive gears have been evolving since the strain wave gear was first patented in Our innovative development and engineering teams have led us to significant advances in our gear technology. In 1988, Harmonic Drive successfully designed and manufactured a new tooth profile, the "S" tooth. Since implementing the "S" tooth profile, improvement in life, strength and torsional stiffness have been realized. In the 199s, we focused engineering efforts on designing gears featuring space savings, higher speed, higher load capacity and higher reliability. Then in the s, significant reduction in size and thickness were achieved, all while maintaining high precision specifications. 3

4 SHG/SHF SHD Series Gear Unit SHD Features Ordering code Technical data Design guide Rating table Outline dimension (2SH) Outline dimension (2UH) Positional accuracy Hysteresis loss Torsional stiffness Starting torque Backdriving torque Ratcheting torque Buckling torque No-load running torque Efficiency (2SH) Efficiency (2UH) Checking output bearing Design guide and assembly tolerances Design guide (2UH) installation and transmission Recessing of the mounting pilot Axial force of the wave generator Lubrication Precautions on assembly

5 Gear Unit SHD Features SHD series Axially compact, these gear units feature a large hollow input shaft and a robust cross roller bearing so loads can be mounted directly to the unit without the need for additional support bearings Features of SHD series Zero Backlash Ultra-flat design - 15% thinner than the SHF Series Large Hollow Input Shaft Accuracy <1 arc-min (most sizes) Rigid cross roller output bearing Lightweight - 3% lower weight than Standard SHF Series Structure of SHD gear unit CRB Fig CRB outer ring Circular spline (CRB inner ring) Flexspline (Output) Wave generator (Input) Bolt to prevent separation * CRB: Cross roller bearing Shaft thickness Fig /2 SHF series (2SO) SHD series 268

6 Application example, SHD series SCARA robot SHD is ideal when space is limited. Gear Unit SHD Fig SHD series Ordering Code SHD SH -SP Series Ratio*1 Model Special specification SHD *1 The reduction ratio value is based on the following configuration: Input: wave generator, fixed: circular spline, output: flexspline SH = Simplicity Unit 2UH = Gear Unit Table LW = Lightweight SP= Special specification code Blank=Standard product 269

7 Gear Unit SHD Technical Data SHD-2SH/SHD-2UH-LW Gear Unit Gear ratio Rated torque at input speed rpm Limit for repeated peak torque Limit for average torque Limit for momentary peak torque Maximum input speed (rpm) Limit for average input speed (rpm) Moment of inertia (2SH) Moment of inertia (2UH) Nm kgfm Nm kgfm Nm kgfm Nm kgfm Grease Grease I x 1-4 kgm 2 J x 1-5 kgfms 2 I x 1-4 kgm 2 J x 1-5 kgfms Outline Dimensions SHD-2SH You can download the CAD files from our website: harmonicdrive.net Fig φn L-φM equally spaced F f (o-ring provided) D E1 E2 Usable pilot length g (seal) e (o-ring provided) R1-R2 equally spaced φs U1-U2 depth V equally spaced φw φo Z2 d H B2 φt φj h7 φz1 φk H7 φc X1 I* G* φc H7 φa φb1 φa h6 P4 P1-P2 length P3 Note 1: See undercutting the housing on Page 24 for details. * Please refer to the confirmation drawing for detailed dimensions. * See Fig. 4-3 on Page 4 for the shapes of the wave generator. X2 C.3 Note 1 b φq 27

8 Dimensions SHD-2SH Symbol Minimum housing clearance φa h6 φb 1 B 2 φc H7 D E 1 E 2 F G* H I* φj h7 φk H7 L φm φn φo P 1 P 2 P 3 P 4 φq R 1 R 2 φs φt U 1 U 2 V φw X 1 X 2 Z 1 Z 2 φa b φc d e f g h Mass (kg) ± M M M C.4 C d37.1d.6 d54.38d1.19 D ± ± M M M C.4 C d45.4d.8 d64.d1.5 D ± M M M C.5 C d53.28d.99 d72.d2. D ± M M M C.5 C d66.5d1.3 d88.62d1.78 D M M M C.5 C d87.5d1.5 d117.d2. D Gear Unit SHD ± M M5.25 M6 9.3 C.5 C d17.5d1.6 d2d2. D Table Unit : mm The following dimensions can be modified to accommodate: Wave Generator: C Flexspline: O and P Circular Spline: X1 and X2 *The G and I sizes indicated by an asterisk are the mounting positions in the shaft direction and allowance of the three parts (wave generator, flexspline, circular spline). Strictly observe these sizes as they affect the performance and strength. As the flexspline is subject to elastic deformation, the inner wall should be φa, b, c or more and it should not exceed φd to prevent possible contact with the housing. Wave generator is removed when the product is delivered. 271

9 Gear Unit SHD Outline Dimensions SHD-2UH T-φU a d H L I G J M N e b c W-X Fig Input shaft φs Q-R φp φd h7 φe h7 φf H7 K P (O) Z φf H7 φc h7 φb φa h7 φv 3-M3 φy Input configuration, size and 17 Dimensions SHD-2UH φa h7 φb φc h7 φd h7 φe h7 φf H7 G H I J K L M N O φp(p) Q R φs T φu φv W X φy Z a b c d e Mass (kg) Table Unit : mm (2.5) 3 M M3 4.5 φ ZZ 684ZZ D49585 S34.5 S (2.5) 3 M M3 4.5 φ ZZ 685ZZ D59685 S25356 S ー M M3 4.5 φ ーー 686ZZ 686ZZ D69785 S345 S ー M M4 6 φ ーー 688ZZ 688ZZ D84945 S38475 S ー M M5 8 φ ーー 6811ZZ 681ZZ D1126 S54645 S ー M M6 9 φ6.6 1 ーー 6813ZZ 6813ZZ D13267 S64745 S

10 Positional Accuracy Positional Accuracy 1-4 rad arc min See "Engineering data" for a description of terms Gear Unit SHD Table Unit: X1-4 rad (arc min) Hysteresis loss Ratio 5 8 or more T1 T2 K1 K2 K3 θ1 θ2 K1 K2 K3 θ1 θ2 1-4 rad arc min 1-4 rad arc min Torsional Stiffness Symbol Ratio 5 Ratio 8 or more Nm kgfm Nm kgfm 1 4 Nm/rad kgfm/arc min 1 4 Nm/rad kgfm/arc min 1 4 Nm/rad kgfm/arc min 1-4 rad arc min 1-4 rad arc min 1 4 Nm/rad kgfm/arc min 1 4 Nm/rad kgfm/arc min 1 4 Nm/rad kgfm/arc min 1-4 rad arc min 1-4 rad arc min See "Engineering data" for a description of terms. Table See "Engineering data" for a description of terms * The values in this table are reference values. The minimum value is approximately 8% of the displayed value Table

11 Gear Unit SHD Simplicity unit (2SH) Starting torque Ratio See "Engineering data" for a description of terms. The values are reference values Table Unit: Ncm Gear unit (2UH) Starting torque Ratio See "Engineering data" for a description of terms. The values are reference values Table Unit: Nm Simplicity unit (2SH) Backdriving torque Ratio Gear unit (2UH) Backdriving torque Ratio See "Engineering data" for a description of terms. The values are reference values See "Engineering data" for a description of terms. The values are reference values Table Unit: Ncm Table Unit: Nm Ratcheting torque Ratio See "Engineering data" for a description of terms Table Unit: Nm Buckling torque All ratios See "Engineering data" for a description of terms Table Unit: Nm 274

12 No-load running torque No-load running torque is the torque which is required to rotate the input side (high speed side), when there is no load on the output side (low speed side). Measurement condition Lubricant Grease lubrication Ratio 1 Gear Unit SHD Table Harmonic Grease SK-1A (size or more) Name Harmonic Grease SK-2 (size, 17) Quantiy Recommended quantity (See page 281) Torque value is measured after 2 hours at rpm input. Compensation Value in Each Ratio No-load running torque of the gear varies with ratio. Graphs to show the values for a reduction ratio of 1. For other gear ratios, add the compensation values in the right-hand table (Table 275-2). Table No-Load Torque Running Torque Compensation Value Unit: Ncm Ratio ー Temperature range of the operating environment Table SK-1A ºC to + 4ºC Grease SK-2 ºC to + 4ºC * Housing temperature should not exceed 8ºC. 275

13 Gear Unit SHD No-load running torque for a reduction ratio of 1:1 SHD-2SH (Simplicity unit) Input speed: 5rpm Input speed: 1rpm 1 Graph Graph No-load running torque (Ncm) No-load running torque (Ncm) Input speed: rpm Ambient Temperature ( o C) Ambient Temperature ( o C) Graph Input speed: 35rpm 1 Graph No-load running torque (Ncm) No-load running torque (Ncm) Ambient Temperature ( o C) Ambient Temperature ( o C) *The values in this graph are average values (X). 276

14 Gear Unit SHD SHD-2UH (Gear unit) Input speed: 5rpm Input speed: 1rpm 1 Graph Graph No-load running torque (Ncm) No-load running torque (Ncm) Input speed: rpm Ambient Temperature ( o C) Ambient Temperature ( o C) Graph Input speed: 35rpm 1 Graph No-load running torque (Ncm) No-load running torque (Ncm) Ambient Temperature ( o C) Ambient Temperature ( o C) *The values in this graph are average values (X). 277

15 Gear Unit SHD SHD-2SH (Simplicity unit) Efficiency The efficiency varies depending on the following conditions. Reduction ratio Input rotational speed Load torque Temperature Lubrication (Type and quantity) Measurements Installation Load torque Lubricant Based on recommended tolerance Rated torque in rating table Grease lubrication Name Quantity Efficiency at rated torque Table Harmonic Grease SK-1A ( or larger) Harmonic Grease SK-2 ( and 17) Recommended quantity Efficiency compensation coefficient When the load torque is lower than the rated torque, the efficiency value decreases. Calculate compensation coefficient Ke from Graph Compensation coefficient Ke rpm 1 rpm rpm 35 rpm Torque ratio α Graph * When the load torque is higher than the rated torque, efficiency compensation value Ke is 1. Ratio 5 17,, 25, 32, 4 1 Graph Graph Efficiency (%) rpm 1rpmn rpm Efficiency (%) rpm 1rpm rpm 35rpm 4 35rpm σ 3% σ 3% Ambient Temperature ( o C) Ambient Temperature ( o C) Ratio 1 17,, 25, 32, 4 Graph Graph Ratio 16, 25, 32, Graph rpm 8 Efficiency (%) rpm 1rpm rpm 35rpm Efficiency (%) rpm rpm 35v σ 3% σ 3% σ 3% 3 4 Ambient Temperature ( o C) Ambient Temperature ( o C) Ambient Temperature ( o C) Efficiency (%) rpm 1rpm rpm 35rpm 278

16 SHD-2UH (Gear unit) Efficiency The efficiency varies depending on the following conditions. Reduction ratio Input rotational speed Load torque Temperature Lubrication (Type and quantity) Measurements Installation Load torque Lubricant Based on recommended tolerance Rated torque in rating table Grease lubrication Name Quantity Efficiency at rated torque Table Harmonic Grease SK-1A ( or larger) Harmonic Grease SK-2 ( and 17) Recommended quantity Efficiency compensation coefficient When the load torque is lower than the rated torque, the efficiency value decreases. Calculate compensation coefficient Ke from Graph Compensation coefficient Ke rpm 1 rpm.3 rpm 35 rpm Torque ratio α Gear Unit SHD Graph * When the load torque is higher than the rated torque, efficiency compensation value Ke is 1. Ratio 5 1 Graph Ratio 1 1 Graph Efficiency (%) rpm 1rpm rpm 35rpm Efficiency (%) rpm 1rpm rpm 35rpm Ambient Temperature ( o C) Ambient Temperature ( o C) Ratio 5 Ratio 1 Ratio 16 17,, 25, 32, 4 17,, 25, 32, 4 17,, 25, 32, 4 1 Graph Graph Graph Efficiency (%) r/min 1r/min 5rrpm 1rpmn r/min rpmn 35rpm 35r/min Efficiency (%) 3 3% rpm 1rpm rpmn 35rpm rpm 1rpmn rrpm 35rpmn Ambient Temperature ( o C) Ambient Temperature ( o C) Ambient Temperature ( o C) Efficiency (%) 279

17 Gear Unit SHD Checking output bearing A precision cross roller bearing is built in the unit type to directly support the external load (output flange). Check the maximum moment load, life of the cross roller bearing and static safety coefficient to fully bring out the performance of the unit type. See page 3 to 34 of "Engineering data" for each calculation formula. Checking procedure (1) Checking the maximum moment load (Mmax) Calculate the maximum moment load (Mmax). (2) Checking the life Calculate the average radial load (Frav) and the average axial load (Faav). (3) Checking the static safety coefficient Calculate the static equivalent radial load coefficient (Po). Maximum moment load (Mmax) allowable moment (Mc) Calculate the radial load coefficient (x) and the axial load coefficient (y). Check the static safety coefficient. (fs) Calculate the lifetime Output bearing specifications The specifications of the cross roller are shown in Table Specifications Table 28-1 Pitch circle dia. of a roller Offset Basic rated load Allowable Moment stiffness Km Basic dynamic rated load Basic static rated load moment load Mc dp R C Co 1 4 Nm/rad kgfm/arc min m m 1 2 N kgf 1 2 N kgf Nm kgfm (Note) * The basic dynamic rated load is the static radial load needed to result in a basic dynamic rated life of one million rotations. * The basic static rated load is the static load that produces a contact stress of 4 kn/mm2 in the center of the contact area between the rolling element receiving the maximum load. * The moment stiffness value is an average. * Allowable moment load is the maximum moment load that may be applied to the output shaft. Please adhere to these values for optimum performance. Moment stiffness is a reference value. The minimum value is approximately 8% of the displayed value. * Allowable axial or radial load is the value that satisfies the reducer life when either a radial load or an axial load is applied to the main shaft. (When radial load is Lr+R=mm, and axial load is La=mm) * As the life of the cross roller bearing of the unit of the reduction ratio corresponding to the table below (Table 28-2) is shorter than that (note) of the gear during operation under the allowable moment load, consideration should be made in designing the load condition and the lifetime. (Note) The life of the gear indicates the life (L1=7 hours) of the wave generator bearing when it operates at rpm input rotational speed and the rated torque (see "Life of the wave generator" on Page ). Life of cross roller bearing < Life of Reducer Table 28-2 Ratio

18 Simplicity Unit (2SH) Design Guide Installation accuracy For peak performance of the gear, it is essential that the following tolerances be observed when assembly is complete. Pay careful attention to the following points and maintain the recommended assembly tolerances to avoid grease leakage. Gear Unit SHD Warping and deformation on the mounting surface Contamination due to foreign matter Burrs, raised surfaces and location around the tap area of the mounting holes Insufficient chamfering on the mounting pilot joint Insufficient radii on the mounting pilot joint Recommended tolerances for assembly Fig φb A Recommended shaft tolerance H6 or h6 A B Case mating face c B Recommended housing tolerance H7 Recommended housing tolerance a φb c d φe a A Flexspline mounting face d B Wave generator mounting face φe B Recommended shaft tolerance h Table Unit:mm H7 Recommended tolerances for assembly Symbol 281

19 Gear Unit SHD Unit Type (2UH) Design Guide Output part and fixed part Fig The output part of the SHD series varies depending on where it is to be fixed. The reduction ratio and the rotational direction also change. The relation is shown below. (A) side (B) side Fixed part (A) side (B) side Output part (B) side (A) side Table Rotational direction and reduction ratio (2) on page 11 (1) on page 11 Installation and transmission torque Installation and transmission torque on (A) side Table Item Number of bolts 8 Bolt size Pitch Circle Diameter Clamp torque mm Nm M M M M M M Transmission torque Nm (Notes) 1. The material of the thread must withstand the clamp torque. 2. Recommended bolt: JIS B 1176 socket head cap screw. Strength range : JIS B 151 over Torque coefficient: K=.2 4. Tightening coefficient: A= Tightening friction coefficient μ=.15 Installation and transmission torque on (B) side Table Item Number of bolts 8 Bolt size Pitch Circle Diameter mm M3 43 M3 52 M M4 76 M5 99 M6 Effective depth of screw part mm Clamp torque Nm Transmission torque Nm (Notes) 1. The material of the thread must withstand the clamp torque. 2. Recommended bolt: JIS B 1176 socket head cap screw. Strength range : JIS B 151 over Torque coefficient: K=.2 4. Tightening coefficient: A= Tightening friction coefficient μ=.15 * Since the flange material on the case side is AL (aluminum), be sure to tighten the bolt to the specified torque as described above. If the tightening torque exceeds the above value, the correct transmission torque may not be secured or the bolt may be loosened. Use washers instead of putting the aluminum directly on the bolt-bearing surface when tightening with the bolt from the A side. 282

20 Recessing of the mounting pilot When the housing interferes with corner A shown below, an undercut in the housing is recommended. Mounting pilot Fig Recommended housing undercut Gear Unit SHD Fig Axial force of the wave generator When a SHD gear is used to accelerate a load, the deflection of the Flexspline leads to an axial force acting on the Wave Generator. This axial force, which acts in the direction of the back end of the Flexspline, (toward the left in fig ) must be supported by the bearings of the input shaft (motor shaft). When an SHD gear is used to decelerate a load, an axial force acts to push the Wave Generator out of the Flexspline (toward the right in fig ). Maximum axial force of the Wave Generator can be calculated by the equation shown to the right. The axial force may vary depending on its operating condition. The value of axial force tends to be a larger number when using high torque, extreme low speed and constant operation. The force is calculated (approximately) by the equation. In all cases, the Wave Generator must be axially (in both directions), as well as torsionally, fixed to the input shaft. (Note) Please contact us for further information on attaching the Wave Generator to the input (motor) shaft. Axial force of the wave generator Fig A Formula for axial force F D T 2μPF Ratio i =5:1 i =1:1 more F=2 F=2 T D T D Axial force by bearing reaction force Model 17 SHD Symbols of the calculation formula Axial force ().254 Output torque Axial force by bearing reaction force Calculation formula.7 tan 3 +2μPF.7 tan +2μPF N m Nm N Table Table μPF(N) Table See Fig See Table Axial force direction when the speed is reduced Lubrication F F Axial force direction when the speed is increased Standard lubrication for SHD series is grease lubrication. See "Engineering data" on Page 16 for details of the lubricant. Calculation example Model : SHD : 32 Ratio : i=5:1 Output torque : Nm F=2.7 tan3 +16 (32.254) F=215N Formula Recommended minimum housing clearance These dimensions must be maintained to prevent damage to the gear and to maintain a proper grease cavity. Minimum housing clearance Symbol φa b φc d e (3) (3) (4.5) (4.5) (6) Table Unit: mm (7.5) (Note) The value in parenthesis is the value when the wave generator is facing upward. Recommended minimum housing clearance Fig Maximum Length for Installation (Internal diameter is d e b used for attachment) φc φa Counter bore for bolt head 283

21 Gear Unit SHD Application guide As the SHD series is shipped with the outer race of the cross roller bearing and the flexspline temporarily bolted together, grease is applied to the gear teeth, the periphery of the flexspline and the tooth groove of the circular spline. Refer to the following application guide for grease application instructions. Application guide Table Cross roller bearing (outer race) Circular spline Wave Generator Flexspline Thickness of diameter of wave generator bearing Apply grease to inner surface in accordance with a value shown below Apply thin coating of grease before installation Fill cavity between retainer and bearing with grease Application quantity Application qty When to replace grease SK-1A SK The wear characteristics of the gear is strongly influenced by the condition of the grease lubrication. The condition of the grease is affected by the ambient temperature. The graph shows the maximum number of input rotations for various temperatures. This graph applies to applications where the average load torque does not exceed the rated torque. Formula when the average load torque exceeds the rated torque Formula Tr LGT=LGTn Tav When to replace grease: LGTn (when the average load torque is equal to or less than the rated torque) Graph The total number of rotations of the wave generator corresponding to the time to replace grease (times) Life of grease 4B No.2 Life of wave generator * Grease temperature ( o C) * Life of wave generator is based on L1 life of the bearing. 3 Symbols for formula LGT LGTn Tr Tav Replacement timing if average load torque exceeds rated torque Replacement timing if average load torque is equal to or less than rated torque (or use formulas, i.e. Tav Tr) Rated torque Average load torque Number of input revolutions Number of input revolutions Nm Nm Table Unit: g Table See Fig. on the left. See the Rating table on Page 27. Calculation formula: See Page. Other precautions 1. Avoid using it with other grease. The gear should be in an individual case when installed. 2. If you use the gear with the wave generator facing upward (see Figure 5-2 on Page 5) at low-speed rotation (input rotational speed: 1 rpm or less) and in one direction, please contact us as it may cause lubrication problems. 3. Fill the gap between the wave generator and the input cover (motor flange) with grease to use the wave generator facing upward or downward (see Figure 94-2 on Page 94). 284

22 Precautions on installation Assembly order of the three basic elements The wave generator is installed after the flexspline and circular spline. If the wave generator is not inserted into the flexspline last, gear teeth scuffing damage or improper eccentric gear mesh may result. Installation resulting in an eccentric tooth mesh (Dedoidal) will cause noise and vibration, and can lead to early failure of the gear. For proper function, the teeth of the flexspline and Circular Spline mesh symmetrically. Assembly order for basic three elements Gear Unit SHD Fig Wave generator Wave generator Precautions on assembly It is extremely important to assemble the gear accurately and in proper sequence. For each of the three components, utilize the following precautions. Circular spline Flexspline Cross roller bearing (Note) Do not build in the wave generator from the diaphragm side of flexspline. Wave generator 1. Avoid applying undue axial force to the wave generator during installation. Rotating the wave generator bearing while inserting it is recommended and will ease the process. 2. Extra care must be given to ensure that concentricity and inclination are within the specified limits (see page 281). 3. Installation bolts on the Wave Generator and Flexspline should not interfere each other. Circular spline The circular Spline must not be deformed in any way during the assembly. It is particularly important that the mounting surfaces are prepared correctly. 1. Mounting surfaces need to have adequate flatness, smoothness, and no distortion. 2. Especially in the area of the screw holes, burrs or foreign matter should not be present. 3. Adequate relief in the housing corners is needed to prevent interference with the corner of the circular spline. 4. The circular spline should be rotatable within the housing. Be sure there is not interference and that it does not catch on anything. 5. Bolts should not rotate freely when tightening and should not have any irregularity due to the bolt hole being misaligned or oblique. 6. Do not tighten the bolts with the specified torque all at once. Tighten the bolts temporarily with about half the specified torque, and then tighten them with the specified torque. Tighten them in an even, crisscross pattern. 7. Avoid pinning the circular spline if possible as it can reduce the rotational precision and smoothness of operation. Flexspline 1. Mounting surfaces need to have adequate flatness, smoothness, and no distortion. 2. Especially in the area of the screw holes, burrs or foreign matter should not be present. 3. Adequate clearance with the housing is needed to ensure no interference especially with the major axis of flexspline 4. Bolts should rotate freely when installing through the mounting holes of the flexspline and should not have any irregularity due to the shaft bolt holes being misaligned or oblique. 5. Do not tighten the bolts with the specified torque all at once. Tighten the bolts temporarily with about half the specified torque, and then tighten them to the specified torque. Tighten them in an even, crisscross pattern. 6. The flexspline and circular spline are concentric after assembly. After installing the wave generator bearing, if it rotates in unbalanced way, check the mounting for dedoidal or non-concentric installation. 7. Care should be taken not to damage the flexspline diaphragm or gear teeth during assembly. Avoid hitting the tips of the flexpline teeth and circular spline teeth. Avoid installing the CS from the open side of the flexspline after the wave generator has been installed. Rust prevention Although Harmonic Drive gears come with some corrosion protection, the gear can rust if exposed to the environment. The gear external surfaces typically have only a temporary corrosion inhibitor and some oil applied. If an anti-rust product is needed, please contact us to review the options. 285

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24 Tooth profile Rotational direction and reduction ratio Rating table definitions Life Torque limits Product sizing and selection Lubrication Torsional stiffness Positional accuracy Vibration Starting torque Backdriving torque No-load running torque Efficiency Design guidelines Assembly guidelines Checking output bearing S tooth profile Cup style Silk hat style Pancake style Grease lubricant Precautions on using Harmonic Grease 4B No.2 Oil lubricant Lubricant for special environments Design guideline Bearing support of the input and output shafts Wave Generator Sealing Assembly Precautions "dedoidal" state Checking procedure How to calculate the maximum moment load How to calculate the average load How to calculate the radial load coefficient (X) and axial load coefficient (Y) How to calculate life How to calculate the life under oscillating movement How to calculate the static safety coefficient

25 Tooth Profile S tooth profile Harmonic Drive developed a unique gear tooth profile that optimizes the tooth engagement. It has a special curved surface unique to the S tooth profile that allows continuous contact with the tooth profile. It also alleviates the concentration of stress by widening the width of the tooth groove against the tooth thickness and enlarging the radius on the bottom. This tooth profile (the S tooth ) enables up to 3% of the total number of teeth to be engaged simultaneously. Additionally the large tooth root radius increases the tooth strength compared with an involute tooth. This technological innovation results in high torque, high torsional stiffness, long life and smooth rotation. *Patented Engaged route of teeth Conventional tooth profile Fig. 9-1 Engaged area of teeth Fig. 9-2 S tooth profile Beginning of engagement Optimum engaged status 9

26 Rotational direction and reduction ratio Cup Style Series: CSG, CSF, CSD, CSF-mini Rotational direction Fig Input * R indicates the reduction ratio value from the ratings table. Output (Note) Contact us if you use the product as Accelerator (5) and (6). FS CS (1) Reducer Input: Wave Generator (WG) Output: Flexspline (FS) Fixed: Circular Spline (CS) WG i= ー 1 R (2) Reducer Input: Wave Generator Output: Circular Spline Fixed: Flexspline i= ー 1 R+1 (3) Reducer Input: Flexspline Output: Circular Spline Fixed: Wave Generator i= ー R R (4) Overdrive Input: Circular Spline Output: Flexspline Fixed: Wave Generator i= ー R+1 R (5) Overdrive Input: Flexspline Output: Wave Generator Fixed: Circular Spline i= R (6) Overdrive Input: Circular Spline Output: Wave Generator Fixed: Flexspline i=r+1 (7) Differential When all of the wave generator, the flexspline and the circular spline rotate, combinations (1) through (6) are available. Silk hat Series: SHG, SHF, SHD Rotational direction Fig Input * R indicates the reduction ratio value from the ratings. table Output (Note) Contact us if you use the product as an overdrive of (5) or (6). (1) Reducer Input: Wave Generator Output: Flexspline Fixed: Circular Spline i= ー 1 R (2) Reducer Input: Wave Generator Output: Circular Spline Fixed: Flexspline i= ー 1 R+1 (3) Reducer Input: Flexspline Output: Circular Spline Fixed: Wave Generator i= ー R R (4) Overdrive Input: Circular Spline Output: Flexspline Fixed: Wave Generator i= ー R+1 R (5) Overdrive Input: Flexspline Output: Wave Generator Fixed: Circular Spline i= R (6) Overdrive Input: Circular Spline Output: Wave Generator Fixed: Flexspline i=r+1 (7) Differential When all of the wave generator, the flexspline and the circular spline rotate, Combinations (1) through (6) are available. 1

27 Pancake Series: FB and FR Rotational direction Fig Input Output (Note) Contact us if you use the product as Accelerator (5) and (6). Output (1) Reducer Input: Wave Generator Output: Circular Spline D Fixed: Circular Spline S Input i= ー 1 R Output (2) Reducer Input: Wave Generator Output: Circular Spline S Fixed: Circular Spline D Input i= ー 1 R+1 Output Input (3) Reducer Input: Circular Spline D Output: Circular Spline S Fixed: Wave Generator i= ー R R Output Input (4) Overdrive Input: Circular Spline S Output: Circular Spline D Fixed: Wave Generator i= ー R+1 R Input Output Input Output (5) Overdrive Input: Circular Spline S Output: Wave Generator Fixed: Circular Spline D i=r+1 (6) Overdrive Input: Circular Spline D Output: Wave Generator Fixed: Circular Spline S i= R (7) Differential When all of the Wave Generator, the Circular Spline S and the Circular Spline D rotate, Combinations (1) through (6) are available. Reduction ratio The reduction ratio is determined by the number of teeth of the Flexspline and the Circular Spline Number of teeth of the Flexspline: Number of teeth of the Circular Spline: Input: Wave Generator Output: Flexspline Fixed: Circular Spline Reduction ratio Zf Zc 1 i1 = = Input: Wave Generator Reduction 1 Output: Circular Spline i2 ratio = = Fixed: Flexspline R 2 R1 indicates the reduction ratio value from the ratings table. R 1 Zf-Zc Zf Zc-Zf Zc Example Number of teeth of the Flexspline: Number of teeth of the Circular Spline: 2 Input: Wave Generator Output: Flexspline Fixed: Circular Spline Input: Wave Generator Output: Circular Spline Fixed: Flexspline Reduction ratio Reduction ratio 1-2 i1 = = = R i2 = = = R

28 Rating Table Definitions See the corresponding pages of each series for values. Rated torque Rated torque indicates allowable continuous load torque at rated input speed. Limit for Repeated Peak Torque (see Graph -1) During acceleration and deceleration the Harmonic Drive gear experiences a peak torque as a result of the moment of inertia of the output load. The table indicates the limit for repeated peak torque. Limit for Average Torque In cases where load torque and input speed vary, it is necessary to calculate an average value of load torque. The table indicates the limit for average torque. The average torque calculated must not exceed this limit. (calculation formula: Page ) Limit for Momentary Peak Torque (see Graph -1) The gear may be subjected to momentary peak torques in the event of a collision or emergency stop. The magnitude and frequency of occurrence of such peak torques must be kept to a minimum and they should, under no circumstance, occur during normal operating cycle. The allowable number of occurrences of the momentary peak torque may be calculated by using formula Maximum Average Input Speed Maximum Input Speed Do not exceed the allowable rating. (calculation formula of the average input speed: Page ). Example of application motion profile + Load torque + Wave Generator rotational speed Start Steady Stop (Speed cycle) Start Abnormal impact torque Time Load Torque Repeated Peak Torque Time Graph -1 Momentary Peak Torque Moment of Inertia The rating indicates the moment of inertia reflected to the gear input. Life Life of the wave generator The life of a gear is determined by the life of the wave generator bearing. The life may be calculated by using the input speed and the output load torque. Calculation formula for Rated Lifetime Ln Tr Nr Tav Nav Series name L1 CSF, CSD, SHF, SHD, CSF-mini 7, hours 35, hours 3 Tr Lh=Ln Tav Life Nr Nav CSG, SHG 1, hours 5, hours L5 (average life) * Life is based on the input speed and output load torque from the rating table. Table -1 Formula -1 Life of L1 or L5 Rated torque Rated input speed Average load torque on the output side (calculation formula: Page ) Average input speed (calculation formula: Page ) Table -2 Relative torque rating Load torque (when the rated torque is 1) Momentary peak torque Graph -2 Buckling torque Racheting torque Life of wave generator (L1) Fatigue strength of the flexspline 2 Repeated peak torque 1 Rated torque Total number of input rotations * Lubricant life not taken into consideration in the graph described above. * Use the graph above as reference values.

29 Torque Limits Strength of flexspline The Flexspline is subjected to repeated deflections, and its strength determines the torque capacity of the Harmonic Drive gear. The values given for Rated Torque at Rated Speed and for the allowable Repeated Peak Torque are based on an infinite fatigue life for the Flexspline. The torque that occurs during a collision must be below the momentary peak torque (impact torque). The maximum number of occurrences is given by the equation below. Allowable limit of the bending cycles of the flexspline during rotation of the wave generator while the impact torque is applied: 1. x 1 4 (cycles) The torque that occurs during a collision must be below the momentary peak torque (impact torque). The maximum number of occurrences is given by the equation below. Calculation formula Caution N= n 2 t 6 Formula 13-1 Allowable occurances N occurances Time that impact torque is applied t sec Rotational speed of the wave generator n rpm The flexspline bends two times per one revolution of the wave generator. If the number of occurances is exceeded, the Flexspline may experience a fatigue failure. Ratcheting torque When excessive torque (8 to 9 times rated torque) is applied while the gear is in motion, the teeth between the Circular Spline and Flexspline may not engage properly. This phenomenon is called ratcheting and the torque at which this occurs is called ratcheting torque. Ratcheting may cause the Flexspline to become non-concentric with the Circular Spline. Operating in this condition may result in shortened life and a Flexspline fatigue failure. * See the corresponding pages of each series for ratcheting torque values. * Ratcheting torque is affected by the stiffness of the housing to be used when installing the circular spline. Contact us for details of the ratcheting torque. Caution Caution When ratcheting occurs, the teeth may not be correctly engaged and become out of alignment as shown in Figure Operating the drive in this condition will cause vibration and damage the flexspline. Once ratcheting occurs, the teeth wear excessively and the ratcheting torque may be lowered. Circular Spline Figure 13-1 Buckling torque When a highly excessive torque (16 to 17 times rated torque) is applied to the output with the input stationary, the flexspline may experience plastic deformation. This is defined as buckling torque. * See the corresponding pages of each series for buckling torque values. "Dedoidal" condition. Flexspline Warning When the flexspline buckles, early failure of the HarmonicDrive gear will occur. 13

30 Product Sizing & Selection In general, a servo system rarely operates at a continuous load and speed. The input rotational speed, load torque change and comparatively large torque are applied at start and stop. Unexpected impact torque may be applied. These fluctuating load torques should be converted to the average load torque when selecting a model number. As an accurate cross roller bearing is built in the direct external load support (output flange), the maximum moment load, life of the cross roller bearing and the static safety coefficient should Flowchart for selecting a size Please use the flowchart shown below for selecting a size. Operating conditions must not exceed the performance ratings. also be checked.+ Checking the application motion profile Review the application motion profile. Check the specifications shown in the figure below. Load torque Output rotational speed ーT1 T2 T3 T4 t1 t2 t3 t4 tn n1 n2 n3 n4 * n1, n2 and nn indicate the average values. nn Tn Time Time Graph -1 Calculate the average load torque applied on the output side from the application motion profile: Tav (Nm). Tav = 3 n 1 t 1 T 1 3 +n 2 t 2 T n n t n T n 3 n 1 t 1 +n 2 t 2 + n n t n Make a preliminary model selection with the following conditions. Tav Limit for average torque torque (See the rating table of each series). Calculate the average output speed: no av (rpm) Obtain the reduction ratio (R). A limit is placed on ni max by motors. Calculate the average input rotational speed from the average output rotational speed (no av) and the reduction ratio (R): ni av (rpm) Calculate the maximum input rotational speed from the max. output rotational speed (no max) and the reduction ratio (R): ni max (rpm) Check whether the preliminary model number satisfies the following condition from the rating table. Ni av n 1 t 1 +n 2 t 2 + n n t n no av = t 1 + t 2 + t n ni max R no max ni av = no av R ni max = no max R Limit for average speed (rpm) Ni max Limit for maximum speed (rpm) NG OK Obtain the value of each application motion profile. Load torque Tn (Nm) Time tn (sec) Output rotational speed nn (rpm) Check whether T1 and T3 are less than the repeated peak torque specification. OK NG Normal operation pattern Starting (acceleration) Steady operation (constant velocity) Stopping (deceleration) Dwell Maximum rotational speed Max. output speed Max. input rotational speed (Restricted by motors) Emergency stop torque When impact torque is applied T1, t1, n1 T2, t2, n2 T3, t3, n3 T4, t4, n4 no max ni max Ts, ts, ns Check whether Ts is less than the the momentary peak torque specification. Calculate (Ns) the allowable number of rotations during impact torque. OK 1 N 4 S = N S n S R 2 t 6 OK NG NG Review the operation conditions and model number Required life L1 = L (hours) Calculate the lifetime. L 1 = 7 ( ) ( ) (hours) OK Tr Tav 3 nr ni av Check whether the calculated life is equal to or more than the life of the wave generator (see Page 13). The model number is confirmed. NG

31 Example of model number selection Value of each application motion profile Load torque T(Nm) n Time t(sec) n Output speed n(rpm) n Maximum rotational speed Max. output speed Max. input speed (Restricted by motors) no max = rpm ni max = 18 rpm Normal operation pattern Starting (acceleration) T1 = 4 Nm, t1 =.3sec, n1 = 7rpm Steady operation (constant velocity) T2 = 3 Nm, t2 = 3sec, n2 = rpm Stopping (deceleration) T3 = Nm, t3 =.4sec, n3 = 7rpm Dwell T4 = Nm, t4 =.2 sec, n4 = rpm Emergency stop torque When impact torque is applied Required life Ts = 5 Nm, ts =.15 sec, ns = rpm L 1 = 7 (hours) Calculate the average load torque to the output side based on the application motion profile: Tav (Nm). Tav = 3 7 rpm.3 sec 4Nm 3 + rpm 3 sec 3Nm 3 +7 rpm.4 sec Nm 3 7 rpm.3 sec+ rpm 3 sec+7 rpm.4 sec Make a preliminary model selection with the following conditions. Tav = 319 Nm 6 Nm (Limit for average torque for model number CSF-4--2A-GR: See the rating table on Page 39.) Thus, CSF-4--2A-GR is tentatively selected. Calculate the average output rotational speed: no av (rpm) Obtain the reduction ratio (R). Calculate the average input rotational speed from the average output rotational speed (no av) and the reduction ratio (R): ni av (rpm) Calculate the maximum input rotational speed from the maximum output rotational speed (no max) and the reduction ratio (R): ni max (rpm) 7 rpm.3 sec+ rpm 3 sec+7 rpm.4 sec no av = = rpm.3 sec + 3 sec +.4 sec +.2 sec 18 rpm = 8.6 rpm ni av = rpm = 4 rpm ni max = rpm = 168 rpm Check whether the preliminary selected model number satisfies the following condition from the rating table. Ni av = 4 rpm 36 rpm (Max average input speed of size 4) Ni max = 168 rpm 56 rpm (Max input speed of size 4) OK NG Check whether T1 and T3 are equal to or less than the repeated peak torque specification. T1 = 4 Nm 617 Nm (Limit of repeated peak torque of size 4) T3 = Nm 617 Nm (Limit of repeated peak torque of size 4) OK NG Check whether Ts is equal to or less than the momentary peak torque specification. Ts = 5 Nm 118 Nm (Limit for momentary torque of size 4) Calculate the allowable number (Ns) rotation during impact torque and confirm Calculate the lifetime. OK OK OK 1 N 4 S == rpm 2.15 sec 6 L 1 = 7 ( ) 294 Nm Nm ( ) rpm 4 rpm (hours) Check whether the calculated life is equal to or more than the life of the wave generator (see Page ). L 1 =761 hours 7 (life of the wave generator: L1) The selection of model number CSF-4--2A-GR is confirmed from the above calculations. NG NG NG Review the operation conditions, size and reduction ratio 15

32 Lubrication : CSD-2A, CSF-2A, CSG-2A, FB-2, FB-, FR-2, SHF-2A, SHG-2A and SHD and SHG/SHF -2SO and -2SH gear units: Grease lubricant and oil lubricant are available for lubricating the component sets and SHD gear unit. It is extremely important to properly grease your component sets and SHD gear unit. Proper lubrication is essential for high performance and reliability. Harmonic Drive component sets are shipped with a rust- preventative oil. The characteristics of the lubricating grease and oil types approved by Harmonic Drive are not changed by mixing with the preservation oil. It is therefore not necessary to remove the preservation oil completely from the gear components. However, the mating surfaces must be degreased before the assembly. : CSG/CSF 2UH and 2UH-LW; CSD-2UF and -2UH; SHG/SHF-2UH and 2UH- LW; SHG/SHF-2UJ; CSF Supermini, CSF Mini, and CSF-2UP. Grease lubricant is standard for lubricating the gear units. You do not need to apply grease during assembly as the product is lubricated and shipped. See Page 19 for using lubricant beyond the temperature range in table * Contact us if you want consistency zero (NLGI No.) for maintenance reasons. Grease lubricant Types of lubricant Harmonic Grease SK-1A This grease was developed for Harmonic Drive gears and features good durability and efficiency. Harmonic Grease SK-2 This grease was developed for small sized Harmonic Drive gears and features smooth rotation of the Wave Generator since high pressure additive is liquefied. Harmonic Grease 4B No.2 This has been developed exclusively for the CSF and CSG and features long life and can be used over a wide range of temperature. (Note) 1. Grease lubrication must have proper sealing, this is essential for 4B No.2. Rotating part: Oil seal with spring is needed. Mating part: O ring or seal adhesive is needed. 2. The grease has the highest deterioration rate in the region where the grease is subjected to the greatest shear (near wave generator). Its viscosity is between JIS No. and No. depending on the operation. NLGI consistency No. Mixing consistency range SK-1A SK-2 4B No.2 Table 16-3 Name of lubricant Table 16-1 Harmonic Grease SK-1A Grease Harmonic Grease SK-2 Harmonic Grease 4B No.2 Oil Industrial gear oil class-2 (extreme pressure) ISO VG68 Temperature Table 16-2 SK-1A ºC to + 4ºC Grease SK-2 ºC to + 4ºC 4B No.2 1ºC to + 7ºC Oil ISO VG68 ºC to + 4ºC * The hottest section should not be more than 4 above the ambient temperature. Note: The three basic components of the gear - the Flexspline, Wave Generator and Circular Spline - are matched and serialized in the factory. Depending on the product they are either greased or prepared with preservation oil. Then the individual components are assembled. If you receive several units, please be careful not to mix the matched components. This can be avoided by verifying that the serial numbers of the assembled gear components are identical. Compatible grease by size Compatible grease varies depending on the size and reduction ratio. See the following compatibility table. We recommend SK-1A and SK-2 for general use. Ratios 3:1 SK-1A SK-2 4B No.2 SK-1A SK-2 4B No.2 SK-1A SK-2 4BNo Ratios 5:1* and above SK-1A - - SK-2 Table 16-5 Table 16-6 : Standard grease : Semi-standard grease : Recommended grease for long life and high load * Oil lubrication is required for component-sets size 5 or larger with a reduction ratio of 5:1. Grease characteristics Grease specification Table 16-4 Table 16-7 Grease Base oil Refined oil Refined oil Base Viscosity cst (25ºC) Thickening agent NLGI consistency No. Additive Storage life Lithium soap base Extreme-pressure additive, others 5 years in sealed condition Lithium soap base Extreme-pressure additive, others 5 years in sealed condition 355 to to 43 Composite hydrocarbon oil 265 to to to 3 Urea No. 2 No. 2 No. 1.5 Extreme-pressure additive, others Drop Point 197ºC 198ºC 247ºC Appearance Yellow Green Light yellow 5 years in sealed condition Grease Durability Fretting resistance Low-temperature performance Grease leakage Excellent : Good : Use Caution : - - 4B No.2 16