A Comprehensive Guide To Load Sharing Design, Verification, Faults And Mitigation

Degraded Transmission Accuracy: Excessive meshing gaps or uneven contact will increase backlash, reducing positioning accuracy and repeat positioning accuracy, which fail to meet the control requirements of precision equipment.

Limited Load-Carrying Capacity: Localized excessive contact on tooth surfaces leads to contact stress concentration, where a single tooth pair bears a load far exceeding the design value, becoming the weak link of the transmission system and restricting the exertion of the rated power of the entire machine.

Increased Vibration and Noise: Non-uniform meshing generates periodic meshing impact and dynamic excitation, resulting in increased vibration amplitude and noise during the operation of the reducer, affecting the stability and user experience of the equipment.

Premature Component Failure: Stress concentration areas are prone to premature failure modes such as tooth surface wear, pitting, scuffing, and even tooth breakage. At the same time, it accelerates the fatigue damage of the flexspline, significantly shortening the service life of the reducer.

Deteriorated Control Performance: The "idle stroke" caused by meshing gaps leads to hysteresis in the response of the control system, reducing the dynamic tracking performance of the system, especially for high-precision servo control.

Tooth Profile Curve Selection: Involute tooth profiles have mature machining processes and smooth meshing, suitable for medium and low-precision scenarios; circular arc tooth profiles have large contact areas and strong load-carrying capacity, which can effectively disperse contact stress; special conjugate tooth profiles (such as double circular arc tooth profiles and modified tooth profiles) achieve "multi-point contact" by accurately calculating the tooth surface morphology of the flexspline after deformation, greatly improving meshing precision and load uniformity, and are the mainstream choice for high-end harmonic drives.

Tooth Thickness and Module Matching: Select the module reasonably according to the transmission ratio and load size, optimize the tooth thickness design by accurately calculating the flexspline deformation, ensure that the tooth surface contact rate between the flexspline and circular spline after deformation is not less than 90%, and control the meshing gap within the range of 0.01~0.03mm (for precision reducers).

Tooth Tip Modification and Tooth Trace Crowning Design: Appropriately modify the tooth tip to avoid tooth tip interference during meshing; adopt tooth trace crowning design to compensate for the possible axial parallelism deviation during assembly, making the tooth surface contact more uniform.

Processing of Flexspline and Circular Spline Tooth Profiles: Adopt high-precision gear grinding technology to control the tooth profile tolerance ≤ ±0.005mm and cumulative pitch error ≤ 0.01mm/m, ensuring the tooth surface roughness Ra ≤ 0.8μm to reduce meshing friction and uneven contact.

Precision Control of Flexspline Thin-Walled Cylinder: As an elastic component, the roundness, cylindricity, and wall thickness uniformity of the flexspline's thin-walled cylinder directly affect the tooth profile fitting degree after deformation. It is necessary to control the roundness error ≤ 0.008mm and wall thickness deviation ≤ ±0.01mm.

Precision Design of Wave Generator: The cam profile precision of the wave generator determines the deformation morphology of the flexspline. When using a roller-type wave generator, the roller diameter tolerance should be controlled ≤ ±0.003mm, and the cam profile roundness error ≤ 0.005mm to ensure uniform deformation of the flexspline.

Control of Axial Alignment: Ensure the coaxiality of the flexspline, circular spline, and wave generator ≤ 0.01mm during assembly to avoid unilateral tooth surface contact caused by axial offset.

Adjustment of Meshing Gap: Precisely control the meshing gap between the flexspline and circular spline by selecting adjusting shims of different thicknesses, ensuring no jamming and minimizing backlash.

Cleanliness Control: The assembly environment should meet Class 1000 cleanliness requirements to avoid impurities entering the meshing surface and causing tooth surface wear and meshing interference.

Material Selection: The flexspline is made of high-strength alloy structural steel with high elastic limit (such as 40CrNiMoA, 17-4PH stainless steel) to ensure no permanent plastic deformation after deformation; the circular spline is made of high-hardness and wear-resistant alloy steel (such as GCr15, 20CrMnTi) to improve the wear resistance of the tooth surface.

Heat Treatment Processes: The flexspline undergoes quenching and tempering + surface nitriding treatment, with hardness controlled at HRC38~42 to ensure a balance between elasticity and wear resistance; the circular spline undergoes quenching + low-temperature tempering treatment, with hardness controlled at HRC58~62 to enhance the tooth surface load-carrying capacity; key components need to undergo aging treatment to eliminate internal stress and ensure dimensional stability.

Definition: The normal gap between the non-working tooth surfaces when the flexspline and circular spline are meshed.

Significance: Meshing gap is a key factor affecting backlash. Precision harmonic drives require jₙ ≤ 0.02mm, and ultra-high precision drives require jₙ ≤ 0.01mm.

Calculation Method: Based on the flexspline elastic deformation theory, establish a tooth profile meshing geometric model, and derive the normal gap value through geometric relationships combined with parameters such as tooth thickness deviation and center distance deviation.

Definition: The ratio of the actual meshing contact tooth surface area to the theoretical meshing area.