ADEKO

Jurnal of Mechanical
Engineering Design

Vol.11 No 1, 2008.
pp 14-22

Scientific paper

Experimental Research Concerning the Deforming Curve

of the Harmonic Drive
Remus I. ERBAN

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In this paper there is presented an experimental research concerning the measurements of the
harmonic drive deforming curve using an elliptical generator. The main purpose is to compare
the real deforming curves of the flexible gear teeth, raised using different loads, with the
calculated deforming curve. The second purpose is to evaluate the influence of the load
primarily on the flexible gear and also on the gearing.

1.

1. Harmonic Drives History and the Actual

Industrial Context

1959. .
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1972. 10,
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1980.
(. Position-Pick-up unit) , 20000 ,
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Harmonic drive, the commercial name of the strain wave

gearing invented and patented by C. Walton Musser
(1959), is the new generation of high ratio gearings. This
can be considered the beginning of the new era for
technical solutions concerning the movement precision of
high ratio gearing. The Musser solution was developed and
utilized for the first time by United Shoe Machinery Ltd.
and Hasegawa Gear Work Ltd. (1964). Among the first
who have been interested in this type of gearing were the
army and the aerospace industry.
Historically the first major application was an aerospace
one, the harmonic drive being used at the mechanical
transmission within the individual wheel drives of the
Lunar Roving vehicle, in the Apollo 15 mission to the
Moon (1971). In the same period another important
application was the telescope drive actuator for the imaging
photopolarimeter assembled on Pioneer 10, NASAs
planetary probe (1972), which operated thirty years later
([1], Schfer and Slatter, 2003).
Since 1980 a special device used for detecting the flap
angle, the Position-Pick-up unit, of the Airbus have been
manufactured in more then 20000 units without a single
operating failure.
There are many other applications within the aerospace
domain: the communications, weather and military
surveillance satellites use harmonic drive mechanism for
antennas actuators and control; the positioning mechanisms
of the Hubble space telescope (launched in 1990);
applications which include communications.

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In the 1970s and 1980s the range of applications begins to

extend into the civil engineering, industrial robotics and
machine tools. The number of applications increases year
after year, so that this type of gearing is now considered
the standard for precise positioning drives.
For the reason of precision and many others harmonic drive
was used and still is used in most fields of technical
conception: machine tools (routers, milling, water jet or
flame cutting machines); printing and converting machines
(small motors, input and speed control equipments);
robotics (arm movement, hand positioning); medical
equipment (patient beds, MRI Cat scan gantries, radiation
therapy equipment, surgical robots, imaging camera
positioning); semiconductors (equipment for high positional
accuracy, reproducibility and low vibration, electron beam
inspection tool); aerospace and military equipment.
The advantages of the harmonic drive are:
High single stage coaxial reduction ratios (1/30 to
1/320);
High positional accuracy and repeatability due to the
great number of mating teeth (50% of the teeth are
mating with 50% of the teeth of the mating gears) which
have as result the equalizing and neutralising the
accumulated pitch errors on rotational accuracy;
High torque ratio in small size (30% smaller then a
conventional product) and lightweight (50% smaller
weight);
High torque capacity due to the 30% of the teeth which
are always taking some load and these teeth come in
contact with one another face to face; Therefore every
tooth is subjected to a minimum force while providing a
maximum of torque;
High efficiency due to the very little slide motion
between the mating teeth; the motion loss due to the
friction is reduced substantially;
Quiet and vibration free operations are possible because
there is no rolling contact between the teeth and the
teeth provide a well balanced force;
Nearly zero backlash;
Capability to work in humid environment;
Capability to work in vacuum environment;
Withstanding of G-force of lift-off;
Smooth operation when reversing direction;
High duty cycle and operational life;
Special materials components manufacturing.

2.

Lets consider a harmonic drive, having a classic shape,

with a cup flexspline and using an elliptic wave generator,
Figure 1.
The main components are: the wave generator, flexspline
and circular spline.
The wave generator is an oval-shaped cam, whose
geometry is elliptic, with a thin ball bearing placed around
the outer circumference of the cam. The wave generator is
mounted onto the motor shaft.

. 1 .
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2. The Trajectory of the Flexible Gear Teeth

15


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.
.

Circular spline
.
Flexspline
Wave generator

The flexspline is a thin, cup-shaped component made of

high resisting and elasticity steel, with teeth formed along
the outer circumference of the cup's opening. The gear's
output shaft is attached to the bottom of the flexspline.
The circular spline is a rigid internal gear with teeth formed
along its inner circumference. These teeth are the same
modulus and the same base pitch size as those of the
flexspline.
The working principle is as it follows, Figure 2: the wave
generator is mounted on the drive shaft and as it is rotated,
it imparts a continuously moving elliptical form or wavelike motion to the flexspline. This causes the meshing of the
external teeth of the flexspline with the internal teeth of the
circular spline. There are two equidistant points of
engagement to progress in a continuous rolling fashion. It
also allows for full tooth disengagement at the two points
opposite the minor axis of the wave generator.

. 1.
( LLC)
Fig. 1. Harmonic drive using elliptic wave generator
(Harmonic Drive. LLC)
. 2.
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z1
z2 (
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16

. 2.

Fig. 2. The harmonic drive principle by using an elliptic
wave generator
Because the number of the teeth of the circular spline z1 is
greater with two then for the flexspline z2 (the elliptic cam
produces two generated waves on the major axis), the
flexible gear pitch is wrapping over the rigid gear pitch.
Due to the difference of the teeth the flexible gear is
rotating, so that at a 360 degree rotation clockwise of the
wave generator the flexspline is rotating with the angle
measured between two teeth. This displacement is always in
the opposite direction of the rotation of the wave generator,
e.g. if the wave generator is rotating in a clockwise
direction, the two teeth per revolution displacement of the
flexspline will be in a counter clockwise direction and vice
versa. The calculated trajectory of the flexspline depends of
modulus and number of teeth.
The theoretic curve corresponding to the teeth trajectory
was determined in my doctoral thesis.
A very important problem is due to low rigidity of the
components: flexible ball bearing and spline, the gearing
could be distorted and the gearing parameters altered. The
measurements of the flexspline deformations when loading
the harmonic drive a necessary to show the real relative
positions of the teeth during gearing and the influence of
the load on the gear kinematics: backlash, carrying capacity
and clearance.
The backlash. Normally the harmonic drive is considered
zero backlash, due to the big number of teeth in contact,
and the clearance becomes zero.
Load torsions the flexible gear and produces some specific
positions different from those theoretically calculated. This


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deflection can reduce the average number of pairs of teeth

in contact. As a consequence, the backlash can increase
especially at the reversing directions.
The carrying capacity. Due to the torque elasticity, the
flexible gear circular deforming creates an effect, which
decreases the carrying capacity, by reducing the gearing
number of teeth.
The clearance. If the deformation of the flexspline is too
high the clearance can reduce to zero in a specific area, the
phenomenon producing the interference of the teeth. In
another specific area the clearance increases and the back
lash can also increase.
Another important influence which must be analysed is the
lubrication of the gearing, when the lubricant film is
squeezed between the flanks of the two gears. If the
uncontrolled deflection of the flexible gear is too high, the
position of the tooth is distorted and in a specific position
the lubricant film can be shared.
heoretical calculus of the stability and rigidity and the
dependence between the rigidity and the thickness wall of a
thin profile is presented by Ponomariov (1964).
Unfortunately a mathematical calculus for the flexible gear
deflection, under the torque ratio is practically impossible.
A mathematical model for the calculus of the torque angle
and the torque deflection is presented in the volume of the
2nd Balkan conference on engineering education (1993).
The model and the results refer to a theoretic calculus on a
hypothetical (ideal) harmonic drive. Practically, the values
of the two parameters are different, due to the complex
stress state which cant be described mathematically with
great precision.

3.

3. Experimental Research for the Deforming

Curve Definition

,
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.

All these reasons lead to experimental measurement of the

deforming curve to clarify the influence of the load on the
parameters described before.
The experiments were made using a cvasistatic testing
stand, which is presented in figure 3.
The stand for static tests is from the class of the linear
testing stands with open energetic flux.
The main components of the stands are:
The rotational displacement transducer is Karl Zeiss,
with precision of 10 seconds;
The income mechanical movement device has the
precision of 60 seconds/ one complete rotation of the
wave generator;
The harmonic drive is a classic gearing with the long
flexible gear;
loading system is mechanical, the maximal torque being
Mt=2000 Nm.
TV camera to view the tooth displacement and the
output rotating angle;
Inductive displacement transducers with precision of
displacement of 0,1 m.

. 3.


Fig. 3. Stand for determining the trajectory of the
flexspline teeth and the displacement of them for an
unloaded and loaded system

3.1. Geometry of the Harmonic Drive Gearing

For the experimental research the main components
(flexspline and circular spline) of the harmonic drive have
been manufactured in the technological laboratories of the
university, using the theoretic results determined by
mathematical modelling of the gearing. The geometric
17

 :
Karl Zeiss,
10 ;

60 ;

;
,
Mt=2000 Nm.

;

0,1 m.
3.1.

( ) ,
.
m = 1 mm (ha = 1 mm; hf = 1,25 mm; c0
= 0,25 mm; = 20).
: z1 = 182 teeth; z2 = 180 teeth; m = 1 mm; x1 = 0,25 mm;
x2 = 0,1; d1 = 182 mm; d2 = 180 mm; da1 =180,5 mm; da2 =
182,2 mm; df1 = 185 mm; df2 = 177,3 mm.
, 180mm.
a = 73,15
mm b = 70,85 mm.
.
3.2.
:
.
(Mt = 0 Nm). .
. 3 . .
.
360.
. . 200, 400, 600, 800 Nm.
200 Nm. , .
,
800 Nm.
,
.

4.

parameters of the two components have been determined

using the basic metric rack normalized for module m = 1
mm (ha = 1 mm; hf = 1,25 mm; c0 = 0,25 mm; = 20). The
main geometric parameters are: z1 = 182 teeth; z2 = 180
teeth; m = 1 mm; x1 = 0,25 mm; x2 = 0,1; d1 = 182 mm; d2
= 180 mm; da1 =180,5 mm; da2 = 182,2 mm; df1 = 185 mm;
df2 = 177,3 mm.
Tooth profile is involute and the length of the cup
flexspline is 180mm.
The wave generator is elliptic with the axis a = 73,15 mm
and b = 70,85 mm. The flexible ball bearing was took over
from the production of a local harmonic drive manufacturer.
3.2. Methodology of Measurements
For defining the trajectory of the flexible gear the
measurements have been made in two situations: unloaded
measurements and loaded measurements.
Unloaded measurements (Mt = 0 Nm). Loading system is
disconnected. The displacements of a tooth are made by
rotating the cam wave generator. The rotation of the cam is
sequential with a step of 3 degrees. The rotation angle is
measured with an high precision microscope. The
displacement of the tooth is measured with the inductive
transducer. The total rotating angle of the wave generator is
360.
Loaded system measurements. For the loaded measurements
the loading equippment is connected. The torque ratios to
which the gearing is tested are: 200, 400, 600, 800 Nm.
The first torque is of 200 Nm. After the measurements of
the flexspline deflexion the system remains loaded. For the
next series of measurements an extra value of the torque is
added, continuing the increasing of the torque, up to the
value of 800 Nm.
The conditions and methodology of testing and the
equipment of measurement are the same.

4. Results of the Measurements

4.1. Measurements of Unloaded Gearing
The diagram of the unloaded system deforming curve is
presented in Figure 4.

4.1.

. 4.
: x - ;
y -
.
18

. 4.
,

Fig. 4. The calculated and the experimental deforming

curve of the flexible gear, for an unloaded system

 , . , .
.

The coordinates are: x axis - the rotation angle of the wave

generator; y axis - vector radius modulus of the elliptical
cam.
The curve marked with () represents the theoretic
deforming curve raised using the algorithm presented in the
paper published in Balkan region conference ([2], 2003).
The curve is described by a point situated at the intersection
of the symmetry axis of the tooth and the pitch circle
(curve).
The curve marked () represents the experimental
deforming curve, measured in a point on the surface of the
cylindrical flexspline, in a position in front of the teeth. If
the two curves are compared, it can be fond out that in the
extreme positions (the rotations angles 0-15 and 75-90)
of the rotating cycle, there is a deviation of approximately
60m, comparative with the theoretical curve.
This fact is explained by the eccentricity of the wave
generator, measured from the symmetry axis. Continuing
the rotation of the cam it can be observed that the deviation
has the same value but it had opposite side. This confirms
the explanation given before.

4.2.

4.2. Measurements of loaded gearing

,
:

.

For the loaded system the diagrams of the deforming curves

had been raised in two situations: the deforming curve at
the beginning of the gearing and the deforming curve at the
end of the gearing.

()
([2], 2003).

().
()
,
, . , (
0-15 and 75-90)
60m, .

I. The deforming curve at the beginning of gearing. The

diagrams have been raised using the same coordinate
system used for measurements of the unloaded deforming
curve. The torque ratios for the experiments were: 200, 400,
600, 800 Nm.
There are three different angular zones:
a) Rotating angle of the wave generator 0 < 30, Fig. 5.
Analysing the diagrams, one can say the following:
the absolute displacement increases by increasing the
torque ratio;
the relative displacement is decreasing by increasing the
torque, figure 6; This happened due to the increasing of
the rigidity which stabilises the flexspline shape.

. 5.
,
0 < 30
Fig. 5. Experimental deforming curves at the beginning of
the gearing, for different torque, rotating angle 0 < 30

. 6.

Fig. 6. The relative deformation under different torque
ratio.
Increasing the absolute displacement, the clearance between
the two teeth is reducing up to zero and the flanks of the
19

I. .

.

: 200, 400, 600, 800 Nm.
:
a) 0 < 30, . 5.
, :

;
, . 6;
.
,
.
.
b) 30 < 60.

.

.
c) 60 < 90, . 7.
. ,
. , 60,
(. 7.)
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.
.
.
,
(RE 6 m).
II. .
. 8.
, .
, .
:
0 < 15 (. 8);
.
,
,
.
15 < 30, (. 8);
. . .
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,
.
20

conjugate tooth come in contact. The lubricant film is

squeezed and frequently cut.
b) Rotating angle of the wave generator 30 < 60.
In this area the experimental curves and the theoretic one
are overlapped.
The teeth begin to enter the gearing and the clearance
becomes smaller up to the minimum value.
c) Rotating angle of the wave generator 60 < 90, Fig. 7.

. 7.
,
60 < 90
Fig. 7. Experimental deforming curves at the beginning of
the gearing, for different torque, rotating angle 60 < 90
In this area it produces the entire gearing, the circular pitch
of rigid gear comes tangent to the curved pitch of the
flexible gear. Due to the torque, beginning with a rotating
angle of 60 degrees the deforming curves separates (see
Fig. 7) and the relative deforming variation is increasing
with the torque.
The phenomenon can be explained by the beginning of the
elastic upsetting of the flexible gear. For this reason it
produces the pushing of the tooth of the flexible gear into
the empty of the rigid gear. The pushing force increases
with the resisting torque.
Concerning the values of the relative displacements, these
are very low (RE 6 m).
II. The deforming curve at the end of the gearing. The
diagrams are presented in figure 8.
Continuing the rotation of the wave generator the
displacement of the gears changes and produces the quitting
of the gearing.

In this area, behind the wave generator in appears the

elastic upsetting of the flexible gear material. There are
three different main zones:
Rotation angle is 0 < 15 (see figure 8); The contact
of the teeth is at the level of the pitch diameter. The teeth
are in full gearing and the elastic upsetting is prevented and
the clearance between the elements in contact becomes
zero.
Rotation angle is 15 < 30, figure 8;
In this area the teeth are getting out from the gearing. The
clearance from flanks increases and the wall of the flexible
gear has free deforming up to the maxima value. The
maximal value of the flexible gear deforming is decreasing
if increasing of the torque. The explanation is that, if the
torque is increasing, due to the elastic deformations the
clearance in that area becomes zero. The rigidity increases
and the deformation decreases. With the increasing of the
torque the propagation of the amplitude of the deformation
increases (see Fig. 10).

. 8.
,
0 < 30
Fig. 8. Experimental deforming curves at the end of
gearing, for different torque, rotating angle 0 < 30
9
.
30 < 90;
(RE) ,

= 0 ( ).

5.

,
:

;
, (
,
);

, . 10;

.
;

. 9.
,
60 < 90
Fig. 9. Experimental deforming curves at the end of gearing
for different torque, rotating angle 60 < 90
Taking count of the hypothesis of constant length of the
flexible gear, this thing arises from the tendency of
propagate the deformation towards the zone which is not in
gearing.
In Fig. 9 one can distinguish the qualitative of the two
consequences presented previously.
21

Rotation angle is 30 < 90; The amplitude of

relative deformations (RE) diminishes, so that to the end of
the loop, these values are approximately equals with the
ones obtained for a rotation angle =0 (the tooth beginning
to gear again).

5. Conclusions

. 10.

Fig. 10. The increasing of the deforming amplitude
depending of the torque

Analyzing the results concerning the deforming curve

resulted from the elliptic wave generator, it can be
concluded that:
Flexible gear follows the theoretical deformation curve;
Relative relief of the deformations doesnt depend on
the shape of the deforming curve, but only of the clearances
among the elements in contact (cam-flexible ball bearingflexible gear);
Increasing the torque the amplitude of maximal
deformation decreases, Fig. 10;
Decreasing the amplitude the site upsetting is
increasing. This fact is favourable to the fatigue resistance
due to the flexion of the flexible gear;
There have been no negative influences, by using the
elliptical wave generator.

- References
[1] SCHFER, I., R SLATTER., Precision mechanisms for UAVs using harmonic drive gears, Proceedings of the 2nd
AIAA UAV Conference, San Diego, CA, 2003,
www.aiaa.org/agenda.cfm?lumeetingid=834&formatview=1&dateget=16-Sep-03.
[2] SERBAN, R. I. (2003). The elliptical trajectory of the harmonic drive, gearing_case study, 2nd Balkan region
conference on engineering education, Sibiu, 2003, pp. 228-230.
[3] C. WALTON MUSSERs US Patents. http://www.walt musser .org/PatentUS.htm.
[4] *** Harmonic drive. LLC, http://www.harmonicdrive.net /products /gearheads/csg-unit/.

- Contact address

Remus I. SERBAN, Prof. D.Sc. Eng.

University of Sibiu, Faculty of Engineering, Str. Zaharia Boiu 4, 550006, Sibiu, Romania
remusiserban@yahoo.com

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