谐波齿轮传动系统齿面磨损机理及其动力学特性退化规律研究

Harmonic drives (HDs) are widely used in many fields, including aerospace, robotics, and weapons, etc., whose operational reliability have directly influence on the performance and service life of mechanical equipment. HDs’ performance degradation induced by surface wear of flex spline and circular spline is one of the main causes of their operational reliability reduction. Therefore, this project focuses on surface wear mechanism and dynamic properties degradation of harmonic drive. Firstly, the surface wear model of flex spline and circular spline is established, and the quantitative relations between the wear loss and key dynamic parameters are presented, in order to reveal the surface wear mechanism and its propagation behaviors of flex spline and circular spline. Then, the dynamic model of harmonic drive considering the surface wear is proposed. Based on this model, the dynamic meshing behaviors and their effects on the surface wear and mixed lubrication properties are studied, in order to investigate the coupling effect between the surface wear and dynamics of harmonic drive system. Finally, the effect of surface wear propagation on the nonlinear dynamic properties of harmonic drive system is analyzed, and the optimal feature subset is selected to identify the wear severity, in order to demonstrate the relation between the surface wear propagation and the dynamic properties degradation of harmonic drive system. The research of this project is capable of providing theoretical foundations for the improvement of HDs’ operational reliability, which has important theoretical value and application prospect.

谐波齿轮传动系统广泛应用于航天航空、机器人、军事等领域，其运行可靠性直接制约着整个设备的工作性能及使用寿命，柔轮—刚轮齿面磨损导致的系统性能退化是降低谐波齿轮传动系统运行可靠性的关键因素之一。本项目针对谐波齿轮传动系统齿面磨损机理及其动力学特性退化规律开展研究，首先，建立柔轮—刚轮齿面磨损模型，建立磨损量与关键动力学参数间的量化关系，揭示柔轮—刚轮齿面磨损机理及其演化行为；然后，建立计入齿面磨损的谐波齿轮系统刚柔耦合动力学模型，研究啮合齿对间动态接触行为及其对齿面磨损及混合润滑特性的影响，揭示谐波齿轮传动系统齿面磨损与其动力学行为交互作用机理；最后，对齿面磨损演化过程中系统非线性动力学特性进行研究，提取能有效量化表征齿面磨损程度的最优特征子集，揭示谐波齿轮传动系统齿面磨损演化与其动力学特性退化间的关联性。本项目的研究可为提高谐波齿轮传动系统可靠性提供理论支撑，具有重要的理论意义和工程价值。

谐波减速器是利用机械波控制柔性构件的弹性变形来实现运动和动力传递的一种精密减速器，是机器人关节、星际探测器、卫星天线及雷达等高端机械设备的核心传动部件之一，其精度性能直接影响末端执行机构的定位精度。齿面磨损是导致谐波减速器精度性能退化的主要损伤模式之一。研究谐波减速器磨损机理及服役性能退化智能评估方法，是提升我国谐波减速器质量稳定性的重要环节。谐波减速器齿面磨损受多因素耦合作用，其磨损机理及演化行为具有复杂性。本课题以国产HMCS-32-80-I双圆弧谐波减速器为研究对象，建立柔轮、刚轮齿廓模型、啮合侧隙模型，基于Archard磨损公式建立考虑柔轮变形、混合润滑状态及动态接触行为的柔轮—刚轮齿面磨损累积模型，研究磨损在齿面上的分布规律，研究磨损对啮合侧隙的影响规律，揭示柔轮—刚轮齿面磨损机理及其演化行为。建立谐波齿轮传动系统刚柔耦合有限元模型，搭建谐波减速器性能测试试验台，开展磨损全过程试验，研究磨损演化过程中系统传动精度、效率及非线性振动特性的退化规律。提出了一种基于LTSS-BoW模型的故障特征提取方法，可用于评估谐波齿轮传动系统动力学特性退化程度。本课题的研究成果可为提高我国谐波减速器运行可靠性提供一定的理论基础。