谐波齿轮廓形多齿运动学优化及其精密成型基础研究

The harmonic gear drive has the advantages of large transmission ratio, higher kinematic accuracy, larger output torque, compact structure and coaxial drive, and it is of great value in both research and application. The harmonic gear reducer is one of the key components of the industrial robot. At present, due to the lack of multi-tooth multiple-point meshing kinematic analysis method, it is difficult to achieve best match of the tooth profiles of flex gear and rigid gear, the high-frequency low-cycle error in the transmission is large, and that directly impacts on the improvement of harmonic gear reducer's accuracy and quality. According to the major requirements for development of industrial robots and high-technique equipments, The project is to study the optimization method of harmonic gear profile based on multi-tooth multiple-point meshing kinematics simulation, to provide the method of generating high-precision hyperbolic-shaped grinding wheel by using linear dressing, and to explore the novel measurement methods of the non-involute profiles, such as linear profile, hyperbolic profile, with the involute gear tester. Through the implementation of this project, the theoretical and technical foundation will be established for the design and manufacturing of high-end harmonic gear reducers.

谐波齿轮传动具有传动比大、运动精度较高、输出力矩较大、结构紧凑及能实现同轴输入与输出等优点，具有重要的研究与应用价值。采用谐波齿轮传动的减速器是工业机器人的核心基础部件之一，目前由于缺少多齿多点啮合的运动学分析手段，刚轮和柔轮的齿廓难以最佳匹配，致使传动中的高频小周期误差偏大，直接影响谐波减速器产品的制造精度和质量。本项目面向国家发展工业机器人和高端装备的重大需求，开展基于多齿多点啮合运动学仿真研究，优化谐波齿轮廓形；提出利用单自由度直线修整运动生成高精度双曲线成型砂轮的方法，创新性地用于谐波齿轮的精密磨削加工；探索基于渐开线齿轮检查仪高精度测量直线齿廓、双曲线齿廓等非渐开线齿廓的新方法。本项目旨在为我国谐波齿轮减速器设计与制造走向高端奠定理论与技术基础。

面向国家发展工业机器人和高端装备对高精度谐波减速器制造技术的需求，开展了谐波齿轮廓形优化设计、谐波齿轮精密磨削技术与工艺、谐波齿轮廓形偏差测量和谐波减速器动态分度误差测量等方面的研究。提出了一种采用旋转变换法优化谐波齿轮共轭廓形的方法；利用空间直线绕坐标轴旋转生成母线为双曲线的原理，提出利用直线修整生成母线为双曲线成型砂轮的方法；开发出一套对称双面高精度修整装置，可实现高精度直线廓形和双曲线廓形成型砂轮的修整；基于建立齿廓展成方向上非渐开线廓形与标准渐开线齿廓之间形状偏差的误差补偿模型，实现非渐开线廓形的精密测量；研制了高精度谐波齿轮磨削装置和谐波齿轮动态传动误差测量试验平台。本项目研制出动态传动误差小于30″的谐波减速器，达到机器人用谐波齿轮减速器国家标准(GB/T 30819-2014)中的高精密级(A级)精度。在本项目的资助下，共发表论文16篇，其中SCI/EI收录期刊论文11篇；申请发明专利32项，获得授权20项(含授权国际专利1项)；精密磨齿工艺、精密测量方面的研究工作，作为部分成果分别获得中国机械科学技术奖一等奖和中国计量测试学会科技进步奖一等奖。项目的研究成果为高精度谐波减速器的制造提供了理论和技术基础。