Kinematic Model of Harmonic Drive in Robot

Joints with Input Eccentricity Error

Huimin Dong ✉ , Tianhang Chen, Delun Wang, and Bo Dong

( )

School of Mechanical Engineering, Dalian University of Technology, Dalian, China

donghm@dlut.edu.cn

Abstract. In this paper, harmonic drive which is commonly used in robot joints
is studied. A kinematic model of harmonic drive with input eccentricity error is
established. The model and the deformation compatibility equation are estab‐
lished to solve the motion trajectory of a point on the neutral layer, the backlash
distribution and the load distribution. Through an example analysis, it is found
that the input eccentricity error makes the motion law of each point on the neutral
layer no longer the same, and makes the backlash distribution uneven and the load
concentrated in the eccentric direction. The model established in this paper can
also provide a basis for the establishment of assembly tolerance.

Keywords: Harmonic drive · Kinematic model · Assembly error

Engagement analysis

1 Introduction

Harmonic drive is a transmission mechanism which is widely used in robot joints. It

consists of three main components, wave generator, flexspline and circular spline. In
robot joints, the input is usually connected to wave generator, and the output is connected
to the bottom of flexspline. In the transmission process, wave generator can cause elastic
deformation of flexspline, that way harmonic gears are engaged in meshing motion.
Therefore, the input assembly error will greatly affect the engagement condition, trans‐
mission precision, vibration and life of HD. As an indispensable reducer of robot joints,
there are abundant research achievements in the related fields of HD. Many scholars
have established a variety of kinematic models to study problems about neutral curve,
engagement and tooth profile [1, 2]. Adequate study is made for the design of double-
circular-arc tooth profile and its optimization of parameters [3]. Many researchers have
also considered the kinematic errors and nonlinear characteristics of HD [4–7]. Trans‐
mission precision models are set up to compensate transmission errors [8]. In addition,
the application of HD in robot joints and its influence on the performance of robots is
one of the current research focus [9].
At present, there is still a lack of systematic research on the assembly error of HD.
In this paper, as an important form of assembly error, the input eccentricity error is
studied, considering the actual situation of robot joint assembly. A kinematic model of
HD with input eccentricity error is established. By solving the model, the motion

© CISM International Centre for Mechanical Sciences 2019

V. Arakelian and P. Wenger (Eds.): ROMANSY 22 - Robot Design,
Dynamics and Control, pp. 134–140, 2019.
https://doi.org/10.1007/978-3-319-78963-7_18
 Kinematic Model of Harmonic Drive in Robot Joints 135

trajectory of every point on the neutral layer of flexspline with input eccentricity error
at different moment can be obtained. With this model, the backlash distribution of HD
can be further solved, and the deformation compatibility equation is established to solve
the load distribution. According to a specific example the backlash distribution and load
distribution with different input eccentricity errors are solved. The influence of input
eccentricity error on the engagement condition is explored, and theoretical basis is
provided for the formulation of assembly tolerance (Fig. 1).

Fig. 1. Three main components of harmonic drive.

2 Kinematic Model of Harmonic Drive with Input Eccentricity

Error

When there is an eccentricity error, the kinematic analysis of HD becomes complicated.

The model contains the definition of the coordinate system, the expression of the error
and the derivation of the position of a point on a tooth.

2.1 Coordinate System Definition

Three coordinate systems are set up as shown in Fig. 2: The global coordinate system S
is set up on the center of the bottom of flexspline. The tooth coordinate system Sf is
established on a point on flexspline’s neutral layer. Xf coincides with the symmetrical
axis of the tooth. The wave generator coordinate system SW is set up on the center of
wave generator. XW coincides with the long axis of wave generator. All Z axises coincide
with the axis of flexspline’s bottom. θf and θW are as shown in Fig. 2. And θ corresponds
to the position of Of on the output end of flexspline.

Fig. 2. Coordinate system definition for harmonic drive.

136 H. Dong et al.

2.2 Kinematic Model of HD with Input Eccentricity Error

When HD has input eccentricity error δ, the model is set up as shown in Fig. 3. The arc
length of the flexspline bottom corresponding to θF is lF. The arc length corresponding
to the sum of θW1 and θW2 is lf. The bottom radius of flexspline is Rb, and the wave
generator contour equidistant curve equation is ρ, function of θW. Using this model, every
points on the neutral layer of flexspline at different moment can be solved.

Fig. 3. Kinematic model of HD with input eccentricity error.

⎧ lF = 𝜃Rb
⎪ 𝜌(−𝜃W1 ) sin(𝜃 W1 ) = 𝛿
⎪ l = ∫ 𝜃W1 √𝜌2 + 𝜌̇ 2 d𝜃 + ∫ 𝜃W2 √𝜌2 + 𝜌̇ 2 d𝜃
⎪ f 0 W1 0 W2
⎨ lF = lf (1)
⎪ 𝜋 𝜌(𝜃W2 )
⎪ 𝜇 = − arctan( )
⎪ 2 𝜌(𝜃
̇ W2 )
⎩ 𝜃f = 𝜃W2 + 𝜇

The gear tooth corresponding to the X axis is the first tooth. When other tooth posi‐
tions are needed, the nth tooth is:

2𝜋
𝜃= n (2)
ZR

The initial hour corresponds to θW1 and θW2. And when the tooth position at other
moments need to be solved, there is:
{
𝜃 ∗ W1 = 𝜃W1 + 𝜃W
𝜃 ∗ W2 = 𝜃W2 − 𝜃W (3)

⎡ cos 𝜃f − sin 𝜃f 𝛿 + 𝜌(𝜃 ∗ W2 ) sin 𝜃 ∗ W2 ⎤

Mf = ⎢ sin 𝜃f cos 𝜃f 𝜌(𝜃 ∗ W2 ) cos 𝜃 ∗ W2 ⎥ (4)
⎢ ⎥
⎣ 0 0 1 ⎦
 Kinematic Model of Harmonic Drive in Robot Joints 137

{ }
{x} = [x, y, 1]T , xf = [xf , yf , 1]T (5)

The motion transformation of the coordinate systems is as follows:

{ }
{x} = Mf xf (6)
{
x = cos 𝜃f xf − sin 𝜃f yf + 𝛿 + 𝜌(𝜃 ∗ W2 ) sin 𝜃 ∗ W2
(7)
y = sin 𝜃f xf + cos 𝜃f yf + 𝜌(𝜃 ∗ W2 ) cos 𝜃 ∗ W2

3 The Method of Engagement Analysis

The engagement condition can be expressed by the backlash distribution and the load
distribution. In order to solve the backlash distribution of HD, it is necessary to find the
minimum clearance of each pair of gear teeth. The one dimensional search method is
used to solve the backlash distribution. It is important to note that, due to input eccen‐
tricity error, the backlash distribution of the same tooth in one cycle is no longer equal
to the backlash distribution of each tooth at the same time. Two different backlash
distributions can be solved according to the model in this paper.
Due to the compliance of flexspline, there is no elastic deformation at the bottom of
the cup, so the additional torsion angle corresponding to the points of the flexspline
neutral layer is equal. And in order to solve the load distribution of HD, the deformation
compatibility equation is set up as follows. In the formula, βi is the additional torsion
angle of the ith meshing tooth pair, Di is the backlash of the ith meshing tooth pair solved
using the model above, and Fni is the load on the ith tooth. K1 is the bending stiffness of
the tooth, which is obtained from the finite element model of tooth, and δi1 is the bending
deformation of the ith tooth. K2 is the torsion stiffness of the tooth, which is obtained
from the finite element model of flexspline, and δi2 is the torsion deformation of the ith
tooth. M is the load torque, and ri is the distance between the contact point of the ith
tooth and the center of the flexspline, and cosαi is the contact angle of the ith meshing
tooth pair. According to the determinant condition βi > Di, the equation set is established
and solved recursively, and the load distribution is obtained.

⎧ 𝛽1 = 𝛽2 = … = 𝛽 i = … = 𝛽 n
⎪ 𝛿 + 𝛿i2 − Di
⎪ 𝛽i = i1
⎪ ri
⎪ 𝛿i1 = K1 ⋅ Fni
⎨𝛿 = K ⋅F (8)
⎪ ni2 2 ni
⎪ ∑ F ⋅ r ⋅ cos 𝛼 = M
⎪ 1 ni i i
⎪𝛽 > D
⎩ i i
138 H. Dong et al.

4 Example Analysis

An example is selected to solve the backlash and load distribution with different input
eccentricity errors in the middle section of wave generator, and results of other sections
can be obtained through the model as well.

4.1 Example Illustration

A cam wave generator with elliptical contour is selected. The major axis is 60.5168 mm,
the minor axis is 59.4808 mm, and the width is 11 mm. The parameters of the tooth
profile are shown in Fig. 4, and the values are shown in Table 1.

Fig. 4. Parameters of double-circular-arc tooth profile

Table 1. Parameters of tooth profiles

(mm) ρa ρf ea ef la
FS 0.2031 0.5046 0.7625 0.6929 0.0548
CS 0.2313 0.4357 1.2201 1.2791 0.0782
(mm) lf ha hf t δ
FS 0.6557 0.2326 0.2193 0.4 −3.99°
CS 0.5886 0.2107 0.15 0.4 −9.88°

4.2 Kinematic Analysis of a Point on Neutral Layer of Flexspline

The trajectory of a point on the neutral layer of flexspline is the basis of kinematic
analysis and engagement analysis of HD. The maximum radial deformation of each
point at the same time, and the trajectory of a point at each moment are shown in Fig. 5.
It can be seen that when there is an input eccentricity error, the radial deformation of
different points on the neutral layer are no longer the same. And when the direction of
the radial deformation is the same as the eccentric direction, the deformation of the point
has the greatest change. As for the same point at different moment, the trajectory with
different input eccentricity errors has a change of position and shape with the law shown
in Fig. 5.
 Kinematic Model of Harmonic Drive in Robot Joints 139

Fig. 5. The point trajectory of flexspline neutral layer

4.3 Engagement Analysis

The distribution of backlash and load with different input eccentricity errors is shown
in Fig. 6. It can be seen that with the increase of the eccentricity error, the symmetry of
the backlash distribution gradually decreases. The backlash of the left half of the
engagement region increases, and the right part of the backlash decreases continuously.
Interference can be found when the eccentricity error is up to 0.023 mm by interference
check. When the rated load is 56NM, with the increase of the eccentricity error, the
coincidence degree decreases, the load is concentrated in the eccentricity direction and
the load distribution is uneven.

Fig. 6. Backlash and load distribution with different input eccentricity errors

Fig. 7. Backlash and load of the same point at different moment

140 H. Dong et al.

As for the 200th point at different moment, its backlash and load with different input
eccentricity errors is shown in Fig. 7. With the increase of input eccentricity error its
backlash increases and the load decreases, which is in accordance with the radial defor‐
mation law of the solution above.

5 Conclusion

In this paper, a kinematic model of harmonic drive in robot joints with input eccentricity
error is established. The model and the deformation compatibility equation are estab‐
lished to solve the motion trajectory of a point on the neutral layer of wave generator,
the backlash distribution and the load distribution. It is found that the input eccentricity
error makes the motion law of each point on the neutral layer no longer the same, and
makes the backlash distribution uneven and the load concentrated in the eccentric direc‐
tion. The model established in this paper can also be used to analyze the influence of
HD assembly errors on the performance of robot joints, and provide a basis for the
establishment of assembly tolerance.

Acknowledgement. The authors appreciate the support from the National Natural Science
Foundation of China (No. 51375065 and No. 50975038).

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