Optimal Tooth Flank Modifications for Compound Planetary Robot Reducer Considering Edge Contact

摘要

The aim of this study was to optimize gear tooth flank modification in a compound planetary reducer with a reduction ratio of 100:1 to achieve uniform load distribution and minimize the face load factor (<italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">K_HB</i>). To achieve this, a prototype of the compound planetary reducer was designed and manufactured, and tests were conducted under temperature-controlled, unlubricated conditions to induce wear on gear tooth surfaces. Microscopic image observations confirmed edge contact on the gear tooth surfaces. Based on these observations, a digital mock-up (DMU) simulation model was developed and validated to align with the experimental results. A parametric analysis of lead slope change was performed using the validated model to determine the optimal value. After optimizing the lead slope, crowning modification was applied to shift the load distribution toward the center of the tooth flank. Comparison of the gear face load factor (<italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">K_HB</i>) showed that applying the modifications improved load imbalance by up to 83.45%, effectively solving the edge contact problem compared to the results without modification. The combined approach of testing under unlubricated conditions and validating the DMU model through both experimental and analytical methods resulted in highly reliable findings, offering valuable insights into improving the performance and durability of compound planetary reducers.