凿岩机缸体零件的机械加工工艺规程和专用机床夹具设计
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本科毕业设计（论文）说明书英文参考资料1Lightweight Harmonic Drive Gears for Service RobotsAbstract: The Harmonic Drive gear has become established as a “classic” robot gear, featuring zero backlash, high single-stage ratios, compact dimensions and a high torque capacity. Nearly all the worlds leading robot manufacturers apply Harmonic Drive gears in one or more of their robot versions. It is the subject of continuous development, which has led to a substantial increase in performance due to new tooth profiles, new component designs and other innovations. In the past few years the torque capacity, operating life and torsional stiffness have been more than doubled by these developments. For new service robotic applications lightweight design is becoming particularly important, so the development engineers at Harmonic Drive AG have recently focused on this subject. During the past 3 years a German state-funded research project has investigated the design and development of lightweight Harmonic Drive gears. The basic target has been to save more than 50% in weight, without negatively influencing other gear specifications, such as torque capacity or accuracy. This paper reviews the basic principles of Harmonic Drive technology and then describes the various approaches to reduce weight. These include the use of non-ferrous metals, composite materials and new tribological coatings. The results of this research project are very positive and the basic elements from this research are already being used in both industrial robots and also a number of leading service robotic research projects in the field of walking machines. Following a description of these applications and the advantages brought by lightweight gears the paper concludes with a vision of further weight-reducing techniques.I. BRIEF HISTORY OF THE HARMONIC DRIVE GEAR The performance capabilities of robots are increasing rapidly. This would not be possible without continuous improvements from the applied technologies and systems. This holds both for industrial and service robots. The gears and actuators used must fulfil a complex set of requirements they must provide high positioning accuracy and repeatability, high torque capacity and high torsional stiffness, a compact and light design at a competitive price with high reliability. These requirements have led to significant further development of the Harmonic Drive gear. This gear type, also known as ,strain wave gearing“ is a standard transmission component in a wide range of application areas, from industrial robots and machine tools to printing machines, medical equipment and machines for semi-conductor manufac turing. Invented in 1959 by Walt Musser in the United States, the Harmonic Drive gear was first applied in aircraft and defense applications. The reliability, low weight and compact design were unique advantages that soon established this new gear principle in these fields. In the 1970s and 1980s the range of applications extended into industrial robotics and machine tools, where the Harmonic Drive has become de facto the standard for precise positioning drives. The 1990s saw a rapid increase in applications as requirements for increased accuracy and improved dynamic performance have necessitated the use of high quality gears and actuators, in fields as diverse as surgical robotics, measuring machines and silicon wafer processing equipment. From its origins in aerospace the Harmonic Drive gear has now established itself in robotics as the ideal solution in a wide range of different robot types. From the early 1970s, when the majority of industrial robots were still hydraulically driven, to the latest generation of highly accurate and dynamic electrically driven robots, many of the most significant improvements in robot performance have been enabled by the continuous development of the Harmonic Drive gear.II. PRINCIPLE OF OPERATION The Harmonic Drive gear is unique in transmitting high torque through an elastically deformable component. The gear has just three concentric elements:The Circular Spline (CS) is a solid cylindrical ring with internal gear teeth. The Flexspline (FS) is a non-rigid, thin cylindrical cup with external teeth at the open end of the cup. The closed end of the cup is provided with a flange connection to following machine elements. The Wave Generator (WG) comprises a thin-raced ball bearing fitted onto an elliptical plug, serving as a high efficiency torque converter. These three basic components function in the following way: The Flexspline is slightly smaller in diameter than the circular spline and usually has two fewer teeth than the CS. The elliptical shape of the Wave Generator causes the teeth of the FS to engage the CS at two regions at opposite ends of the major axis of the ellipse. As the WG (input) rotates, the zone of tooth engagement travels with the major axis of the ellipse. For each 180clockwise movement of the WG, the FS (output) moves counterclockwise by one tooth relative to the CS (fixed). Each complete clockwise rotation of the WG results in the FS moving counterlockwise by two teeth from its previous position relative to the CS. The reduction ratio is therefore not a function of the relative sizes of the toothed components, as is the case for spur gears or planetary gears, but simply of the number of teeth and its difference between CS and FS. Using this principle of operation, reduction ratios of 30:1 to 320:1 can be achieved with just three basic components. Gears are available with outer diameters from 20 to 330 mm with a peak torque capacity from 0.5 to more than 9000 Nm respectively.III. KEY FEATURES Compared to conventional gearing the Harmonic Drive gear offers the user a number of significant advantages: The key feature is the exceptionally high positioning accuracy and repeatability. This is the result of the high transmission accuracy, which is better than 1.5 arc minutes for standard series gears with a repeatability of +/- 6 arc seconds. Due to the small number of basic components and the multiple tooth engagement, the transmission accuracy is not so dependent on the accuracy of many gear components or on individual tooth pitch errors. These values are assisted by the fact that the Harmonic Drive gear can operate with zero backlash. Due to natural radial pre-loading in the region of tooth engagement, the gear operates without any backlash over its whole lifetime, i e. the characteristics will not change. Since power is transmitted through multiple tooth engagement (typically about 30% of the teeth are used simultaneously for torque transmission), Harmonic Drive gears offer a very high torque capacity, equal to conventional drives twice its size and three times its weight. The tooth engagement mechanism characteristics ensures that the gear is stick-slip free, even for very slow movements. Harmonic Drive gears exhibit very high torsional stiffness with an almost linear stiffness characteristic. The hysteresis losses are also extremely low, which reflects the very low internal friction within the gear assembly. For conventional gears backlash can usually only be removed by means of external pre-loading, which then results in increased hysteresis losses and increased lost motion. Compared to other high ratio gears the efficiency of the Harmonic Drive gear is very high. An efficiency of over 80% is typical for a gear with ratio 100:1 at rated torque and rated input speed. The high efficiency as a speed reducer also means that the gear is reversible. In an emergency situation it is possible to back-drive the gear. For robotic applications the compact, lightweight design are particularly important, as well as the design flexibility offered by this principle. As will be seen later, all the basic gear components can be readily modified to reduce weight, and can be manufactured in materials suitable for demanding new applications in difficult environments, such as in space. IV. DEVELOPMENT THEMES The Harmonic Drive gear is the subject of continuous development, due to new market requirements from each of the major application areas. Common requirements are the desire for higher power density and higher torsional stiffness. There are therefore three key themes driving current product development - Increased torsional stiffness - Reduced size - Reduced weight Improvement of the tooth profileThe development of the tooth profile is a key development area. It was recognized early on that many properties of the Harmonic Drive gear can be improved by means of an optimisation of the tooth profile. Complex calculations, computer simulations of the tooth engagement locus and exhaustive tests provided the basis for an improved tooth profile, the IH profile, which was patented in 1989 and has been steadily further developed since. For the conventional involute tooth profile ca. 15% of teeth are in simultaneous contact, while for the IH profile this proportion increases to ca. 30% This development brings three significant advantages: 1. The torsional stiffness of the gear is primarily dependent on the number of teeth in contact. The increase in the area of tooth engagement leads to a doubling of the torsional stiffness of the gear. 2. The operating life of the gear is determined by the wave generator bearing. The increased area of tooth engagement leads to a more even loading of the bearing, which in turn leads to a doubling of the operating life. 3. The larger tooth root radius of the IH profile reduces the critical stress in the Flexspline and so leads to a significant increase in torque capacity within the same gear envelope. New Flexspline designAnother key development theme is the reduction in the axial length of the Flexspline cup. As can be seen in Fig. 3, the axial length of the HDUC-type gear could be reduced by 40% with the introduction of the short Flexspline HFUC-type gear. This reduction in axial length has also enabled a 20% reduction in weight for the same torque capacity. The FEM analysis that supported the introduction of the HFUC-type gear is also the basis for the new ,super-flat“ component set, shown also in Fig. 3. The axial length of the Flexspline cup could be reduced once again and is just over 50% of the length of the HFUC-type gear. The increased conical deformation of the cup means that the torque capacity is reduced slightly compared to the standard gear. Lightweight component set designIn a large number of service robot developments, whether for terrestrial or space applications, the market requirement is for higher power density. The development of lightweight gears is therefore a further key development area. Since 2001 Harmonic Drive AG has coordinated a German state-funded research project to develop lightweight gears using non-ferrous metals, special tooth profiles and new tribological coatings. This project has a duration of three years and involves a consortium of gear manufacturers, coating equipment suppliers and research institutes 3. As can be seen from Fig. 4 there are four basic methods for reducing the weight of the gear and/or the surrounding machine elements in the user machine: Modification of the individual gear components, to simplify the integration of the gear and so reduce the weight of the surrounding machine elements. Integration of spur- or planetary-gear stages within the Harmonic Drive gear, in order to realize very high reduction ratios in the smallest possible envelope. This allows small, high speed motors to be used, so optimizing the power density of the complete gear-motor assembly. Use of special surface treatments to improve the load carrying capacity of individual gear components to so increase torque capacity and power density. Application of new materials for the individual gear components, in order to minimize the weight of the gear itself. Fig. 5 shows a special design, where the Circular Spline has been strongly modified to simplify the integration of the gear into the joints of a telerobotic manipulator. Fig. 6 shows a further design example, where a planetary-gear stage has been integrated within the elliptical wave generator plug. This design makes use of the space available within the Flexspline to achieve a total reduction ratio of 800:1 in a very small envelope. Here, too, the circular spline has been modified to simplify integration within the joint of a portable service robot. Fig. 7 shows the most effective technique to reduce weight, that is, to substitute “conventional” gear materials, such as cast iron and steel, with lightweight non-ferrous metals such as aluminium or titanium. Both the Circular Spline (housing) and Wave Generator plug of the lightweight unit, comprising gear component set and output bearing, are manufactured primarily from aluminium or titanium alloy. Two design techniques are particularly interesting for the circular spline. Fig. 7 shows a composite design, where the Circular Spline teeth are machined into a thin cast iron ring, which has been cast into the aluminium housing. Another approach is to coat the teeth of the Circular Spline using a special principle to achieve the same load carrying capacity as the standard gear teeth. The wave generator ellipse is manufactured from a special aluminium alloy, which has almost the same coefficient of thermal expansion as steel. As can be seen from table 1, both weight and moment of inertia of the gear component set can be reduced by more than 50 %, leading to an increase in specific torque capacity of 105 %. The performance data of the lightweight gears has been verified in numerous practical tests. The transmission accuracy, torsional stiffness, durability and performance at low and high temperature have all been tested for the lightweight gears. The project objectives have been fully achieved for both the design variant using titanium alloy for the Circular Spline and Wave Generator plug, as well as the composite design described above. In both cases the weight of the gear or unit has been reduced by more than 50% without any negative effects on accuracy or durability. More details can be found at the project web-site (www.lezabs.de). V. APPLICATIONS As indicated above, there is already a wide range of different robotic applications for Harmonic Drive gears. The new developments in the field of lightweight gear design are opening up new applications in both industrial and service robots. Thefollowing are just a few recent examples showing how lightweight Harmonic Drive gears, developed in the above-mentioned research project are already being used in practice. SCARA RobotsThe primary axes of Scara robots are a traditional application area. Here the required speed is increasing dramatically without any compromise in accuracy. This is also necessitating the use of lightweight gears. Lower gear mass for the elbow-joint reduces the overall mass of the arm, which allows faster cycle times. Reducing the moment of inertia of both shoulder- and elbow-joint gears also allows faster acceleration and therefore reduced cycle times. Fig. 8 shows the new PowerSCARA robot developed by Bosch Rexroth AG and presented to the public for the first time in June 2004 at the Automatica Exhibition in Munich. During the development of this new Scara robot type lightweight gear units were tested for more than 5000 hours in a robot of an earlier type The robot exhibited consistently high accuracy during the complete endurance test and the robot achieved faster cycle times, whilst the effective motor current was reduced by more than 10 %. Lightweight robots Lightweight component sets are also used in the 3 generation of lightweight robots currently under development at the Institute of Mechatronics and Robotics at the German Aerospace Center /DLR) 2. The robot uses 7 Harmonic Drive gears in all axes and can carry a payload of 13 kg, while only weighing 13 kg itself. This relationship is currently the worlds best value. Harmonic Drive gears are also used in the unique 4-fingered hand shown in Fig.9. A modified version of this robot is also to be used as a service robot on the International Space Station. Walking Robots Another area with expanding Harmonic Drive applications is the field of walking robots. A particularly ambitious research project is the bi-pedal robot “Johnnie”, developed by the Institute of Applied Mechanics at the Technical University of Munich 1. This robot features no less than 17 lightweight Harmonic Drive gears. “Johnnie” has a very high level of autonomy and can mount or avoid numerous obstacles at a walking speed of up to 2 km/hour. Johnnie is 1,8 m tall, yet weighs just 45 kg. VI. CONCLUSION Harmonic Drive gears have a long success story in demanding robotic applications. The range of applications is increasing quickly due to continuous product development, which is leading to greatly improved product performance. One area of particular interest is the development of lightweight gears. The latest research results can reduce weight by more than 50 % without any reduction in torque capacity, accuracy or durability. Until now the research has concentrated on reducing the weight of the gear component set. In all practical applications the gear component set is mounted inside a housing or arm structure and also requires an output-side bearing to support the load. Further development is therefore required to reduce the weight of housing components and output bearing assemblies to achieve an even higher power density. The research is now continuing into reducing the weight of these additional components in the environment of the gear. VI. REFERENCES 1 K. Loffler, M. Gienger, F. Pfeiffer, Sensor and Control Design of a Dynamically Stable Biped Robot, Proc. of 2003 IEEE International Conference on Robotics and Automation 2 Schafer, B. Hirzinger, G.: On Design, Dynamics and Simulation of Space Robotics Nd at DLR, Proc. of 2International Congress on Mechatronics, Graz, 2003 3 Slatter, R.: Leichtbaugetriebe fr Roboter in der Raumfahrt, Antriebstechnik 41 (2002) Nr.英文参考资料2Computer Aided Process PlanningAccording to the Tools Manufacturing Engineers Handbook, process planning is the systematic determination of methods by which a product is to be selection, calculation, and documentation. Process, machines, tools operations, and sequences must be selected. Such factors as feeds, speeds, tolerances, dimensions, and costs must be calculated. Finally, document in the form of illustrated process sheets, operation sheets, and process routes must be prepared. Process planning is an intermediate stage between designing and manufacturing the product. But how well it bridge design and manufacturing?Most manufacturing engineers would agree that, if ten different planners were asked to develop a process plan for the same part, they would probably come up with ten different plans. Obviously, all the these plans cannot reflect the most efficient manufacturing methods, and , in fact, there is no guarantee that any one of them will constitute the optimum method for manufacturing the part.What may be even more disturbing is that a process plan developed for a part during a current manufacturing program may be quite different from the plan developed for the same or similar part during a previous manufacturing program and it may never be used again for the same or similar part. That represents a lot of wasted effort and produces a great many inconsistencies in routing, tooling, labor requirement, costing, and possibly even purchase requirements.Of course, process plans should not necessarily remain static. As lot sizes change and new technology , equipment, and process become available, the most effective way to manufacture a particular part also changes, and those changes should be reflected in current process plans released to the shop.A planner must manage and retrieve a great deal of and many documents,including established standards, machinability data, machine specifications, tooling inventories, stock availability, and existing process plans. This is primarily an information-handling job, and the computer is an ideal companion. There is another advantage to using computers to help with process planning. Because the task involves many interrelated activity, determining the optimum plan requires many iterations, many more alternative plans can be explored than would be possible manually. A third advantage in the use of computer-aided process planning is uniformity. Several specific benefits can be expected from the adoption computer-aided process-planning techniques: Reduced clerical effort in preparation of instructions. Fewer calculation errors due to human error. Fewer oversights in logic or instructions because of the prompting capability available with interactive computer programs. Immediate access to up-to-date information from a central database. Consistent information, because every planner accesses the same database. Faster response to changes requested by engineers of other operating departments. Automatic use of the latest revision of a part drawing. More-detailed, more-uniform process-plan statements produced word-processing techniques. More-effective use of inventories of tools, gages, and fixtures and a concomitant reduction in the variety of those items. Better communication with shop personnel because plans can be more specifically tailored to a particular task and presented in unambiguous, proven language Better information for production planning, including cutter-life, forecasting, materials-requirements planning, scheduling, and inventory control. Most important for CIM, computer-aided process planning produces machine-readable data instead of handwritten plans. Such data can readily be transferred to other system within the CIM hierarchy for use in planning. There are basically two approaches to computer-aided process planning: variant and generative. In the variant approach, a set of standard process plans is established for all the parts families that have been identified through group technology. The standard plans are stored in computer memory and retrieved for new parts according to their family identification. Again, GT helps to place the new part in an appropriate family. The standard plan is then edited to suit the specific requirements of a particular job.In the generative approach, an attempt is made to synthesize each individual plan using appropriate algorithms that define the various technological decision that must be made in the course of manufacturing. In a truly generative process-planning system, the sequence of operations, as well as all the manufacturing-process parameters, would be automatically established without reference to prior plans. In its ultimate realization, such an approach would be universally applicable: present any plan to the system, and the computer produces the optimum process plan. No such system exists, however. So called generative process-planning system-and probably for the foreseeable future-are still specialized system developed for a specific operation or a particular type of manufacturing process. The logic is based on a combination of past practice and basic technology.中文翻译1服务性机器人上的轻型协调性驱动齿轮摘记：这种协调性驱动齿轮，已经确立为一种典型的机器人的齿轮，以无反冲力，较高的单级比率、体积小及高效率的扭转力为特色。几乎世界上所有最重要的机器人制造中都为一个或多个机器人样本提供协调性驱动齿轮。因为它已成为一个不断发展的主题，机器性能得到了实质性的改进，出现了新的齿轮外形，新的零件设计及其他革新。由于这些发展在过去的短短几年里，这种扭转力已经可以兼备运作活体模型及扭转力的灵活性。因为齿轮的轻量性在服务性机器人的应用上变得特别重要，所以Harmonic Drive AG的机械师们目前已经把焦点对准于这个主题，在过去的三年中一个德国受资助的研究项目已经探究出这种设计及对轻量级协调性驱动齿轮的开发。其基本目标就是保留将近50%的重量而不影响其他齿轮的特性，如扭转力或准确度。 这篇论文提出了协调驱动技术的基本原则，而后又描述了减重的各种各样的方法。他们都包括不含铁金属、合成材料及新的摩擦表层的运用。 这项研究项目的结果是肯定的，而且还得出：在具有特殊功能的机器领域中，上些基本的成分不仅能够被运用于工业机器人，还能运用于一些主导性服务机器人的研究项目里。 根据这些应用及轻量级齿轮优点的叙述，此论文对减重技巧有了更一步的展望。 1、协调性驱动齿轮简史 机器人的工作能力不断地变化，如果没有技术与系统的不断改进，这种变化将不可能实现。它也牵制着工业性及服务性的机器人。齿轮与传动装置的运用满足一套综合的需求它们可以以具有竞争性的价格并伴着很强的可靠性，提供准确的定位及重复，高效的扭转力及扭转灵活性，小而轻的设计。 这些需求导致了这种协调性驱动齿轮的进一步民展，这种齿轮类型，正如我们所知的Stain uave齿轮装置，即从工业性机器人、机械工具到机器的印刷、医学设备和半导体的制造等广泛的运用领域。 协调性驱动齿轮由美国人Walt Mqsser发明，它是第一次被运用于航空及防御上，它的可靠性、轻盈及极小的设计都是它独特的优点，以至于很快人们就建立了此种新型齿轮在各个领域运用的原则，从1970年到1980年协调性驱动齿轮已经更进一步实现对于精确的定位驱动装置的标准以至于运用范围不断地向工业机器人与工具上延伸，到1990年它的运用范围不断地再扩大，准确度的进步及动力性能的改进急需高质量的齿轮与传动装置，例如在机器人上，测量机器硅晶片的处理装置上等多个领域。 协调性驱动齿轮由于来源于宇宙空间，现在已经在机器人学上有关不同的机器人样本配置上有了自己的最好的解决方法。十九世纪七十年代早期，大多数工业机器人都由水驱动，而由于高效的准确度及由电动力驱动的机器人的新产生，许多在机器人性能上的重要改进已经使协调性驱动齿轮不断发展成为肯定。 2、操作原则 协调性驱动齿轮在传递扭转力时很独特，它是通过一种柔韧变形的零件传递的。这种齿轮由三个同轴的元件构成。 圆形齿条是位于内部齿轮的一个坚实的圆柱体环状物。 韧性齿条是位于外部齿轮杯状的开口处的一个薄而不固的圆柱体杯状物，而且它是由一个轮缘连接其他机器零件。 波状发生器包括一个很薄的球状轴承，并连接一椭圆形塞子，充当了一个高效率的扭力变换器。 以下就是这三种基本零件的作用： 韧性齿条有比圆形齿条更小的直径，而且比起圆形齿条它有两个小型齿轮。波状发生器椭圆形的样式导致它的齿轮在椭圆主轴尾部相对的两个区域接圆形齿条。 由内部韧性齿条转动时，齿轮的转动区域将会伴着椭圆的主轴转动，因为波状发生器是LX1800的顺时针方向转动因此，韧性齿轮相对于圆形齿条来说，通过一个齿轮以逆时针方向 波状发生器的每一次完事的顺时针转动将导致韧性齿条相对于圆形齿条，由两个齿轮通过它的精确的定位而完成转动。 这种变形的比率不是由齿形零件大小作用的，如钉形齿轮与行星状齿轮，而是齿轮的数量及其与圆形齿条与韧形齿条与韧形齿条的不同之处取决。通过运用这个操作原则，由30：1到320：1的变形比率将通过这三个基本零件而完成。齿轮由外部直径通过一个最大扭转力从工作出发20毫米到330毫米变至0.5毫米甚至9000纳米都是可以适用的。 3、主要特征 当常规的齿轮装置相比，这种协调性驱动齿轮为使用者提供了许多重要的便利： 它的主要特征就是独特的高效定位准确度和重复性。对于标准大小的齿轮，这则是高效率的传递准确度结果。由于基本零件数量少及多样性的齿轮衔接，这种传递准确度不仅仅是领先许多齿轮零件的准确度或是个别齿轮的程度误差。 可见事实就是这种协调性驱动齿轮能够掌控反冲力。即使齿轮衔接区域仍用普通的半径装载，但齿轮仍能在没有反冲力的情况下掌控，即其牲性永远都不会变。 既然动力是通过复合的衔接传递的（通常是在扭转力传递过程中齿轮的30%将被除数同时），时那么协调性驱动齿轮提供的高效率的扭转力则等同于常规齿轮驱动的两倍或三倍的重量。 这种齿轮衔接机械装置的特性确保了此种齿轮是任意的，甚至可以运用于那些相当慢的运动中。 协调性驱动齿轮展示了非常高效的扭转韧性。滞后现象的破坏是非常小的，它可能反映出在整个齿轮装配中有极低的内部摩擦。因为常规的齿轮反冲力通常仅通过外部装配方法来移动，导致迟滞现象的增加甚至失败。 与其他高比率的齿轮相比，协调性驱动齿轮的效率是非常高的。对于一个齿轮以扭转率与速率为100：1，像这种80%高效率是很典型的。 这种高效率是一个减速者，也意味着齿轮是可翻转的，在紧急情况下，阻止齿轮驱动。 因为小而轻的设计的运用与其设计的柔韧性同样特别重要，许多基本的齿轮零件被运用于减重，还继续生产出适合应用在不同环境的新齿轮，例如太空环境。 4、发展主题 这种协调性驱动齿轮引起了各个主要齿轮运用领域新的市场需求成为不断发展的主题，普通的需求便是较高的动力密度及较高的扭转韧性。 现有三个主题推动着目前产品的不断发展。 扭转韧性的改进；大小尺码的减小，重量减轻；齿轮外形的改进。 齿轮外形的发展是一个极为重要的发展领域。协调性驱动齿轮通过齿轮外形而被改进，这是先前早已被承认的。衔接轨迹的复杂计算及电脑模拟和广泛的测试已经为一种改进了的齿轮外形，即在1989年已被取得专利权且已有了进一步发展的IH外形。 对于常规齿轮的复杂齿轮外形CD15%是同时接触的，而对于IH外形齿轮，这种比例将增至30%。 这个发展将带来三个极具重要意义的优点： 1、齿轮的扭转韧力在接触中主要领先齿轮数量的多少，齿轮衔接区域的增加导致了齿轮扭转韧力的翻倍。 2、齿轮的运行活动由波协发生器的轴承决定，齿轮衔接区域的增加不仅引起轴承装载的变化，还导致了齿轮运行活动的翻倍。 3、这种IH齿轮外形的最大齿轮核心半径减小了韧性齿条上关键性的压力，从而在相同的齿轮封皮范围内，引起了扭转韧力的增加新的韧性齿条设计。 另外的一个发展主题是韧性齿条轴长的减小，观察关于韧性齿条图了，这种HDUC样式的齿轮的轴长，通过小的HFUC样式的韧性齿条的引进，而被减小到了40%，这种在轴长的缩小也同样引起扭转韧力重量缩短了20%，FEM分析说，提供这种HFUC样式齿轮说明的，同样也是新的“super-ftat”零件的基础。韧性齿条的轴长还将再一次被除数缩短，直至达到这种HFUC样式齿轮长度的50%，韧性杯状齿条样式的不断变形，意味着扭转力相对于标准齿轮来说，已被缩小到很小。 轻量级零件的设计 随着服务性机器人的发展的不断扩大，不管是地球上或空间宇宙上的运用，市场需求仍是对较高的动力密度的需求。而轻车级齿轮的发展则成为更进一步重要发展的领域。 直到2001年，Harmonic Drive AD已开发出研究项目，至力于将不含铁金属，具体的齿轮外形和新摩擦表层开发在轻量级齿轮上。这个项目有三的持续时间，其中包括一个齿轮制造者团体、外层装备供应者及研究所。 从Fig.4图中可以看出，这里有四种减小齿轮重量的基本： 1、个别齿轮零件的修改是为了简化齿轮的整体，同时也减轻了周围机械成分的重量。 2、钉形或行星形齿轮的整体在协调性驱动齿轮范围内运行，是为了在可能最小的封皮上实现较高的缩小率，它允许运用低或高速的发动机，所以要充分运用这种完整的齿轮发动机装配的动力密度。 3、对于具体表面外置的运用，是为了改进个别齿轮的载重力以增加扭转力与动力密度。 4、对于个别齿轮零件新零件的运用，是为了将齿轮的重量减小到最低值。 Fig.5图中显示了一种特殊的设计，即圆形齿条已被很大程度上修改，通过连接一个控制器去简化齿轮整体装备。 Fig.6图显示行星形齿轮通过运用椭圆波状发生器的塞子而被完成。这个设计在韧性齿条范围内通过运用适合的空间而完成了在很小的封皮情况下，一个完全的缩小比率800：1，同样，图形齿条已被修改并减化了轻便机器人的整体装置。 Fig.7图显示缩减重量的最为有效的技术，即将常规齿轮的材料，如铸造铁或钢代替为轻量的不含铁金属，如铝或钛。 图形齿条与带有轻型装置并复带齿轮零件与外部轴的波状发生器塞子都是由铝合金或钛合金制成，两种设计手法对圆形齿条来说特别有意义。图7中显示了一个复杂的设计，即这种图形齿轮
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