Harmonic Gearbox On-site Assembly Guide

I. Core Component Pre-Inspection

1. Wave Generator

Inspect the elliptical cam surface for scratches and the bearing raceway for indentations.

Confirm that the pre-installed oil seal model matches the reducer specifications.

Test the rotational resistance for uniformity and no sticking.

2. Flexspline Assembly

Measure the wall thickness tolerance of the cup-shaped elastomer (±0.02mm).

Inspect the tooth meshing area for damage.

Verify the flatness of the diaphragm and output shaft connection surfaces (≤0.05mm).

3. Rigid Pulley Assembly

Confirm that the fixing holes match the mounting base.

Inspect the tooth chamfers for burrs.

Measure the clearance between the inner diameter and the outer diameter of the flexspline (0.5-1.2mm).

 

II. Key Assembly Processes

1. Wave Generator Installation

Use a dedicated guide sleeve to assist insertion. Maintain axial pressure ≤50N during rotational installation.

After installation, manual rotation should produce no periodic resistance waves. 2. Rigid Pulley Alignment

Use the diagonal step-by-step tightening method (50% → 80% → 100% rated torque).

Use a feeler gauge to check the mounting surface clearance (≤ 0.03mm).

Do not use dowel pins for securing.

3. Flexspline Assembly

Apply special grease (thickness 0.1-0.2mm) before assembly.

Use an elliptical expansion tool to control deformation (major axis/minor axis ratio 1.8:1).

Check the tooth side clearance after installation (0.05-0.15mm).

III. Quality Verification Standards

 

1. No-load Test

Operating Temperature ≤ 65°C (Ambient Temperature 25°C)

Noise ≤ 65dB (at 1 meter)

Axial Play ≤ 0.02mm

2. Load Test

Transmission Efficiency ≥ 85% at rated torque

Backlash ≤ 1 arc minute

No abnormal temperature rise after 4 hours of continuous operation.

 

IV. Troubleshooting

Fault Symptoms Possible Causes and Solutions

Abnormal noise and vibration. Wave generator eccentricity. Re-adjust the coaxiality.

Excessive temperature rise. Insufficient lubrication. Add special grease.

Drive seizure. Tooth surface damage. Replace the flexible wheel assembly.

Note: All operations must be performed in a dust-free environment (Class 1000). The first run test must be completed within 48 hours of assembly.