The role of a gearhead is closely related to motor development. Originally, when the AC motor was a simple rotating device, the gearhead was mainly used to change the motor speed and as a torque amplifier. With the introduction of motors incorporating speed control functions, the primary role of the gearhead was to amplify torque.
But with the wide acceptance of stepping motors to meet the requirements for control of speed and position, gearheads found new purposes, including the amplification of torque, improvement in permissible inertia and reduction of motor vibration. Furthermore, the accurate positioning capability of motors has created a demand for high-precision, backlash-free gearheads, unlike the conventional gearheads for AC motors.
Oriental Motor, keeping up with these trends, has been developing specific gearheads having optimal characteristics needed to preserve the characteristics of the motor with which it is used. Gearheads for AC motors are designed with emphasis on high permissible torque, long life, low noise and a wide range of gear ratios to use continuously for power source.
By contrast, gearheads for stepping motors are designed for high accuracy positioning, where a high accuracy, high permissible torque and high speed operation are important. The following sections describe these gearheads in detail.
Standard AC motors have a long history, as do the gearheads used with these motors. During the course of that history, AC motors and gearheads have found a wide spectrum of applications and user needs including low noise level, high power, long life, wide range of gear ratios and resistance to environmental conditions.
Oriental Motor has therefore been developing products in order to accommodate various needs. Following is a description of the major mechanical categories applying to gearheads.
Parallel shaft gearheads are the most commonly used gear systems today. Our parallel shaft gearheads employ spur gears and helical gears. Particularly, helical gears are used for low noise, high strength performance.
In both types of gearheads, the helical configuration is employed for the motor pinion and its mating gear. This contributes significantly to noise reduction because of their high contact speeds, thereby achieving lower noise output.
The long life, low noise GN-S gearhead and GV gearhead is illustrated in the following as examples. The GN-S gearhead generates less noise than the conventional
gearhead. Thanks to the gear case made more rigid and gears with a special shape and surface machining assembled with the use of advanced technology.
The GN-S gearhead and GE-S gearhead achieve a rated life of 10000 hours by adopting a large, specially designed bearing and reinforced gears.
The GV gearhead achieves noise reduction through improving gear case rigidity, further improvement of gear machining technology, and higher accuracy in assembly technology. The GV gear head, with their hardened gears by carburizing and quenching and the larger bearings, also achieves permissible torque of two to three times that of conventional products, as well as a rated life of 10000 hours.
Moreover, the GV gearhead will survive 20000 hours of operation when used under the same torque commonly expected of conventional gear heads. Indeed, the GV gearhead provides a great way to extend maintenance intervals and save energy and resources.
For use with standard AC motors, many of which are constant speed motors, the availability of various gear ratios suits a wide range of desired speeds. We support these motors with 20 different gear ratios, ranging from 3:1 to 180:1.
• Right-Angle Gearheads (Solid shaft and hollow shaft)
The right-angle gearhead is designed to facilitate the efficient use of limited mounting space and the elimination of couplings and other power-transmission components (in the case of the hollow shaft gearhead).
Oriental Motor's gearhead consists of right-angle, hollow shaft gearheads and right-angle, solid shaft gearheads (RH, RA), which have worm gears, screw gears or hypoid gears [□104 mm (4.09 in.)]. Both right-angle gearheads incorporate right-angle gearing at the final stage, leaving the input end identical to that of the parallel shaft gearheads (GN-S, GE-S, GU).
This facilitates the conversion from the parallel shaft gearhead to a right-angle gearhead without changing the motor.
The worm gear transmits power from a single or multiple threaded worm to a mating worm wheel. The worm gear have a long history as the spur gear, but its application has been limited due to its relatively low efficiency and difficulty of manufacturing. Oriental Motor has successfully incorporated the worm gear based on its right-angle property and capacity for large gear ratios, and has improved its efficiency over conventional types by increasing the lead.
A single screw gear appears to be another regular helical gear. While the mating helical gears in the parallel shaft configuration have equal helix angles and contact with the helixes running in opposite directions, the screw gears are designed to contact their shafts crossing at right angles. Due to their point-to-point contact configuration, they're mainly used under relatively small loads, such as at low gear ratios with our right-angle gearheads.
Generally, the differential gears for automotive use have been hypoid gears. Being something of a midpoint between the 0 offset bevel gear and maximum-offset worm gear, the hypoid gear achieves a combination of high strength and efficiency. The offset placement of the pinion gear of hypoid gear allows the suppression of vibration and helps obtain higher gear ratios, as compared to the bevel gear. The hypoid gears in Oriental Motor's gearheads are incorporated at the final stage, facilitating the disassembly of the gears from the motor.
BH Series, Hypoid Gear
Brushless motors used for speed control have a high maximum speed in a range of 3000 to 4000 r/min. Accordingly, gearheads to be combined with these motors must keep the noise level low even at high speeds, while also ensuring high permissible torque and long life to fully utilize the characteristics of the high output motors.
Oriental Motor's gearheads for brushless motor provide parallel shaft gearheads having the same structure as AC motor gearheads, and hollow shaft flat gearheads achieving a hollow shaft specification with the parallel shaft structure.
• Hollow Shaft Flat Gearheads
Hollow shaft flat gearheads need few connection parts such as couplings, and also prevent saturation of permissible torque even at high gear ratios. Accordingly, these products are ideal for applications where high permissible torque is required.
Combination of hollow shaft flat gearhead and compact brushless motor realizes a compact installation without a right-angle shaft mechanism.
Hollow shaft flat gearheads are structured to increase the space volume beyond the levels achieved with conventional parallel shaft gearheads by extending the gear shaft layout in the longitudinal direction. At the same time, the gear case has been made more rigid while the gear and bearing outer diameters have been increased.
These features make it possible to provide a hollow output shaft with the parallel shaft structure, which helps increase the permissible torque and life of the product.
In addition, the parallel shaft structure ensures higher gear transmission efficiency compared to conventional right-angle shaft mechanisms.
Our brushless motors offer as combination type with motor and gearhead pre-assembled. This enables easy mounting to the machinery and also allows the gearhead to be replaced to change the gear ratio.
Since stepper motors and other control motors are designed to allow accurate positioning, the gearheads used for these motors must provide the same level of accuracy. Accordingly, Oriental Motor has developed a mechanism to minimize backlash in gears used with stepper motors in order to ensure low backlash properties.
Generally speaking, a stepper motor features greater output torque than an AC motor of the same frame size. Therefore, the stepper motor is designed to accommodate high torque and high speed so as not to diminish the motor's characteristics.
The basic principles and structures of typical control motor gears are explained below.
TH (Taper Hobbed) Gears
◇ Principle and Structure
Tapered gears are used for the final stage of the spur gear's speed reduction mechanism and the meshing gear. The tapered gear is produced through a continuous profile shifting toward the shaft. The tapered gears are adjusted in the direction of the arrows, as shown
in the figure below, to reduce backlash.
◇ Principle and Structure
The planetary gear mechanism is comprised mainly of a sun gear, planetary gears and an internal tooth gear. The sun gear is installed on the central axis (in a single stage type, this is the motor shaft) surrounded by planetary gears enclosed in an internal tooth gear centered on the central axis. The revolution of planetary gears is translated into rotation of the output shaft via carriers.
The PN gear employs the planetary gear speed-reduction mechanism. The PN gear achieves the specified backlash of three arc minutes through the improved accuracy of its components and the backlash-elimination mechanism. That mechanism is comprised of two sets of internal and planetary gears on the upper and lower levels with the internal gear teeth twisted in the circumferential direction. The upper internal gears and planetary gears reduce clockwise backlash; the lower internal gears and planetary gears reduce counterclockwise backlash.
◇ High Permissible Torque
In conventional spur-gear speed reduction mechanisms, gears mesh one to one, so the amount of torque is limited by the strength of each single gear. On the other hand, in the planetary gear speed reduction mechanism, a greater amount of torque can be transmitted, since torque is distributed through dispersion via several planetary gears.
The torque applied to each gear in the planetary gear speed reduction mechanism is obtained through the following formula:
The dispersion coefficient indicates how evenly the torque is dispersed among the individual planetary gears. The smaller the coefficient, the more evenly the torque is dispersed and the greater the amount of torque that can be transferred. To evenly distribute the transferred torque, each component must be accurately positioned.
◇ Gear Characteristics
When a load is applied to the PN gear's output shaft, displacement (torsion) occurs by the spring characteristics of gear. The graph below shows data for torsion angles measured by gradually increasing and decreasing the load on the output shaft in the forward and backward directions. Since the PN gear's backlash is maintained at or below three arc minutes, the torsional torque will not result in an abrupt increase in torsion angle.
◇ Principle and Structure
The harmonic gear offers unparalleled precision in positioning and features a simple structure utilizing the metal's elastodynamics property. It is comprised of three basic components: a wave generator, flex spline and circular spline.
• Wave Generator
The wave generator is an oval-shaped component with a thin ball bearing placed around the outer circumference of the oval cam. The bearing's inner ring is attached to the oval cam, while the outer ring is subjected to elastic deformation via the balls. The wave generator is mounted onto the motor shaft.
• Flex Spline
The flex spline is a thin, cup-shaped component made of elastic metal, with teeth formed along the outer circumference of the cup's opening. The gear's output shaft is attached to the bottom of the flex spline.
• Circular Spline
The circular spline is a rigid internal gear with teeth formed along its inner circumference. These teeth are the same size as those of the flex spline, but the circular spline has two more teeth than the flex spline. The circular spline is attached to the gearbox along its outer circumference.
Unlike conventional spur gears, the harmonic gear is capable of averaging the effects of tooth pitch errors and accumulated pitch errors to the rotational accuracy, thus achieving highly accurate, non-backlash performance. However, the gear's own torsion may become the cause of a problem when performing ultra-high accuracy positioning of two arc minutes or less. When using a harmonic gear for ultra-high accuracy positioning, remember the following three points.
● Lost Motion
Lost motion is the total value of the displacement produced when about 5% of permissible torque is applied to the gear's output shaft. Since harmonic gears have no backlash, the measure indicating the gear's accuracy is represented as lost motion.
• Hysteresis Loss
When torsion torque is gradually applied to the gear output shaft until it reaches the permissible torque in the clockwise or counterclockwise direction, the torsion angle will become smaller as the torque is reduced. However, the torsion angle never reaches 0, even when fully returned to its initial level. This is referred to as "hysteresis loss," as shown by B-B' in the figure. Harmonic gears are designed to have a hysteresis loss of less than two minutes. When positioning in the clockwise or counterclockwise direction, this hysteresis loss occurs even with a friction coefficient of 0. When positioning to two minutes or less, positioning must be done in a single direction.
• Torque – Torsion Characteristics
Displacement (torsion) is produced by the gear's spring constant when a load is applied to the output shaft of the harmonic gear. The amount of this displacement, which is caused when the gear is driven under a friction load, is the same as the value when the motor shaft is held fixed and torsion torque is applied to the gear's output shaft.
The amount of displacement (torsion angle) can be estimated through use of a formula, as shown below. The harmonic gear's torsion angle – torque characteristics curve is not linear, and the characteristics can be expressed in one of the following three formulas depending on the load torque:
Torsion angles obtained by these formulas are for individual harmonic gears.
Geared stepper motors are designed mainly for speed reduction, higher torque and high resolution as well as the following purposes:
• High Rigidity (making the motor less prone to the effects of fluctuation in friction load)
With the motor's power on, the output shaft is subjected to torsion applied externally to measure the amount of displacement (torsion angle) for comparison of rigidity. At a given torque, the smaller displacement (torsion angle) means higher rigidity. For example, the AS66AAE-T7.2 geared motor receives backlash effects at a light load of 0.1 N・m torsional torque, but becomes less prone to twisting than the AS98AAE as the torsion increases. The AS66AAE-N5 motor receives little in the way of backlash effects at a light load, and maintains high rigidity throughout the entire torque range.
Comparison of Torsional Rigidity between Standard Type Motor and Geared Motor
Positioning accuracy against the fluctuating friction load is an important determinant of motor rigidity. Positioning accuracy can be measured by the stop position accuracy (angular transmission error for the geared motor). The stop position accuracy (angular transmission error) refers to the difference between the theoretical rotation angle (this is the rotation angle calculated from the number of input pulses) and the actual output shaft's rotation angle. The error closer to 0 represents higher rigidity.
The standard type AS98AAE motor and AS66AAE-N5 geared motor are compared by measuring the stop position accuracy (angular transmission error) under no load and a friction load, at 0.36˚ intervals for a rotation. The results of comparison show that standard type motor's stop position accuracy significantly increases when the load is applied while the geared motor's angular transmission error barely changes, even when the load is applied. In other words, the geared motor is more resistant to fluctuations in friction load, thus achieving more stable positioning. This feature applies to any type of geared motor. Therefore, geared motors are more effective for positioning operation for vertical drive and other applications in which friction load fluctuates due to the varying quantity and weight of the load.
Comparison of Stop Position Accuracy (Angular transmission error) between AS98AAE and AS66AAE-N5
To drive a large inertial load within a short period of time, the use of a geared motor will achieve a shorter positioning time than a standard type motor.
Assume that the standard type AS98AAE motor is connected to inertial loads that are 5 and 30 times the rotor inertia, and that each of these inertial loads is connected to the geared type AS66AAE-N5 motor. The shortest positioning time for each rotation angle is measured as shown in the graphs below.
The geared motor is more effective in reducing the positioning time for a smaller positioning angle and a larger inertial load. The geared motor tends to achieve shorter positioning time in a wider range of positioning angles with a larger inertial load.
The geared motor reduces positioning time for the following reasons:
Another advantage of the geared motor is its ability to maintain a consistent positioning time regardless of changes in inertial load. The graphs below show changes in the shortest positioning time of the standard type motor and geared motor when each motor is subjected to variations in inertial load.
While the shortest positioning time of the standard type motor changes significantly with the increase in inertial load, that of the geared motor shows little change. In other words, the geared motor is capable of driving a larger inertial load within the most consistent, shortest positioning time.
No matter how quickly a motor can perform positioning, the failure to achieve stable operation against inertial load fluctuations may result in a problem. Therefore, it is also important to study how the operation waveform is shaped according to fluctuations in inertial load.
Connect the same inertial load to both the standard type motor and geared motor, under the operating conditions that allow for the shortest positioning. Then switch the inertial load to a smaller inertial load without changing the operating conditions. The operation waveform for each of these cases is shown in the graphs below.
Even under the operating conditions that are optimized to reduce damping with a given inertial load, the damping characteristics of the standard type motor will deteriorate with fluctuations in inertial load. For the motor it is therefore necessary to reset the operating conditions for optimal performance each time the inertial load fluctuates. On the other hand, the geared motor's damping characteristics change little with fluctuations in inertial load, thereby ensuring steady operation.
• Low Vibration
Vibration characteristics are represented in voltage, into which the vibration width of the output shaft in rotation is converted. Vibration of the geared motor can be reduced for the following reasons:
• Planetary Gears (PJ)
PJ gears are planetary gears with high strength and high accuracy, developed for use in NX series servo motor units.
Like the PN gear, the PJ gear also achieves the specified backlash of three minutes (0.05°) or less through the improved accuracy of its components and the backlash eliminator with twisting upper and lower internal gears. (Click here for more details).
• High Permissible Torque
Because it adopts the same planetary gear mechanism employed by the PL gear, PS gear and PN gear, the PJ gear can also transmit torque in a dispersed manner using multiple gears and consequently achieve high permissible torque. (Click here for more details).
Also, because the internal gears and case are integrated in PJ gears, the space volume is increased beyond the levels achieved with conventional planetary gears, and the gears have a larger diameter. They are stronger as a result, and achieve a strength that can handle the maximum instantaneous torque of an NX servo motor.
• Improved Permissible Thrust Load and Moment Load
PJ gears employ an output shaft configuration, with which direct load installation is possible. As a result, the thrust load and moment load must be received by the output shaft. Double row, deep-groove ball bearings are used in the output shaft of PJ gears, meaning that a high permissible thrust load and moment load are achieved. Calculate moment load with the following formula.
• Angular Transmission Accuracy
Angular transmission accuracy is the difference between the theoretical angle of rotation of the output shaft as calculated from the input pulse count, and the actual angle of rotation. Represented as the difference between minimum value and maximum value in the set of measurements taken for one rotation of the output shaft starting from an arbitrary position.
Angular Transmission Accuracy
4.09 in. (104 mm)
4 min. (0.067°)
The following section describes how to utilize maximum torque, which PS gears, PN gears and harmonic gears have.
Maximum torque is the maximum torque value that can be applied to an output gear shaft.
Permissible torque is the torque that is continuously applied to an output gear shaft.
During acceleration and deceleration, a larger amount of torque than during operation at constant speed is applied to the output gear shaft as acceleration torque, due to load inertia.
The following formula shows that acceleration torque increases as load inertia increases, or as acceleration/deceleration time decreases. As a result, the positioning time is shorter as the torque applied to the output gear shaft increases.
Here, when the same size inertia body is driven, positioning times are compared as an example of maximum torque being utilized. An AR66AC-PS50-3 is used, and the speed-torque characteristics are shown below.
The graphs below comparing torque patterns and positioning times show that positioning time is faster at 0.1s or more when maximum torque is utilized, which can lead to increased productivity.