Search Results (23)

Cycloidal reducers are widely used in precision drive systems due to their reduced backlash in meshing and compact design. However, their operational durability is limited by surface wear and lubricant degradation under elevated contact loads and boundary lubrication conditions. This study introduces a modified wear prediction model based on four-ball tribological testing, specifically adapted to simulate the complex tribological conditions in cycloidal gear contacts. The model incorporates the total acid number (TAN) and thermal conductivity coefficient of the lubricant as dimensionless factors, enabling a dynamic prediction of wear intensity as the lubrication degrades. This innovation allows an accurate estimation of service life and reliability in high-load, small-contact-area mechanical systems and offers a practical diagnostic tool for the predictive maintenance of gear transmissions. Full article

The recent advancements in wearable exoskeletons have highlighted their effectiveness in assisting humans for both rehabilitation and augmentation purposes. These devices interact with the user; therefore, their actuators and power transmission mechanisms are crucial for enhancing physical human–robot interaction (pHRI). The advanced progression of 3D printing technology as a valuable method for creating lightweight and efficient gearboxes enables the exploration of multiple reducer designs. However, to the authors’ knowledge, only sporadic implementations with relatively low reduction ratios have been reported, and the respective experimental validations usually vary, preventing a comprehensive evaluation of different design and implementation choices. In this paper, we design, develop, and examine experimentally multiple 3D-printed gearboxes conceived for wearable assistive devices. Two relevant transmission ratios (1:30 and 1:80) and multiple designs, which include single- and double-stage compact cam cycloidal drives, compound planetary gearboxes, and cycloidal and planetary architectures, are compared to assess the worth of 3D-printed reducers in human–robot interaction applications. The resulting prototypes were examined by evaluating their weight, cost, backdrivability, friction, regularity of the reduction ratio, gear play, and stiffness. The results show that the developed gearboxes represent valuable alternatives for actuating wearable exoskeletons in multiple applications. Full article

Despite their complex design, cycloidal gearboxes are characterized by high efficiency. Nevertheless, due to friction, some power is lost during gearbox operation. Basically, these losses occur in two structural nodes: the cycloid gearing and the output mechanism. Since the first of these nodes has been well discussed in the literature, the output mechanism will be discussed in this article. The design of the output mechanism has a significant impact on mechanical power losses. There are several mechanism design solutions. One of them is a mechanism with serially arranged rollers. Three solutions that are different in design but work identically will be discussed. Due to this affinity, a single, common mathematical model will be used to determine the value of losses. As will be shown, the value of losses is directly affected by the backlash, number, and diameter of the rollers used in the output mechanism and indirectly by the ratio and eccentricity of the cycloidal gearbox. Sample calculations were carried out using the developed model of mechanical power losses in the output mechanism. This made it possible to analyze the distribution of backlash created by manufacturing tolerances. It was also shown that the backlash has a significant effect on the number of rollers involved in torque transmission, as well as on the distribution of loads, contact pressures, and mechanical power losses. Full article

Currently, mechanical gears with cycloid engagement are increasingly used in mechanisms along with involute ones. In modern drive mechanisms, using pin gears and gears with intermediate rolling elements (IRE) is widespread, which simultaneously use cycloid gears. To a greater extent, pin gears are now being investigated, but IRE gears have their undeniable advantages. Many works are devoted to the study of cycloid toothing for certain gears, but the efficiency, especially that of IRE gears, has practically not been investigated. Therefore, the analysis of power losses in the engagement of a gear with IRE and a free cage (IREFC) is relevant. In this analysis, the authors of the work have used laws of mechanics, methods of energy flows and a secant normal. Mathematical expressions have been obtained to estimate slip speeds and power friction losses in the engagement of a gear with IREFC, and a formula has been derived to determine the efficiency of a mentioned mechanical transmission. The calculation of slip speeds and power losses at the points of contact of a rolling element with cycloid profiles of wheels for selected initial parameters of a gear with IREFC has been presented. The friction power and the overall efficiency of the entire gear engagement have also been calculated. This work shows that power friction losses at the points of contact of a rolling element with cycloid profiles of tooth wheels of a gear with IREFC are not the same. The friction power in the contact of a rolling element with a cycloid profile of a cam is an order of magnitude higher than the friction power in the contact of a rolling element with a cycloid profile of a crown. Full article

Longer distance water delivery culverts pose obstacles such as deposited silt, stones, and dead trees. In this paper, a crawling robot is designed to mimic the joint structure of a turtle using bionic design principles. The mechanism and gait of the robot are analyzed. The kinematics model of the robot is established using the D-H method and analytical approach, while the dynamics model is established using Lagrange’s method. Based on kinematics and dynamics analysis theory, compound cycloid and cubic polynomial motion trajectories for the robot foot are planned along with a crawling gait resembling that of a turtle’s abdomen. Simulation experiments and scale prototype experiments confirm that when gait parameters are identical, the energy consumption of compound cycloid trajectory exceeds that of cubic polynomial foot trajectory. When planning these two types of foot trajectories, it was observed that energy consumption ratio decreases with increasing step length but increases with increasing step height. Full article

This article proposes a new method for optimizing tooth profile modification amounts of cycloidal reducers. By optimizing transmission error and transmission ratio fluctuation, the objective optimization function is determined, and the influence of optimized modification amount on various transmission performances is studied. In addition, this article also conducted mechanical analysis on the cycloidal reducer and obtained the results of tooth contact force. The mathematical model for the mechanical analysis of the cycloidal reducer was established, and the variation law of force distribution between the internal and external gears of the cycloidal reducer was calculated. The results indicate that the needle tooth force, bearing force, transmission ratio, and transmission error obtained through the mechanical analysis model using optimized modification quantities tend to stabilize and exhibit periodic changes, which corresponds to the actual scenario. Full article

Cycloid drives are generally used in precision machinery requiring high-reduction ratios, such as robot joint (RV) reducers. The contact stress of cycloidal gears greatly affects lifetime and transmission performance. Traditional finite element method (FEM) has less computational efficiency for contact analysis of complex surface. Therefore, in this paper, isogeometric analysis (IGA) was employed to explore the multi-tooth contact problem of the cycloid pinwheel drive. Based on the nonuniform rational B spline (NURBS) curved surface generation method, the NURBS tooth profile of the cycloid gear was reconstructed. In addition, the NURBS surface of the cycloid gear–pin tooth–output pin was generated via the element splicing method. A geometrical analysis model of cycloid pinwheel drive was established to solve the contact force of the meshing pair under different input angles and compared with the finite element method in terms of convergence, resultant accuracy, and solving timeliness. The results show that isogeometric analysis has higher accuracy and efficiency than the finite element method in calculating the contact stress and contact force. The error of the IGA is only 8.8% for 10 × 10 elements in contact, while the error of the finite element method reaches about 40%. The method can improve the contact simulation accuracy of the cycloid drive and provides a reference for the design evaluation of RV reducer. Full article

Cycloid drives are widely used in various mechanical systems due to their high reduction ratio, compact size, and high efficiency. Tooth surface wear is a major problem that affects the reliability and durability of cycloid drives. However, compared to the research on the wear of involute gears, the prediction of tooth surface wear in cycloid drives is relatively limited and less extensive. To fill this gap, the theoretical wear model of the tooth surface of cycloid-pin gear pairs is proposed based on the Hertz contact theory and Archard’s formula, with consideration of tooth profile modifications. Firstly, the loaded tooth contact analysis model is established to determine the relative sliding velocity and tooth contact stress. Secondly, the calculation steps of single tooth surface wear are presented within one gear mesh cycle. With this, the effects of the tooth profile modifications, the operating conditions such as output torque, input speed, and the assembly eccentricity on the wear depth within one gear mesh cycle are investigated. This study gives a deeper understanding of the tooth surface wear mechanisms of cycloid drives and could be employed to assist gear design and to improve the wear resistance. Full article

In order to improve the service life of the needle roller bearing used in a precision cycloid reducer, and to reveal the skew and collision phenomenon of the needle roller bearing, based on the force analysis of the transmission mechanism of the cycloid reducer and considering the friction between the cycloid wheel, needle roller, cage, and crank shaft, the dynamic contact between the rolling bodies is simulated by the Hertz elastic contact, where the contact between the cage pocket hole and needle roller is equivalent to the spring and damping, and a nonlinear dynamic model of the needle roller bearing is established. The influence of different load and cage clearances on the deflection impact of the rotating needle roller bearing is calculated. The results show that the inclination of rollers is different under different pocket clearances, and the larger the pocket gap, the greater the fluctuation of the roller inclination angle; the action force of the crank shaft on the roller suppresses the deflection of the roller; the impact force of the roller on the cage has periodicity, which is consistent with the impact force of the crank shaft on the roller. The impact force of the cage is different under different loads, and the greater the load, the more rollers there are in the bearing area, the larger the impact force is, and the smaller the impact force of the rollers in the middle of the bearing zone is, compared with that of the rollers on the two sides; when the load is small, a pocket cage gap of 0.3 mm is selected, and when the load is heavy, a pocket cage gap of 0.2 mm is selected in order to make the bearing run more smoothly. Full article

The paper is devoted to the development of an algorithm for the automated calculation of force characteristics of cycloid toothing when the initial parameters vary widely. The algorithm forms a structured data array that accelerates finding and outputting the necessary parameters and reduces the probability of error in determining these parameters. The algorithm serves the basis for a program that allows for the examination of the change in force and geometrical parameters in various combinations. The study includes the analysis of the dependence of forces and contact stresses in transmission toothing with intermediate rolling elements and a free cage on the initial parameters of this transmission. The obtained results will make it possible to select optimal combinations of initial parameters in order to minimize the force impact on the mechanism parts when designing modern compact mechanisms based on the cycloid with intermediate rolling elements and a free cage. Full article

Trochoid milling can improve the quality of machining of difficult materials as well as the efficiency of machining. However, its complex tool trajectory makes it difficult to predict the instantaneous cutting forces during cutting. Therefore, in this paper, the transient cutting thickness model in the cycloidal milling process was established using numerical combined with analytical methods, and the semi-mechanical cutting force model was established. Experiments were designed to compare the differences between the cutting force coefficients extracted from the slot milling experiments and those extracted from the trochoid milling. Finally, experiments were designed to validate the established cutting force model. The results showed that there was an error of 5–23% between the tangential cutting force coefficients extracted from slot milling and the tangential cutting force coefficients extracted from trochoid milling, while there was an error of 21–35% in the radial cutting force coefficients, indicating that the cutting force coefficients extracted from slot milling cannot be used to predict the cutting force in the trochoid milling process. It was verified that the error of the established cutting force model in predicting the cutting force of trochoid milling was 12%, indicating that the established model has a high accuracy, which provides a theoretical basis for the selection of cutting parameters and parameter optimization in the future. Full article

To solve the design problem of non-circular gears with cusp pitch curves, this paper proposed a new variable-involute and incomplete variable-cycloid composite tooth profile (VIIVC-CTF), deduced the new VIIVC-CTF mathematical model, and constructed the conjugate gear model based on the envelope method. The design software of the non-circular gear with a cusp pitch curve was developed based on MATLAB. The variation law of rolling radius on an incomplete cycloid profile and its characteristics such as pressure angle and radius of curvature were analyzed. The variation relationship of the rolling radius on the meshing line and the contact ratio of the VIIVC-CTF were studied. The variation relationship of incomplete variable-cycloid profile shape, pressure angle, and curvature radius corresponding to different elliptical eccentricities were analyzed. The meshing analysis of the non-circular gear transmission mechanism was carried out based on virtual software. A comparison of the consistency of the theoretical value and simulation value of the transmission ratio curve verified that the tooth profile design method was feasible, and the VIIVC-CTF was applied to the seedling pick-up mechanism of the non-circular gear planetary gear train. Through the seedling picking experiment of the seedling pick-up mechanism, the feasibility of the application of the VIIVC-CTF was verified. Full article

A powered transfemoral prosthesis is needed as people with transfemoral amputation show 60 percent extra metabolic cost when compared to people with no amputation. Recently, as illustrated in the literature, the most high-torque robotic knee prosthesis utilize harmonic reducers. Despite the advantage of high reduction ratio and efficiency, the harmonic drive cannot be back-driven. Therefore, the harmonic drive is not an optimal solution for prosthetic systems with direct and indirect contact with the environment. In this paper, we outline an initial design of robotic knee prosthesis. The proposed robotic knee prosthesis consists of BLDC motor, cycloidal gear with reduction ratio 13:1, four-bar mechanism, and timing belt transmission with 4:1 reduction ratio. To optimize the torque transmission and range of motion (RoM), a multiobjective optimization problem must be undertaken. The end-effector motion depends on each bar length in the four-bar mechanism. The four-bar mechanism was optimized using particle swarm optimization (PSO). To complete the optimization, a set of 50 steps was collected using wearable sensors. Then, the data of sagittal plan were processed to identify the target profile for PSO. The prototype’s computer-aided manufacturing (CAM) was completed using a MarkTwo 3D printer with carbon fiber composite. The overall design can achieve a maximum torque of 84 N.m. However, the current design lacks the elastic component (no spring is added on the actuator output), which is necessary for a functional prosthesis; this limitation will be addressed in future study. Full article

In order to make a robot track a desired trajectory with high precision and steady gait, a novel intelligent controller was designed based on a new mechanical structure and optimized foot trajectory. Kinematics models in terms of the D-H method were established to analyze the relationship between the angle of the driving joint and the foot position. Inspired by a dog’s diagonal trot on a flat terrain, foot trajectory planning in the swing and support phases without impact were fulfilled based on the compound cycloid improved by the Bézier curve. Both the optimized cascade proportional–integral–derivative (PID) control system and improved fuzzy adaptive PID control system were applied to realize the stable operation of a quadruped robot, and their parameters were optimized by the sparrow search algorithm. The convergence speed and accuracy of the sparrow search algorithm were verified by comparing with the moth flame optimization algorithm and particle swarm optimization algorithm. Finally, a co-simulation with MATLAB and ADAMS was utilized to compare the effects of the two control systems. The results of both displacement and velocity exhibit that the movement of a quadruped bionic robot with fuzzy adaptive PID control systems optimized by the sparrow search algorithm possessed better accuracy and stability than cascade PID control systems. The motion process of the quadruped robot in the co-simulation process also demonstrates the effectiveness of the designed mechanical structure and control system. Full article

The aim of the study was to determine the acute effects of single-whole-body vibration (WBV) on resting metabolic rate (RMR) and carbohydrate–lipid profile of blood in young, healthy women. The participants, in a randomised controlled crossover study, participated in two trials: WBV and a vibration simulation (placebo). The WBV was performed in the prone position and cycloidal-oscillatory vibration was used. The RMR measurement (calorimetry) was performed: before the WBV, during WBV, immediately after the completion of WBV, and 1 h after the completion of WBV. For biochemical analyses, venous blood was collected. During WBV, there was a significant increase in RMR compared to baseline. Immediately after and 1 h following the end of the WBV, RMR was close to baseline levels (p > 0.05). The increased energy expenditure resulted from the increased utilisation of carbohydrates and proteins during the vibration. In the placebo condition, there were no significant changes over time in the level of the studied indices during calorimetry. The WBV had no significant effects on the level of glucose in the blood. The applied vibration did not significantly affect the concentration of the analysed lipid indices, which were within the physiological norms for all measurements. Results indicate the need for further research to establish the physiological mechanisms underlying the observed effects of WBV on resting metabolic rate. Full article