Determination of Mechanical Power Loss of the Output Mechanisms with Serially Arranged Rollers in Cycloidal Gears While Taking into Account Manufacturing Tolerances

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.