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Harmonic Drive
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HFUS-25-2A
Engineering Data
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Harmonic Drive HFUS-2A, HFUS-14-2A, HFUS-17-2A, HFUS-20-2A, HFUS-25-2A Engineering Data

...
Engineering Data
HFUS-2A Component Sets
QUICKLINK
www.harmonicdrive.de/3050
Contents
1. General ................................................................................................................................................. 03
1.1 Description of Safety Alert Symbols ...................................................................................................................................04
1.2 Disclaimer and Copyright .....................................................................................................................................................04
2.1 Hazards .................................................................................................................................................................................05
2.2 Intended Purpose ................................................................................................................................................................. 06
2.3 Non Intended Purpose .......................................................................................................................................................... 06
2.4 Declaration of Conformity .................................................................................................................................................... 07
3.1 Product Description ..............................................................................................................................................................08
3.2 Ordering Code ....................................................................................................................................................................... 09
3.3 Technical Data ........................................................................................................................................................................10
3.3.1 General Technical Data ...............................................................................................................................................10
3.3.2 Dimensions ..................................................................................................................................................................11
3.3.3 Minimum Housing Clearance.....................................................................................................................................15
3.3.4 Accuracy ......................................................................................................................................................................15
3.3.5 Torsional Stiness .....................................................................................................................................................15
4.1 Selecting Harmonic Drive® Gears .......................................................................................................................................... 18
4.1.1 Torque Based Dimensioning ...................................................................................................................................... 19
4.1.2 Life of the Wave Generator Bearing..........................................................................................................................21
4.1.3 Stiness Based Dimensioning ................................................................................................................................. 22
4.2 Calculation of the Torsion Angle .......................................................................................................................................... 24
4.3 Accuracy of the Oldham Coupling ........................................................................................................................................ 24
4.4 Eciency Versus Load ......................................................................................................................................................... 25
4.4.1 Eciency Calculations .............................................................................................................................................. 25
4.4.2 Eciency Tables........................................................................................................................................................ 26
4.5 No Load Starting-, Back Driving- and Running Torque ...................................................................................................... 29
4.5.1 No Load Running Torque .......................................................................................................................................... 29
4.5.2 No Load Starting Torque ...........................................................................................................................................30
4.5.3 No Load Back Driving Torque .................................................................................................................................... 30
4.6 Lubrication ............................................................................................................................................................................. 31
4.6.1 Grease Lubrication ..................................................................................................................................................... 31
4.6.2 Oil Lubrication ........................................................................................................................................................... 33
4.7 Axial Forces at the Wave Generator .................................................................................................................................... 34
5. Installation and Operation ...................................................................................................................35
5.1 Transportation and Storage ................................................................................................................................................. 35
5.2 Gear Conditions at Delivery .................................................................................................................................................. 35
5.3 Assembly Instructions .......................................................................................................................................................... 36
5.4 Recommended Tolerances for Assembly ............................................................................................................................40
5.5 Wave Generator Components ...............................................................................................................................................41
5.6 Bore Diameter for Solid Wave Generators ...........................................................................................................................41
5.7 Lubrication ............................................................................................................................................................................ 42
5.7.1 Grease Lubrication .................................................................................................................................................... 42
5.7.2 Grease Reser voir ....................................................................................................................................................... 44
5.7.3 Grease Change ...........................................................................................................................................................44
5.7.4 Gears with Oil Lubrication ........................................................................................................................................ 45
5.7.5 Lubrication Holes ...................................................................................................................................................... 46
5.8 Preparation for Assembly ....................................................................................................................................................46
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5.9 Assembly ............................................................................................................................................................................... 47
5.9.1 Assembly of the Circular Spline ...............................................................................................................................48
5.9.2 Assembly of the Flexspline ...................................................................................................................................... 48
5.9.3 Flexspline Screws ...................................................................................................................................................... 49
5.9.4 Assembly of the Wave Generator to the Input Shaft ............................................................................................. 50
5.9.5 Check before Assembly of the Wave Generator ...................................................................................................... 50
5.9.6 Final Check of Position of the Wave Generator .......................................................................................................50
5.9.7 Assembly Control ...................................................................................................................................................... 50
6. Glossary ................................................................................................................................................. 51
6.1 Technical Data ........................................................................................................................................................................ 51
6.2 Labelling, Guidelines and Regulations .................................................................................................................................57

1. General

About this documentation
This document contains safety instructions, technical data and operation rules for products of Harmonic Drive AG. The documentation is aimed at planners, project engineers, commissioning engineers and machine manufacturers, oering support during selection and calculation of the servo actuators, servo motors and accessories.
Rules for storage
Please keep this document for the entire life of the product, up to its disposal. Please hand over the documentation when re-selling the product.
Additional documentation
For the configuration of drive systems using the products of Harmonic Drive AG, you may require additional documents. Documentation is provided for all products oered by Harmonic Drive AG and can be found in pdf format on the website.
www.harmonicdrive.de
Third-party systems
Documentation for parts supplied by third party suppliers, associated with Harmonic Drive® components, is not included in our standard documentation and should be requested directly from the manufacturers.
Before commissioning products from Harmonic Drive AG with servo drives, we advise you to obtain the relevant documents for each device.
Your feedback
Your experiences are important to us. Please send suggestions and comments about the products and documentation to:
Harmonic Drive AG Marketing and Communications Hoenbergstraße 14 65555 Limburg / Lahn Germany E-Mail: info@harmonicdrive.de
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1.1 Description of Safety Alert Symbols

Symbol Meaning
Indicates an imminent hazardous situation. If this is not avoided, death or
DANGER
WARNING
ATTENTION
ADVICE
serious injury could occur.
Indicates a possible hazard. Care should be taken or death or serious injury may result.
Indicates a possible hazard. Care should be taken or slight or minor injury may result.
Describes a possibly harmful situation. Care should be taken to avoid damage to the system and surroundings.
INFORMATION
This is not a safety symbol. This symbol indicates important information.
Warning of a general hazard. The type of hazard is determined by the specific warning text.
Warning of dangerous electrical voltage and its eects.
Beware of hot surfaces.
Beware of suspended loads.
Precautions when handling electrostatic sensitive components.

1.2 Disclaimer and Copyright

The contents, images and graphics contained in this document are predected by copyright. In addition to the copyright, logos, fonts, company and product names can also be predected by brand law or trademark law. The use of text, extracts or graphics requires the permission of the publisher or rights holder.
We have checked the contents of this document. Since errors cannot be ruled out entirely, we do not accept liability for mistakes which may have occurred. Notification of any mistake or suggestions for improvements will be gratefully received and any necessary correction will be included in subsequent editions.
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2. Safety and Installation Instructions

Please take note of the information and instructions in this document. Specialy designed models may dier in technical detail. If in doubt, we strong recommend that you contact the manufacturer, giving the type designation and serial number for clarification.

2.1 Hazards

DANGER
Electric products have dangerous live and redating parts. All work during connection, operation, repair and disposal must be carried out by qualified personnel as described in the standards EN50110-1 and IEC 60364! Before starting any work, and especially before opening covers, the actuator must be properly isolated. In addition to the main circuits, the user also has to pay attention to any auxilliary circuits.
Observing the five safety rules:
• Disconnect mains
• Prevent reconnection
• Test for absence of harmful voltages
• Ground and short circuit
• Cover or close o nearby live parts
The measures taken above must only be withdrawn when the work has been completed and the device is fully assembled. Improper handling can cause damage to persons and property. The respective national, local and factory specific regulations must be adhered to.
DANGER
Electric, magnetic and electromagnetic fields are dangerous, in particular for persons with pacemakers, implants or similiar. Vulnerable groups must not be in the immediate vicinity of the products themselves.
DANGER
Built-in holding brakes alone are not functional safe. Particularly with unsupported vertical axes, the functional safety and security can only be achieved with additional, external mechanical brakes.
WARNING
The successful and safe operation of gears, products requires proper transport, storage and assembly as well as correct operation and maintenance.
ATTENTION
The surface temperature of gears, motors and actuators can exceed 55 degrees Celsius. The hot surfaces should not be touched.
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ADVICE
Movement and lifting of products with a mass > 20 Kg should only be carried out with suitable lifting gear.
ADVICE
Cables must not come into direct contact with hot surfaces.
INFORMATION
Special versions of drive systems and motors may have diering specifications. Please consider all data sheet, catalogues and oers etc. sent concerning these special versions.

2.2 Intended Purpose

The Harmonic Drive® products are intended for industrial or commercial applications. They comply with the relevant parts of the harmonised EN 60034 standards series.
Typical areas of application are robotics and handling, machine tools, packaging and food machines and similar machines.
The products may only be operated within the operating ranges and environmental conditions shown in the documentation (altitude, degree of predection, temperature range etc). Before plant and machinery which have Harmonic Drive® products built into them are commissioned, the compliance must be established with the Machinery Directive, Low Voltage Directive and EMC guidelines.
Plant and machinery with inverter driven motors must satisfy the predection requirements in the EMC guidelines. It is the responsibility of the installer to ensure that installation is undertaken correctly. Signal and power lines must be shielded. The EMC instructions from the inverter manufacturer must be observed in order that installation meets the EMC regulations.

2.3 Non Intended Purpose

The use of products outside the areas of application mentioned above or, inter alia, other than in the operating areas or environmental conditions described in the documentation is considered as non-intended purpose.
ADVICE
The following areas of application are, inter alia, those considered as non-intended purpose:
• Aerospace
• Areas at risk of explosion
• Machines specially constructed or used for a nuclear purpose whose breakdown might lead to the emission of radio-activity
• Vacuum
• Machines for domestic use
• Medical equipment which comes into direct contact with the human body
• Machines or equipment for transporting or lifting people
• Special devices for use in annual markets or leisure parks
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2.4 Declaration of Conformity

Harmonic Drive® gears are components for installation in machines as defined by the machine directive 89/392/EWG. Commissioning is prohibited until such time as the end product has been proved to conform to the provisions of this directive.
Essential health and safety requirements were considered in the design and manufacture of these gear component sets. This simplifies the implementation of the machinery directive by the end user for the machinery or the partly completed machinery. Commissioning of the machine or partly completed machine is prohibited until the final product conforms to the EC Machinery Directive.
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3. Technical Description

3.1 Product Description

Compact with largest hollow shaft
HFUS-2A Series Component Sets are available in nine sizes with gear ratios of 30, 50, 80, 100, 120 and 160:1 oering repeatable peak torques from 9 to 1840 Nm and a power density of up to 384 Nm/kg.
If required, the Component Sets are available as specific configurations tailored to your application, including special lubricants for extended temperature ranges or special materials for extreme ambient conditions. Consisting of just three individual components, they are very lightweight and compact.
The enlarged hollow shaft can be used to feed through supply lines, shafts or cables for further axes. Due to their positioning accuracy stable machine properties with short cycle times are guaranteed.
-
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3.2 Ordering Code

Table 9.1
Series Size Ratio
14 30 50 80 100
17 30 50 80 100 120
1)
Version Special design
2A-R
20 30 50 80 100 120 160
25 30 50 80 100 120 160
HFUS
32 30 50 80 100 120 160
40 50 80 100 120 160
2A-GR
According to customer requirements
45 50 80 100 120 160
50 50 80 100 120 160
58 50 80 100 120 160
Ordering code
HFUS 25 100 2A-GR SP
1)
The ratios shown here are for a standard driving configuration with the circular spline fixed, the Wave Generator used for the input and the Flexspline attached to the
output. Other configurations are possible. Please consult chapter 4 “Ratio”.
Table 9.2
Version
Ordering code Description
2A-R
2A-GR
Component Set
Erläuterungen zu den technischen Daten finden Sie im Kapitel „Glossar“
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3.3 Technical Data

3.3.1 General Technical Data

Table 10.1
Unit HFUS-14-2A HFUS-17-2A
Ratio i [ ] 30 50 80 100 30 50 80 100 120
Repeatable peak torque T
Average torque T
Rated torque T
Momentary peak torque T
Maximum input speed (Oil Lubrication) n
Maximum input speed (Grease Lubrication) n
Average input speed (Oil Lubrication) n
Average input speed (Grease Lubrication) n
Moment of inertia J
Weight m [kg] 0.11 0.18
[Nm] 9.0 18 23 28 16 34 43 54 54
R
[Nm] 6.8 6.9 11 11 12 26 27 39 39
A
[Nm] 4.0 5.4 7. 8 7. 8 8.8 16 22 24 24
N
[Nm] 17 35 47 54 30 70 87 110 86
M
[rpm] 14000 10000
in (max)
[rpm] 8500 7300
in (max)
[rpm] 6500 6500
av (max)
[rpm] 3500 3500
av (max)
[x10-4 kgm²] 0.033 0.079
in
Table 10.2
Unit HFUS-20-2A HFUS-25-2A
Ratio i [ ] 30 50 80 100 120 160 30 50 80 100 120 160
Repeatable peak torque T
Average torque T
Rated torque T
Momentary peak torque T
Maximum input speed (Oil Lubrication) n
Maximum input speed (Grease Lubrication) n
Average input speed (Oil Lubrication) n
Average input speed (Grease Lubrication) n
Moment of inertia J
[Nm] 27 56 74 82 87 92 50 98 137 157 167 176
R
[Nm] 20 34 47 49 49 49 38 55 87 108 108 108
A
[Nm] 15 25 34 40 40 40 27 39 63 67 67 67
N
[Nm] 50 98 127 147 147 147 95 186 255 284 304 314
M
[rpm] 10000 7500
in (max)
[rpm] 6500 5600
in (max)
[rpm] 6500 5600
av (max)
[rpm] 3500 3500
av (max)
[x10-4 kgm²] 0.193 0.413
in
Weight m [kg] 0.31 0.48
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3.3.2 Dimensions

Illustration 11.1 Illustration 11.2[mm]
HFUS-14-2A HFUS-17-2A
[mm]
Illustration 11.3 Illustration 11.4[mm] [mm]
HFUS-20-2A HFUS-25-2A
QUICKLINK
www.harmonicdrive.de/CAD3050
111019658 11/2014
Table 12.1
Unit HFUS-32-2A HFUS-40-2A
Ratio i [ ] 30 50 80 100 120 160 50 80 100 120 160
Repeatable peak torque T
Average torque T
Rated torque T
Momentary peak torque T
Maximum input speed (Oil Lubrication) n
Maximum input speed (Grease Lubrication) n
Average input speed (Oil Lubrication) n
Average input speed (Grease Lubrication) n
Moment of inertia J
[Nm] 100 216 304 333 353 372 402 519 568 617 647
R
[Nm] 75 108 167 216 216 216 196 284 372 451 451
A
[Nm] 54 76 118 137 137 137 137 206 265 294 294
N
[Nm] 200 382 568 647 686 686 686 980 1080 1180 1180
M
[rpm] 7000 5600
in (max)
[rpm] 4800 4000
in (max)
[rpm] 4600 3600
av (max)
[rpm] 3500 3000
av (max)
[x10-4 kgm²] 1.69 4.5
in
Weight m [kg] 0.97 1.86
Table 12.2
Unit HFUS-45-2A HFUS-50-2A
Ratio i [ ] 50 80 100 120 160 50
Repeatable peak torque T
Average torque T
Rated torque T
Momentary peak torque T
Maximum input speed (Oil Lubrication) n
Maximum input speed (Grease Lubrication) n
Average input speed (Oil Lubrication) n
Average input speed (Grease Lubrication) n
Moment of inertia J
[Nm] 500 706 755 823 882 715 941 980 1080 1180
R
[Nm] 265 390 500 620 630 350 519 666 813 843
A
[Nm] 176 313 353 402 402 245 372 470 529 529
N
[Nm] 950 1270 1570 1760 1910 1430 1860 2060 2060 2450
M
[rpm] 5000 4500
in (max)
[rpm] 3800 3500
in (max)
[rpm] 3300 3000
av (max)
[rpm] 3000 2500
av (max)
[x10-4 kgm²] 8.68 12.5
in
1)
80 100 120 160
Weight m [kg] 2.64 3.53
1)
Only with oil lubrication. Grease lubrication is possible if the average torque Tav does not exceed half the rated torque TN.
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Illustration 13.1 Illustration 13.2[mm] [mm]
HFUS-32-2A HFUS-40-2A
Illustration 13.3 Illustration 13.4[mm] [mm]
HFUS-45-2A HFUS-50-2A
QUICKLINK
www.harmonicdrive.de/CAD3050
131019658 11/2014
Table 14.1
Unit HFUS-58-2A
Ratio
Repeatable peak torque
Average torque
Rated torque
Momentary peak torque
Maximum input speed (Oil Lubrication)
Maximum input speed (Grease Lubrication)
Average input speed (Oil Lubrication)
Average input speed (Grease Lubrication)
Moment of inertia
Weight
1)
Only with oil lubrication. Grease lubrication is possible if the average torque Tav does not exceed half the rated torque TN.
Illustration 14.2
HFUS-58-2A
i [ ]
[Nm]
T
R
[Nm]
T
A
[Nm]
T
N
[Nm]
T
M
[rpm]
n
in (max)
[rpm]
n
in (max)
[rpm]
n
av (max)
[rpm]
n
av (max)
[x10-4 kgm²]
J
in
m [kg]
[mm]
1)
50
1020 1480 1590 1720 1840
520 770 1060 1190 1210
353 549 696 745 745
1960 2450 3180 3330 3430
80 100 120 160
4000
3000
2700
2200
27.3
5.17
QUICKLINK
www.harmonicdrive.de/CAD3050
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3.3.3 Minimum Housing Clearance

Table 15.1
Size 14 17 20 25 32 40 45 50 58
u 1.7 2.1 2.0 2.0 2.0 2.0 2.3 2.5 2.9
ØW 31 38 45 56 73 90 101 113 131
x 24.5 27.5 30.5 35.5 43.5 53.0 59.0 65.0 75.5
y 2.9 3.6 3.7 4.2 4.8 5.4 6.1 6.8 7.9
ØZ 38 45 53 66 86 106 119 133 154
Illustration 15.2
[mm]

3.3.4 Accuracy

Table 15.3 [arcmin]
Size 14 17 ≥20
Ratio 30 ≥50 30 ≥50 30 ≥50
Transmission accuracy
1)
<2 <1.5 <1.5 <1.5 <1.5 <1
Hysteresis loss <3 <1 <3 <1 <3 <1
Lost Motion <1
Repeatability < ± 0.1
1)
Higher precision on request
3.3.5 Torsional Stiness
Table 15.4
Size 14 17 20 25 32 40 45 50 58
T
[Nm] 2 3.9 7 14 29 54 76 108 168
1
[Nm]
T
2
i = 30
i = 50
i > 50
K
[x10³ Nm/rad]
3
K
[x10³ Nm/rad]
2
K
[x10³ Nm/rad]
1
K
[x10³ Nm/rad]
3
K
[x10³ Nm/rad]
2
K
[x10³ Nm/rad]
1
K
[x10³ Nm/rad]
3
K
[x10³ Nm/rad]
2
K
[x10³ Nm/rad]
1
6.9 12 25 48 108 196 275 382 598
3.4 6.7 11 21 49 – – – –
2.4 4.4 7.1 13 30 – – – –
1.9 3.4 5.7 10 24 – – – –
5.7 13 23 44 98 180 260 340 540
4.7 11 18 34 78 140 200 280 440
3.4 8.1 13 25 54 100 150 200 310
7.1 16 29 57 12 230 330 440 710
6.1 14 25 50 11 200 290 400 61 0
4.7 10 16 31 67 130 180 250 400
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4. Driving Arrangements

A variety of dierent driving arrangements are possible with Harmonic Drive® gears.
Equation 16.1
Ratio i =
Input speed
Output speed
Overview Harmonic Drive® Products
The three main components of the Harmonic Drive® units, Circular Spline (CS), Flexspline (FS) and Wave Generator (WG) can be seen in the illustration 16.2.
Illustration 16.2
The values for ratios of Harmonic Drive® gears refer to the standard input and output arrangement (example 1 in the table below). Other arrangements are possible, and also shown in the table.
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Ratio
1) 2) 3)
WG
FS
CS
Reduction gearing
CS Fixed WG Input FS Output
Equation 17.1
Ratio = -
Input and output rotate in opposite directions. Input and output rotate in same direction. Input and output rotate in same direction.
i 1
Reduction gearing
FS Fixed WG Input CS Output
Equation 17.2
Ratio =
i +1
1
Reduction gearing
WG Fixed FS Input CS Output
Equation 17.3
Ratio =
i +1
1
4) 5) 6)
Speed increaser gearing
WG Fixed
CS Input
FS Output
Equation 17.4
Speed increaser gearing
CS Fixed FS Input WG Output
Equation 17.5
Speed increaser gearing
FS Fixed CS Input WG Output
Equation 17.6
Ratio =
Input and output rotate in same direction. Input and output rotate in opposite directions. Input and output rotate in same direction.
i +1
Ratio =
i
1
­i
Ratio =
1
i +1
7)
Dierential gear
WG Control input CS Main drive input FS Main drive output
Numerous dierential functions can be obtained by combinations of the speed and rotational direction of the three basic elements. Please refer to our broshure “Dierential Applications” available to download from our website.
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4.1 Selecting Harmonic Drive® Gears

When choosing a gear, both torque as well as stiness requirements should be take into account. In robot applications, for example, the necessary torque is the more crucial factor for the gear size, while the torsional stiness is often decisive in machine tool applications. We therefore recommend that you always take both criteria into account according to the following procedures.
Application
Gear preselection
Torque based dimensioning
according to selection
procedure on page 19
Selection of a
bigger size
Yes
Yes
Gear size
sucient?
Stiness based dimensioning
according to selection procedure on page 22
Gear size
sucient?
End of gear
selection
No
Selection of a
bigger size
No
18 1019658 11/2014
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