06FTM04

Precision Planetary Servo Gearheads

by: G.G. Antony, Neugart USA LP

and A. Pantelides, mG miniGears North America

American Gear Manufacturers Association

TECHNICAL PAPER
Precision Planetary Servo Gearheads

Gerhard G. Antony, Neugart USA LP and Arthur Pantelides, mG miniGears

North America

[The statements and opinions contained herein are those of the author and should not be construed as an
official action or opinion of the American Gear Manufacturers Association.]

Abstract
Modern automated machineries are increasingly using flexible high dynamic servomotors because of their
ability to speed up and flexibly automate complex motions these machineries need to perform. Planetary
gearheads are used frequently in conjunction with servomotors to match the inertias, lower the motor speed,
boost the torque, and at the same time provide a sturdy mechanical interface for pulleys, cams, drums and
other mechanical components.
This paper addressing following topics:
-- main reasons why the planetary (epicyclical gear systems) are the preferred choice for ”servo
applications” (applications using servo motors);
-- what influencing the positioning accuracy repeatability of a planetary servo gear;
-- helical gears in planetary systems;
-- the rating practices establishing a transparent ”comparability” of different torque listings;
-- introduction of a simple reliable method to the required gearbox torque rating for a servo--application
based on the selected motor toque data.

Copyright © 2006

American Gear Manufacturers Association

500 Montgomery Street, Suite 350
Alexandria, Virginia, 22314

October, 2006

ISBN: 1--55589--886--6
 Precision Planetary Servo Gearheads

Gerhard G. Antony, PhD, Neugart USA LP

with contributions from Arthur Pantelides, mG miniGears North America

Because of their versatility as well as their ability to 1. The Planetary (Epicyclical) Gear
speed--up and automate a wide--range of highly-- System as the “System of Choice” for
complex motion sequence programs required in Servo Gearheads
many of today’s industries, computer--controlled,
Frequent misconceptions regarding planetary
programmable, highly dynamic--capable servo mo-
gears systems involve backlash: planetary sys-
tors are increasingly being used in modern machin-
tems are used for servo gearheads because of their
ery required in complex automation applications.
inherent low backlash; low backlash is the main
Precision planetary gearheads are frequently used
characteristic requirement for a servo gearboxes;
in conjunction with such servo motors in order to:
backlash is a measure of the precision of the plane-
balance inertial loading conditions seen during fre-
tary gearbox.
quent speed cycling sequences, decrease motor
speeds, and boost torque, while at the same time, The fact is, fixed--axis, standard, “spur” gear ar-
provide a robust mechanical interface for pulleys, rangement systems can be designed and built just
cams, drums, and other mechanical transmission as easily for low backlash requirements. Further-
components. more, low backlash is not an absolute requirement
for servo--based automation applications. A moder-
This paper shall present a foundation and funda- ately--low backlash is advisable (in applications with
mental approach for understanding why the plane- very high start/stop, forward/reverse cycles) to
tary system is the preferred design choice for servo avoid internal shock loads in the gear mesh. That
gearheads; clear up some misconceptions about said, with today’s high--resolution motor--feedback
planetary servo gearheads; compare rating practic- devices and associated motion controllers it is easy
es by establishing a transparent comparability of dif- to compensate for backlash anytime there is a
ferent torque listings; and introduce a simple and re- change in the rotation or torque--load direction.
liable method of determining the required gearbox If, for the moment, we discount backlash, then what
torque rating for a selected servo motor/gearbox are the reasons for selecting a more expensive,
application. seemingly more complex planetary systems for ser-
vo gearheads? What advantages do planetary
Main topics covered in the paper shall be: gears offer?
High Torque Density -- Compact Design
-- The planetary (epicyclic) gear system as the
“system of choice” for servo gearheads; An important requirement for automation applica-
tions is high torque capability in a compact and light
-- The best “balanced” planetary ratio from a package. This high torque density requirement (a
torque density point of view; high torque/volume or torque/weight ratio) is impor-
tant for automation applications with changing high
-- The gearhead design influence on positioning--
accuracy and repeatability; dynamic loads in order to avoid additional system
inertia.
-- Typical dynamic servo applications and servo Depending upon the number of planets, planetary
gearhead torque ratings; systems distribute the transferred torque through
-- How to establish comparative torque ratings; multiple gear mesh points. This means a planetary
gear with say three planets can transfer three times
-- Sizing/selection of servo gearheads for match- the torque of a similar sized fixed--axis “standard”
ing AC servo motors in automation applications. spur gear system. Reference Figure 1.

1
 Fixed axis “standard” gear Planetary “Epicyclical” gear system
Figure 1.
Rotational Stiffness/Elasticity An additional, important factor is in regards to lu-
brication and operating speed. Fixed--axis spur
High rotational stiffness, or minimal elastic windup,
gears will exhibit lubrication “starvation” and quickly
is important for applications with elevated position-
fail if running at high speeds because the lubricant is
ing accuracy and repeatability requirements; espe-
slung away. Only special means such as expensive
cially under fluctuating loading conditions. The load
pressurized forced lubrication systems can solve
distribution unto multiple gear mesh points means
this problem. On the other hand, grease lubrication
the load is supported by N contacts (where N = num-
is impractical because of a its “tunneling effect,” in
ber of planet gears) increasing the torsional stiff-
which the grease, over time, is pushed away and
ness of the gearbox by factor N. This means it con-
cannot flow back into the mesh.
siderably lowers the lost motion compared to a
similar size standard gearbox; and this is what is de- In planetary systems the lubricant cannot escape —
sired. it is continuously redistributed, “pushed and pulled”
or “mixed” into the gear contacts, ensuring safe lu-
Low Inertia brication practically in any mounting position and at
Added inertia results in an additional torque/energy any speed. Furthermore, planetary gearboxes can
requirement for both acceleration and deceleration. be grease lubricated. This feature is inherent in
The smaller gears in planetary system result in low- planetary gearing because of the relative motion be-
er inertia. Compared to a same torque rating stan- tween the different gears making up the
dard gearbox, it is a fair approximation to say that arrangement.
the planetary gearbox inertia is smaller by the 2. The Best “Balanced” Planetary Ratio
square of the number of planets. Again, this advan- from a Torque Density Point of View
tage is rooted in the distribution or “branching” of the
load into multiple gear mesh locations. For easier computation it is preferred that the plane-
tary gearbox ratio is an exact integer (3, 4, 6 ...).
High Speeds Since we are so used to the decimal system, we
tend to use 10:1 even though this has no practical
Servomotors run at high rpm, hence a servo gear-
advantaged for the computer/servo/motion control-
box must also operate in a reliable manner at high
ler. Actually, as we will see, 10:1 or higher ratios are
input speeds. For servomotors 3,000 rpm is practi-
the weakest, using the least “balanced” size gears
cally the standard and in fact speeds are constantly
and hence have the lowest torque rating.
increasing in order to optimize more and more com-
plex application requirements. Servomotors run- This paper addresses “simple planetary” gear ar-
ning at speeds in excess of 10,000 rpm are not un- rangements, meaning all gears are engaging in the
common. From a rating point of view with increased same plane. The vast majority of the epicyclical
speed the power density of the motor increases pro- gears used in servo applications are of this “simple
portionally without any real size increase of the mo- planetary” design. Figure 2a illustrates a cross--
tor or electronic drive. Thus Amp rating stays about section of such a planetary gear arrangement with
the same while only the Voltage must be increased. its central sun gear, multiple planets (3), and the

2
ring--gear. The definition of the ratio of a planetary planet bearings and carrier pins, hence limiting the
gearbox shown in the figure is obtained directly from loadability. The 4:1 ratio is an well--balance ratio,
the unique kinematics of the system. It is obvious with sun and planets having the same size. 5:1 and
that a 2:1 ratio is not possible in a simple planetary 6:1 ratios still yield fairly good balanced gear sizes
gear system, since to satisfy the above equation for between planets and sun. With higher ratios ap-
a ratio of 2:1 the sun gear would need to have the proaching 10:1, the small sun--gear becomes a
same diameter as the ring--gear. Figure 2b shows strong limiting factor for the transferable torque.
the sun gear size for different ratios. With increased Simple planetary designs with 10:1 ratios have very
ratio the sun gear diameter (size) is decreasing. small sun--gears, which sharply limits torque rating.
Adding more planets can increase the torque densi-
Since gear size effects loadability the ratio is a
ty of the arrangement. To this effect we see that with
strong and direct influence factor for the torque rat-
lower ratios additional planet gears can be used;
ing. Figure 3a below shows the gears in a 3:1, 4:1,
but for higher ratios, such as 10:1, multiple gears
and 10:1 simple system. At 3:1 ratio, the sun gear is
beyond say 3 planets, would cause interference.
large and the planets are small. The planets are be-
coming “thin walled” thus limiting the space for the This is illustrated in Figure 3b.

Ring gear Diameter

Ratio = +1
Sun gear Diameter

Ring gear Number of Teeth

Ratio = +1
Sun gear Number of Teeth

Figure 2a. Definition of the (Reduction) Ratio for a simple planetary gear arrangement having a
stationary ring gear. The input is at the sun--gear and output at the planet carrier shaft.

Figure 2b. Sun gear size for different ratios

3
 Figure 3a. Planetary gear ratios and the relationship between sun/planet size

Ratio 3:1 with 5 planets Ratio 4:1 with 4 planets Ratio 10:1
max. 3 planets possible
Figure 3b. 10:1 ratios should be avoided unless absolutely necessary from a technical point of
view. If such ratios are used additional consideration must be given to arrangement/size
vs. rating
3. How Positioning--Accuracy & Repeat- quirement the feedback signal is generated by a
ability is Effected by the Precision and feedback devise (resolver, encoder) in the motor. In
Quality Class of the Servo Gearhead this case auxiliary mechanical components at-
tached to the motor such as a gearbox, couplings,
As previously mentioned, it is a general misconcep-
pulleys, belts, etc., will influence the positioning ac-
tion that the backlash of a gearbox is a measure of
curacy.
the quality or precision. The fact is that the backlash
has practically nothing to do with the quality or preci- Influence of the Gearbox:
sion of a gear. Only the consistency of the back- Gearbox Stiffness/Elasticity -- The elastic de-
lash can be considered, up to certain degree, a form formation or the “wind--up” of the components under
of measure of gear quality. From the application load can significantly affect the positioning accura-
point of view the relevant question is “what gear cy; and the positioning error is load--dependant
properties are influencing the precision of the since the wind--up of course depends on the load.
motion?”
Backlash -- the clearance between mechanical
Positioning Accuracy – is a measure of how exact components -- (such as the backlash of a gearbox)
a desired position is reached. In a closed loop sys- can contribute to the positioning error if the sense of
tem the prime determining/influencing factor of the the rotation or torque is changed during the position-
positioning accuracy is the accuracy and resolution ing move. The overall rotational backlash of a gear-
of the feedback device and where the position is box is determined not only by the clearance be-
measured. If the position is measured at the final tween the gear teeth in mesh, it is influenced also by
output of the actuator the influence of the mechani- the other components of the gearbox such as the
cal components can be practically eliminated. (Di- housing, bearings, shafts, and shaft/hub connec-
rect position measurement is used mainly in very tion to name a few.
high precision applications such as machine tools). Transmission Error – (TE) can be also described
In applications with a lower positioning accuracy re- as “the fluctuation of the theoretical reduction ratio”

4
the output does not follow the input rotation exactly Repeatability – a measure of how exact a certain
at the theoretical reduction ratio but fluctuates (+/--) position is reached when a positioning motion cycle
a certain angle during the rotation, due to the incon- is repeated a number of times.
sistencies of the gears (gear errors). These include
Influence of the Gearbox Stiffness – if the
pitch, lead, profile error, general eccentricity due to
repeated motion cycle is performed with different
non--optimum positioning/placement, and others.
loads the stiffness of the system has a significant
The TE of a gear is directly dependent to the gear
influence on the repeatability.
precision or gear class of the particular gear in ques-
tion. And, just like the backlash, the overall gearbox Influence of the Gearbox Backlash – If the motion
TE is influenced by the other components of the cycle is exactly repeated the backlash of the gear-
gearbox. box has theoretically NO influence on the repeat-
Example 1: ability; not even at fluctuating loads.

Given: 4. Torque Rating of Servo Gearheads in

S Gearhead PLS115 Automation, Motion Control, and Robotics
S 4:1 ratio Applications
S worst case backlash 3 min
The basic limiting factor for electrical devices is the
S rotational stiffness = 20 Nm/arcmin
S Torque rating 200 Nm temperature; more specifically, the instantaneous,
S Neugart 115 measured gearbox transmission or gradual breakdown of the insulation of the device
error (TE) approximately +/-- 1.25 arc min due to temperature, ultimately resulting in a failure
condition. Other than the strength of the magnets
1. What is the worst case positioning error from the
TE? used in a particular motor design, or the currents,
and demagnetization characteristics, the torque rat-
' 1.25 arc min
ing of an AC servo motor is mainly determined by its
2. What is the worst case positioning error due to “thermal loadability.” In a motor the generated heat
the Backlash in a motion cycle with motion direc- is proportional to R x I2 x t and the rating limitation is
tion reversal at rated torque load? the RMS value of the current (I) and its duration (t).
' 3 arc min Therefore RMS Torque is proportional to the cur-
3. What is the worst case positioning error due to rent.
the Stiffness or “wind--up” in a motion cycle with On the other hand from a mechanical point of view,
motion direction reversal at nominal torque
the basic limiting factors of mechanical devices are
load?
the mechanical stresses, tension, compression,
' 200 [Nm] x 2/20 [Nm/arc min] bending, shear, and Hertzian Pressure. The ther-
= 20 arc min mal loading is secondary.
Gear Precision Class -- a number of geometrical
In virtually all automation applications, frequently
measurements and associated tolerances and
changing loads created by duty cycles with multiple
deviations for these determine gear precision class.
starts/stops and accelerations/decelerations are
Various national and international organizations
present and very common in the servo drives asso-
have established standards which define various
ciated with these applications. Even if the external
gear precision class levels; these include AGMA,
loads are constant, all major components of a gear-
ISO, DIN, JIS, and others. It is a frequent miscon-
head are subjected to cyclic mechanical stresses.
ception that the low backlash is a prerequisite for
high precision. The fact is that the gear precision As an example, we calculate the number of peak
class has little to no influence on the backlash. On load cycles being subjected to the sun gear in a
the other hand it has a determining influence on the moderate/low cycle automation application. In the
TE as indicated in the example above. Also, as case of a 5:1 ratio planetary gearbox, with 3 planets,
shown, the stiffness can have considerably higher driven at 3000 rpm input, 2 peak load cycles of 1 sec
influence on the positioning error as opposed to ei- duration, the sun--gear must withstand: 2.304 x 106
ther the Backlash or the TE, again shown above. peak load cycles in 10 days of operation!

5
See Figure 4/Example 2. The stress cycle rate on
the planetary gears are lower, but they are sub-
jected to reverse bending which fatigues the materi-
al even more.

Example 2:
Moderate/Low Cycle Rate Automation Application
S 2 load cycles per minute (acceleration/
deceleration)
S 16 hours/day operation
S 1 second (1/60 min) -- peak load duration/cycle
Figure 4/Example 2.
S 3000 rpm motor speed during the peak load
period Fatigue Behavior of Components Made of
Ferrous Materials
S Unit characteristics: ratio 5:1, with 3 planet
gears Fatigue phenomena of metallic ferrous components
Number of load cycles on one sun gear tooth after is well known. Parts subjected to cyclic loads will fail
10 days of operation: after a certain finite number of load cycles even
though the magnitude of the stress load is consider-
3 gear planets ably lower than the static strength, which the part
x [ 3000 rpms – (3000/5) relative rpms ]
can endure without any damage. If the magnitude of
x 1/60 (rps/rpm)
the cyclic stress load is decreased, one can observe
x 1 sec (peak load duration)
that at a certain stress level the part can endure un-
x 2 (peak load cycles/min)
limited load cycles. This stress level is called the
x 60 (min/hr)
x 16 (hours per day operation) x 10 “endurance limit.” This behavior is well repre-
(days) sented graphically by S--N Curves ( Stress over the
= 2,304,000 or 2.304 x 106 Number of Cycles ). We can conclude, components
Peak loads on each sun--gear tooth every 10 loaded at or below the endurance limit will endure
days virtually unlimited load cycles.

Figure 5.

6
Countless tests have confirmed that for ferrous ma- The above relationships allow us to calculate life ex-
terials the progressive exponential relationship be- pectancy at a certain stress load level. If we expand
tween the stress S and the Number of endured load to estimate cumulative impact under a range or set
cycles N without damage levels--off into the “endur- of different stress levels and frequency of stress lev-
ance limit” (the constant horizontal part of the S--N el occurrence, that is, the repetition of various load-
curve) at about 2x106 ~ 2x107 cycles. This is valid if ings, the analysis could then be done using various
the part is subjected to bending, shear, tension, or “Damage Accumulation” calculation methods which
compression. Based on this we can distinguish 2 combine individual analysis into a comprehensive
characteristic areas of the S--N relationship, name- estimation. One such well--known method is
ly: “Miner’s rule.”

I. The “area of limited load cycles” (limited life) – 5. Establishing The Torque Rating of a
essentially the exponential relationship between Gearbox
S and N. This area is mathematically described
as: The majority of real--world applications subject gear
components to a significantly higher cycle loading
S = 1/N1/E ' S = N–1/E or N = 1/S E than just 2 x 106 load cycles. Therefore, the recom-
mendation of practically all gear rating standards (
In its logarithmic form:
log S = - 1/E x log N or log N = - E x log S AGMA, ISO, DIN, etc. ) is to determine and list the
torque rating of a gearbox based on the endurance
II. The “area of unlimited load cycles” -- the limit and on a certain minimum bearing life; for ex-
horizontal portion of the S--N curve. ample for industrial gear boxes AGMA recom-
mends 5,000 ~ 10,000 hours.
In the above equations “E” is an empirically--deter-
mined factor which relates material properties, heat From a purely technical point of view, there is only
treat processes, and type of loading. Graphically it one “true rated--torque” for a gearbox and that is,
represents the slope of the line defining Area I. It the rated--torque under continuous duty condi-
should be expected for E to have a wide range of tions. Unfortunately, for various non--technical rea-
values since there is a wide range of materials being sons, often times additional ill--defined torques such
heat treated under various processes. Normally as acceleration torque, peak torque, emergency--
E = 6 ~ 80. Note that if we plot on a logarithmic stop torque, etc., are listed and taken under consid-
scale, E demonstrates a linear relationship. See eration but without reference to the number of load
Figure 6. cycles.

Figure 6.

7
It is possible to establish a comparison to the “artifi- is strictly only applicable to the bearings and not the
cial” torque ratings listed for a certain gearbox’s true other vital components of the gearbox such as the
rated--torque, based on the endurance limit, using gear teeth or shafts. A correct calculation requires
the similar basic concept used in Miner’s rule and the application of unique exponents, for the individ-
S--N curves. ual components, made of different materials, with
different heat treatment, and loading conditions, as
Let us consider the following relationship for 2
shown in previous Figure 6. Thus we desire to es-
gearboxes:
tablish a torque rating based on a similar
(TNG2/TAG2)E2 = (TNG1/TAG1)E1 method/algorithm as that of Miner’s rule.

where: 6. A Reliable and Realistic Selection

Method for Gearheads for Applications
TNG1 = true rated torque (based on endur-
with Repeated Dynamic Loading
ance limit) of gearbox 1
Automation, motion control and positioning applica-
TNG2 = true rated torque (based on endur-
tions are characterized by repeated acceleration
ance limit) of gearbox 2
and deceleration cycles associated with frequent
TAG1 = artificial torque rating of gearbox 1 starts/stops and direction reversals. The character-
istic load cycle of an application usually consist of a
TAG2 = artificial torque rating of gearbox 1
number of load peaks of different intensity and dura-
E1, E2 = exponents/S--N slopes for gearbox tion. The exact load cycle of a machine is not easy to
1 and 2 respectively predict; however, it can be measured and a statisti-
Using the above, an equivalent to artificial torque cally representative load characteristic cycle can be
rating of a gearbox 2 can be determined using the generated.
following: In most cases, the exact load cycle is not known and
TAG2 = (TAG1/TNG1)E1/E2 x TNG2 the task is to size/select a gearbox for a given servo-
motor. With basic load related data, namely the load
The fact remains that only in applications where the inertia, the magnitude of the maximum non--dynam-
number of load cycles is below 2x106 are higher ic load (such as friction load) and the available mo-
loads than the rated load permissible. However, the tor data a reliable and realistic estimation of the re-
majority of real world automation applications reach quired gearbox torque rating is possible.
this number of load cycles in just a few days, weeks,
or at best, after some months of operation. There- For a given servomotor, the maximum dynamic (ac-
fore for a safe servo gearhead selection the rule celeration) peak torque is known from the motor
must be: data sheet. To assume that the gearbox is exposed
to the maximum motor peak torque can easily lead
If the peak load cycle is part of the standard (de- to over--sizing and associated cost increases. In the
signed) working duty cycle of the machinery, the vast majority of real applications a substantial por-
peak load should not be higher than the rated tion of the motor peak acceleration torque is not
torque unless the machinery is only working a
transmitted through the gearbox because a signifi-
very limited time “say an hour a day” or if the user
cant part of it is “consumed” in order to accelerate
and OEM does not expect an extended long
maintenance--free life from the machinery. To the motor rotor i.e. only a part of the motor peak
predict the life in such applications a detailed torque will “travel” through the gearbox.
analysis of the load spectrum is required.
The Torque Magnitude Through the Gearbox
The familiar and frequently used method based on in a System with Cyclic Dynamic Loading,
the “Root Mean Cube” (RMC) torque value, Such as Start/Stop.

1∕3 We shall now derive the general governing equa-

⎡N1t1T 31 + N2t2T 32 +⋅⋅⋅ + NitiT3i⎤ tion, which will allow us to determine the magnitude
T RMC =⎪ ⎪ of the peak torque of a gearbox. Knowing the magni-
⎣ N1t1 + N2t2 +⋅⋅⋅ + Niti ⎦ tude of the peak torque traveling through the gear-

8
box there is a straight forward method which can be Introducing the “inertia parameter” k = JM /(JLR +JM ),
used to easily select an appropriate gearbox size. which is a function of the system inertias only, the
torque through the gearbox can be written in the
Consider the system consisting of Motor, Gearbox
form:
and Load, shown in Figure 7. All system parame-
ters are reflected to the motor axis i.e., “JLR = JL/ i 2” T GR = T M − T LR × (1 − k) + T LR
and TLR = TL d /i with “i” being the reduction Ratio,
This is an easy to use formula and one which is valid
JL the load inertia at the output, and TL the true
for all motor inertial and frictional torque
torque at the output. The TLR load torque is the fric-
combinations.
tion torque and/or a gravity--born torque present in
the system under steady state condition as well as
during the acceleration phases of the motion cycle.
TL represents the non- inertial resistance forces
the drive has to overcome.

Figure 8. Typical characteristic torque/speed

curve of an AC servo motor
To have a long, maintenance--free gearbox life, the
calculated gearbox load “TGR x i” should be equal
Figure 7.
to or less than the gearbox torque rating. The inertia
The torque equilibrium equation during the accel- parameter defined above, k = JM /(JLR + JM ), is
eration, with the maximum available motor peak closely related to the Inertia Match Ratio which is
torque “TM ”, motor rotor inertia “JM ”, and “a” as Load Inertia/Motor Inertia, IMR = JLR /JM .
the angular acceleration, can be written as: With some substitutions above we have:
k = 1/(IMR+1). With the IMR being a widely-- used
T M − T LR − J M × a − JLR × a = 0 (1)
basic characteristic of a servo--driven system. It
Solving for angular acceleration: shows how well the system is balanced from the
control as well as the overall economic point of view.
T M − T LR Systems with “balanced” inertias, meaning IMR of
a=
J M + J LR (1a) approximately ≈ 1:1, have good responsive control
characteristics.
The torque traveling through the gearbox is:
Consider a servo system with matched inertias of
T GR = T M − JM × a (2) 1:1. If we assume we have only dynamic inertial
Similarly we have: loads, i.e. (TLR =0), with IMR = JLR /JM = 1 the iner-
tia parameter k becomes:
T GR = T LR + JLR × a (2a)
k= 1 = 0.5
Substituting Equation 1a, into Equation 2, for the ac- (1 + 1)
celeration, we can derive the following equation: which will result in:

 
T GR = T M × 0.5
1 − JM T LR × JM
T GR = T M × + This means, in a system with 1:1 inertia ratio, 50%
JLR + JM J LR + J M of the motor peak torque will be “consumed” or ex-

9
pended to accelerate the motor rotor and only the of accelerations/decelerations, and the available
other 50% of it will “travel through” the gearbox to motor torque is considerably less than the peak
accelerate the load. Using the above equation, an torque, if not, the motor can burn out.
appropriate gearbox can be selected based on this
For high cycle rate applications repeating many
calculated maximum output torque requirement of
times in a minute or even multiple times in a second,
“TGR x i” instead of selecting one based on the full
it is practically a must to have a low IMR close to, or
peak motor torque, i.e. based on “TM x i”.
even less than unity, IMR ≦ 1.
Based on the proposed method developed here, On the other hand, low cycle rate applications cer-
one can visualize the torque through the gearhead tainly can utilize the peak torque since it does not
in terms of percent of the motor peak torque. In occur with high frequency over the motion cycle,
Figure 9 the torque through the gearbox is depicted here we can have a larger inertial mismatch which
as a function of IMR (Inertia Match Ratio). The non-- means high torques will be transmitted through the
dynamic torques such as friction torque, again, gearbox.
relative to the motor peak torque, is used as a
parameter. Furthermore, contrary to the common belief that
high cyclic operations are tough on gearheads, high
High Cycle Rate Applications cyclic automation application, with matched inertias
using the methods outlined in this paper, in fact can
The peak torque of the servo motor can be utilized utilize lower torque rating (smaller size) gearheads;
only within very limited time parameters in the mo- compared to low cycle rate operation, with high iner-
tion cycle, i.e. in high cycle rate applications, motor tial mismatch, where a gearbox with larger torque
full peak torque is not available for a rapid sequence rating is needed .

Figure 9

10
The described selection method is generally appli- concept of inertial matching or balancing in order to
cable and can be expanded for use with all gear- optimize planetary gearhead/servo motor selection.
boxes and gear motors as long as the gearbox
It is the intention of the author to stimulate further re-
torque rating is a “true rating” and the application
search, thought, and open discussion on the poten-
does not have frequent external heavy shock load-
tial use, further rating refinement, and general opti-
ing, such as sudden jam or frequent emergency
mization of precision planetary servo gearheads in
stops.
various demanding applications for which they are
best suited.
Conclusion
References:
This paper presented a general foundation for the Antony, Gerhard., Service Factors Help Fine--Tune
further approach and understanding of planetary Gear Selection., Power Transmission Design, 1988
gearing and why such type of gearing system is the Antony, Gerhard., Getriebeauswahl durch realis-
preferred design choice for servo gearheads. This tische Abschatzung des Erforderlichen Betriebsfak-
was done within the context and discussion of tors, SEW Eurodrive., 1989.
torque density, rotational stiffness, inertia, speed,
positioning accuracy, and other important factors Herr, Thomas., Planetary Servogears., PT Design
and requirements in demanding applications such Planetary Gear Report., August 2000.
as automation, motion control and robotics. Kaim, Charles., The World of Planetary Gears., PT
Design Planetary Gear Report., August 2000.
The paper also attempted to clear up some miscon-
Predki, Wolfgang, et.al., Load Distribution in Plane-
ceptions about planetary servo gearheads; it laid
tary Gears., 4th World Congress on Gearing and
the groundwork for a unique rating method by start-
Power Transmission, Paris, March 1999.
ing with a discussion of fatigue behavior, and the ex-
pansion of well known concepts into a rating method Townsend, Dennis (Editor in Chief)., Dudley’s Gear
of a system with cyclic dynamic loading, with the Handbook, 2nd edition, McGraw--Hill, Inc. 1991.

11