HARMONIC DRIVE GEARBOX CSF-25-100-2A-GR

ASSEMBLY MANUAL

SEE HARMONIC DRIVE INSTALLATION & OPERATION MANUAL FOR ADDITIONAL

INFORMATION

Materials Needed:

1 -- CSF-25-100-2A-GR, includes:

-Circular Spline

-Wave Generator

-Flexspline

1 – Aluminum Output Plate

1 – Aluminum Mount Plate

1 – Machined Gearbox Shaft with key

1 -- 3/8" Shaft, 9/16" W Needle Roller Bearing (McMaster# 6383K17)

1 -- 3/8" Shaft, 1/4" W Steel Ball Bearing (McMaster# 6338K415)

1 -- Gearbox shaft screw with washer (McMaster# 90128A942)

1 -- Gearbox shaft washers (Inner Gearbox Nylon Spacers; Lowe’s)

8 -- Gearbox output screws (McMaster# 91420A428)

With nylon insert nuts (Lowe’s)

12 -- Gearbox mounting screws (McMaster# 91280A144)

With nuts (McMaster# 90591A255)

Gearbox Grease

Tools Needed:

1 – Phillips Head Screwdriver

1 – 7mm Socket

1 – 10mm Socket

1 – Metric Caliper

1 – Ratchet or Nut Driver

Figure 1

Ensuring the features are concentric as shown above, assemble the Flexspline to the Aluminum Output Plate, using the Gearbox Output Screws. Make sure the shoulder on the Circular Spline is facing away from the Aluminum Output Plate

Flexspline

Ensure these are concentric!

Circular Spline

Aluminum Output Plate

Figure 2

Fill the gearbox with grease as shown above. Also at this step, grease the teeth on the Flexspline. with just enough to fill the crevices in the teeth.

Figure 3

Pack the Wave Generator with grease as shown above. Rotating the bearing while doing this ensures the entire bearing is greased well.

Wave Generator

Figure 4

Install the key into the Machined Gearbox Shaft. The key will slide directly into the keyway in the Wave Generator as the shaft is placed inside. Install the Gearbox Shaft Washer on the Machined Gearbox Shaft.

Gearbox Shaft Washer

Machined Gearbox Shaft

Figure 5

Slide the Wave Generator Assembly into the Flexspline assembly as shown above. Do not push the edge of the Wave Generator flush with the edge of the Flexspline yet. With the Wave Generator slightly outside of the Flexspline as shown above, pull the Circular Spline over the Flexspline. This will require little force. IT IS CRUCIAL TO ENSURE THAT DEDOIDAL ASSEMBLY DOES NOT OCCUR. IF YOU DO NOT KNOW WHAT THIS IS LOOK IT UP IN THE HARMONIC DRIVE CATALOG. At this step, the shoulder of the Circular Spline should be 37mm from the front of the Flexspline, where it mounts to the Aluminum Output Plate. From this point, apply pressure to the Wave Generator until the silver part (called out above) is flush with the edge of the shoulder on the Circular Spline. This is easier to see in Figure 6.

Wave Generator/Flexspline Offset

Circular Spline Shoulder

Silver Part to be flush with Circular Spline Shoulder

Figure 6

Once assembled as shown above, check again that dedoidal offset has not occurred.

Figure 7

Install whichever type Aluminum Mount Plate you are assembling, ensuring all Gearbox Mount Screws line up in the Circular Spline holes. Lastly install the Gearbox Shaft Screw and washer in location shown above.

Aluminum Mount Plate

Gearbox Shaft Screw and Washer inserts here

TIGERBOT VI LOWER BODYASSEMBLY MANUAL

This is a brief overview so please contact AJ Szklany at 716-799-5849 or

ajs3414@rit.edu if there are any questions or concerns.

Figure 8

You will need to install the ankle gearbox and support plates to the upper foot plate, prior to the foot assembly. Assemble both front and back support plates between upper foot plate and foot plate. Assemble motor, shaft coupling and gearbox, to each other first. Once complete, place assembly into the foot.

Figure 9

Support Plates

Upper Foot Plate

Figure 10

Assemble shin plates onto ankle. Ensure the upper shaft holes are aligned axially. Install lower motor support with motor. Assemble knee gearbox to upper motor support. Install upper motor support with gearbox, ensuring the gearbox is in line axially with the upper shaft holes. See Figure 11 for more information.

Lower Motor Support

Figure 11

Upper Motor Support

Upper Shaft Holes

Shin Plates

Figure 12

Assemble thigh plates onto shin. Ensure the upper shaft holes are aligned axially. Install lower motor support with motor. Assemble hip FB gearbox and motor to upper motor support. Install upper motor support with gearbox and motor, ensuring the gearbox is in line axially with the upper shaft holes. See Figure 13 and 14 for more information.

Figure 13

Figure 14

Assemble support plates for the hip LR motion as well as leg top plate with it’s own support plates. Assemble hip LR gearbox ensuring axial alignment. All above steps can be done before or after torso is assembled. See Figure 15 for more information.

Support Plates

Figure 15

Figure 16

Hip Twist Plates

Center Plate

Figure 17

Bottom Support Plate

Figure 18

Figure 16-18 show the assembly of the torso. Both directly driven setups can be constructed first and assembled to the center plate. The torso box and bottom support plate can then be assembled. Hip Twist plates and supports can then be installed.

Torso Box