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<p>The performance of rehabilitation robotic joints, particularly their motion smoothness and control precision, is critically dependent on the instantaneous efficiency of their reducers. Conventional analyses, often relying on time-averaged efficiency and constant friction models, fail to capture the dynamic fluctuations that induce output torque ripple. This paper presents a comprehensive framework for the high-fidelity prediction of the instantaneous efficiency of a 2&#xa0;K-H planetary reducer. The primary contributions of this work are threefold: First, a time-varying friction model based on the Schlenk equation is developed at the component level, accounting for real-time variations in load, speed, and contact geometry. Second, a hierarchical “component-system-machine” methodology is established, systematically integrating the dual-stage gear meshing losses with the often-neglected frictional loss from the eccentric carrier bearing. Third, a thorough parametric analysis is conducted to identify critical design parameters. Numerical simulations demonstrate that the carrier bearing loss can reduce the overall efficiency by 2–3% points, a factor critical for accurate performance evaluation. The analysis further reveals that gear surface roughness is the most influential parameter, followed by operating speed and input torque. The established framework provides a robust and accurate tool for the design and optimization of high-performance, low-fluctuation reducers for next-generation rehabilitation robotics.</p>

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Instantaneous efficiency modeling and analysis of 2 K-H reducers for rehabilitation robots

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Shuaidong Zou,
  • Wenjie Yan,
  • Huachao Xu,
  • Xiaohui He,
  • Yun Zhao

摘要

The performance of rehabilitation robotic joints, particularly their motion smoothness and control precision, is critically dependent on the instantaneous efficiency of their reducers. Conventional analyses, often relying on time-averaged efficiency and constant friction models, fail to capture the dynamic fluctuations that induce output torque ripple. This paper presents a comprehensive framework for the high-fidelity prediction of the instantaneous efficiency of a 2 K-H planetary reducer. The primary contributions of this work are threefold: First, a time-varying friction model based on the Schlenk equation is developed at the component level, accounting for real-time variations in load, speed, and contact geometry. Second, a hierarchical “component-system-machine” methodology is established, systematically integrating the dual-stage gear meshing losses with the often-neglected frictional loss from the eccentric carrier bearing. Third, a thorough parametric analysis is conducted to identify critical design parameters. Numerical simulations demonstrate that the carrier bearing loss can reduce the overall efficiency by 2–3% points, a factor critical for accurate performance evaluation. The analysis further reveals that gear surface roughness is the most influential parameter, followed by operating speed and input torque. The established framework provides a robust and accurate tool for the design and optimization of high-performance, low-fluctuation reducers for next-generation rehabilitation robotics.