WO2018000995A1 - 用于谐波减速器的柔轮及其制造方法 - Google Patents

用于谐波减速器的柔轮及其制造方法 Download PDF

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Publication number
WO2018000995A1
WO2018000995A1 PCT/CN2017/085403 CN2017085403W WO2018000995A1 WO 2018000995 A1 WO2018000995 A1 WO 2018000995A1 CN 2017085403 W CN2017085403 W CN 2017085403W WO 2018000995 A1 WO2018000995 A1 WO 2018000995A1
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Prior art keywords
ring gear
nano
metal ring
harmonic reducer
manufacturing
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PCT/CN2017/085403
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English (en)
French (fr)
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乐桂荣
汤海舰
廖国福
肖光伟
樊秀兰
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比亚迪股份有限公司
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Publication of WO2018000995A1 publication Critical patent/WO2018000995A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H49/00—Other gearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
    • F16H55/02—Toothed members; Worms
    • F16H55/17—Toothed wheels

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  • the invention relates to the technical field of harmonic reducers, in particular to a flexible wheel in a harmonic reducer and a manufacturing process thereof.
  • a harmonic reducer is a kind of transmission device that uses a flexible component to produce controllable elastic deformation and meshes with a rigid component to transmit power and motion.
  • the working process is called "harmonic gear transmission (referred to as harmonic transmission)" .
  • the harmonic reducer mainly consists of three components: a rigid wheel with internal teeth, a flexible wheel with external teeth, and a wave generator.
  • the harmonic reducer has the characteristics of small size, light weight, high transmission efficiency, long service life, stable transmission, no impact, no noise, high motion precision, etc., so it is a widely used reducer.
  • the flexible wheel needs to bear a large alternating load during the reduction transmission process, the flexible wheel is easily damaged, so the anti-fatigue strength, processing and heat treatment technology of the flexible wheel material are required, and the process technology is also complicated.
  • the existing flexible wheel is generally made of alloy steel by machining (specifically, by a combination of turning and hobbing); the processing technology has a long processing time of one piece and low production efficiency. And the accuracy and longevity of the flexible wheel are difficult to guarantee.
  • the technician found that the structure of the flexible wheel for the harmonic reducer can be divided into upper and lower parts, the lower end of which forms a cup-shaped structure, the upper end is an annular ring gear; the lower end is a cup-shaped structure; In the middle, the transmission accuracy of the ring gear is very high (up to 0.005MM or more), but the accuracy of the lower cup-shaped structure can be lower (generally 0.01mm).
  • the technicians found a flexible wheel that can simplify the production process, shorten the single-piece processing time, improve the production efficiency, reduce the production cost, and maximize the benefit, while ensuring the accuracy and service life of the flexible wheel, and the manufacturing method thereof. .
  • the present invention aims to solve at least one of the technical problems in the related art to some extent. To this end, the present invention provides a flex wheel for a harmonic reducer and a method of manufacturing the same.
  • One aspect of the present invention provides a flex wheel for a harmonic reducer, including a metal ring gear and a plastic cup bottom;
  • the metal ring gear is provided with a nano bond portion, and the inner and outer surfaces of the nano bond portion are nano-treated;
  • the plastic cup bottom is injection molded; the nano joint portion of the metal ring gear is embedded on the bottom of the plastic cup.
  • the invention provides a flex wheel for a harmonic reducer, which has a metal ring gear which requires higher dimensional accuracy and a plastic cup bottom which requires relatively low dimensional accuracy.
  • the manufacturing process can be simplified, the processing time of a single piece can be shortened, the production efficiency can be improved, the production cost can be reduced, and the benefit can be maximized.
  • annular groove is formed on the nano joint portion of the metal ring gear; the metal ring gear is embedded in the annular groove.
  • the material of the metal ring gear is a metal alloy.
  • a metal alloy that satisfies the surface hardness, dimensional accuracy, fatigue strength, and yield strength required for the flexible wheel.
  • the metal alloy is one of chromium manganese spring steel, bonded steel or amorphous alloy.
  • the amorphous alloy is a zirconium-based alloy.
  • the material of the plastic cup bottom is one of PEEK, NYLON, PBT, PPA or PPS.
  • a second aspect of the present invention provides a method of manufacturing a flex wheel for a harmonic reducer, comprising the steps of:
  • the nano-treated metal ring gear is placed in a plastic mold and then injection molded, and a plastic cup bottom is formed on the nano joint portion.
  • the method for manufacturing a flexible wheel for a harmonic reducer provided by the invention adopts a metal ring gear with high precision requirement in a stepwise manner, and then adopts nano-processing, and finally adopts in-mold injection molding on the metal ring gear.
  • the plastic cup bottom is injection molded, and finally the flexible wheel is obtained; on the one hand, the precision and the service life of the flexible wheel for the harmonic reducer can be ensured by the manufacturing method.
  • the process is very simple, which can shorten the processing time of a single piece, increase production efficiency, and reduce production costs to maximize benefits.
  • the “obtaining the metal ring gear” specifically includes the following steps: obtaining the metal ring gear by machining, die casting, hot forging or extrusion processing.
  • the metal ring gear is specifically obtained by an extrusion molding process.
  • nano processing specifically includes the following steps:
  • the nano-bonding portion of the metal ring gear is subjected to T treatment to form nanopores on the inner and outer surfaces of the nano-bonding portion.
  • T treatment with T liquid can increase the bonding strength between the plastic cup bottom and the metal ring gear.
  • the T process includes the following steps:
  • the T liquid is a weakly acidic solution.
  • the cleaning comprises the steps of: sequentially washing with water, caustic washing, washing with water, pickling, and washing with water.
  • the nanopores have a pore diameter of 6 to 12 nm.
  • 1a is a schematic cross-sectional view of a metal ring gear provided in an embodiment of the present invention
  • FIG. 1b is a schematic cross-sectional view of a plastic cup bottom provided in an embodiment of the present invention.
  • FIG. 2 is a schematic cross-sectional view of a flex wheel for a harmonic reducer provided in an embodiment of the present invention
  • FIG. 3 is a perspective view of a flex wheel for a harmonic reducer provided in an embodiment of the present invention.
  • FIG. 4 is a front elevational view of a flex wheel for a harmonic reducer provided in an embodiment of the present invention
  • FIG. 5 is a flow chart of a method of manufacturing a flex wheel for a harmonic reducer provided in an embodiment of the present invention.
  • the flexible wheel for the harmonic reducer disclosed in this example comprises a metal ring gear 1 and a plastic cup bottom 2;
  • the metal ring gear 1 is provided with a nano-bonding portion 11 on which the inner and outer surfaces of the nano-bonding portion 11 are nano-treated;
  • the plastic cup bottom 2 is injection molded; the nano joint portion 11 of the metal ring gear 1 is embedded on the plastic cup bottom 2.
  • the above-mentioned nano-processing and injection molding process is a combination of a metal material and a plastic material using nanotechnology, and the nano-bonding portion 11 after nano-treatment can obtain a more stable adhesion force during the injection molding process.
  • the nano-joining portion 11 of the metal ring gear 1 is embedded on the bottom 2 of the plastic cup
  • the metal ring gear 1 is placed in a plastic mold to perform molding. Injecting, the result of injection molding is to embed the metal ring gear 1 on the plastic cup body, and form the metal ring gear 1 and the plastic cup body into one piece.
  • FIG. 1b when the plastic cup bottom 2 is injection molded, the nano joint portion 11 of the metal ring gear 1 is formed thereon. a matching annular groove 21; the metal ring gear 1 is embedded in the annular groove 21.
  • the material of the metal ring gear 1 is a metal alloy.
  • the metal alloy satisfies the requirements of the surface hardness of the flexible wheel (hardness between HRC30 and HRC40), dimensional accuracy ( ⁇ 0.005), fatigue strength, and yield strength.
  • the metal alloy may be a chromium manganese spring steel (such as 50CrMn, which has a fatigue limit of 610 MPa and a yield limit of 1100 MPa), a combined steel (such as 40CrNiMoA, a fatigue limit of 530 MPa, a yield limit of 950 MPa) or an amorphous alloy.
  • the metal alloy is an amorphous alloy (zirconium-based alloy).
  • the zirconium-based alloy provided in this example is Zr 63 AL 3.5 Cu 25 Ni 5.5 , the balance being inevitable impurities, or a zirconium-based alloy of the composition shown in the following table:
  • the material of the plastic cup bottom 2 satisfies the requirements of the flexible wheel on dimensional accuracy, fatigue resistance, and controllable elastic deformation.
  • the material of the plastic cup bottom 2 is PEEK (English name: polyetheretherketone, Chinese name: polyetheretherketone), NYLON (nylon), PBT (English name: polybutylene terephthalate, Chinese name: polybutylene terephthalate) Alcohol ester), PPA (English name: Polyphthalamide, Chinese name: polyphthalamide) or PPS (English name: Polyphenylene sulfide, Chinese name: polyphenylene sulfide).
  • the metal ring gear 1 has an annular structure as a whole, and the outer side wall is provided with outer teeth 12, and the number of teeth of the outer teeth 12 is set as needed.
  • the lower end of the metal ring gear 1 is provided with a certain height of the nano joint portion 11, and the height thereof is not particularly limited, and may be, for example, 3 to 5 mm.
  • the plastic cup bottom 2 also has an annular structure as a whole, and the metal ring gear 1 nanometer joint portion 11 is injection molded on the upper end of the plastic cup body 2.
  • the specific combination of the metal ring gear 1 and the plastic cup bottom 2 can adopt a structure known to those skilled in the art, and specific parameters can also be designed according to requirements, for example, by selecting different plastic materials to calculate and design a suitable one.
  • Side wall thickness can be greater than 0.5mm
  • structural parameters transition fillet and other structural parameters affecting the amount of fatigue
  • the structural parameters of the metal ring gear 1 are calculated and designed by selecting different metal alloys and the like to satisfy the dimensional accuracy and fatigue strength required for the flexible wheel.
  • the thickness of the side wall of the plastic cup is larger than the thickness of the metal ring gear 1 (the radial distance between the inner surface of the metal ring gear 1 and the addendum circle of the outer gear 12).
  • the flexible wheel for the harmonic reducer provided in this example has a metal ring gear 1 which requires higher dimensional accuracy and a plastic cup bottom 2 which requires relatively low dimensional accuracy. In this way, on the one hand, it can guarantee the flexibility for the harmonic reducer. Wheel size accuracy and service life. On the other hand, the production process can be simplified, the processing time of a single piece can be shortened, the production efficiency can be improved, and the production cost can be reduced to maximize the benefit.
  • metal ring gear obtaining step as shown in FIG. 1a, a metal ring gear 1 is obtained; wherein the metal ring gear 1 can be processed by machining, die casting, hot forging or extrusion process to obtain the metal ring gear 1.
  • the metal ring gear 1 is specifically obtained by an extrusion molding process, and the extrusion processing is less difficult and the processing efficiency is high.
  • metal ring gear nano-processing step as shown in FIG. 1a, a nano-bonding portion 11 is disposed on the metal ring gear 1, and nano-processing is performed on the inner and outer surfaces of the nano-bonding portion 11; Nanopores are formed on the outer surface of the nanobonding portion 11 to enhance the bonding force between the metal ring gear 1 and the plastic cup.
  • the nano processing specifically includes the following steps:
  • the nano-bonding portion 11 of the metal ring gear 1 is subjected to T treatment to form nanopores on the inner and outer surfaces of the nano-joining portion 11.
  • the T process includes the following steps:
  • the cleaning includes washing, pickling, and alkali washing, for example, specifically, washing with water, followed by alkali washing (20-100 g/L lye, soaking for about 30-60 seconds), and then washing with water. It is pickled (100-200 g/L acid solution, soaked for 40-90 seconds), washed with water, etc., and impurities such as grease on the surface of the metal ring gear 1 are removed during alkali washing.
  • alkali washing for example, specifically, washing with water, followed by alkali washing (20-100 g/L lye, soaking for about 30-60 seconds), and then washing with water. It is pickled (100-200 g/L acid solution, soaked for 40-90 seconds), washed with water, etc., and impurities such as grease on the surface of the metal ring gear 1 are removed during alkali washing.
  • alkali washing for example, specifically, washing with water, followed by alkali washing (20-100 g/L lye, soaking for about 30-60 seconds),
  • T liquid for several times of T treatment, such as immersing it in 8 T liquid treatment tanks, soaking for about 3 minutes each time; and drying the water to make T liquid stored in the nanopores, can increase the plastic The bonding strength between the cup bottom 2 and the metal ring gear 1.
  • a honeycomb pore layer having nanopores having a diameter of 6 to 12 nm can be formed on the surface of the nanobonding portion 11.
  • the T liquid is a weakly acidic solution, the composition of which is well known to those skilled in the art, and is specifically formulated according to the metal material to be subjected to the T treatment.
  • the nano-treated metal ring gear 1 is placed in a plastic mold and then injection molded, and a plastic cup bottom 2 is formed on the nano-joining portion 11.
  • the injection molding process is known to the public for in-mold molding.
  • the nano-treated metal ring gear 1 is placed in a plastic mold and positioned so that the plastic cup 2 is injection molded only on the nano joint portion 11 during injection molding.
  • the specific in-mold injection molding method is known to the public and will not be described again. Among them, the plastic cup body 2 after injection molding is shown in Fig. 1b, and the whole of the flexible wheel for the harmonic reducer is shown in Fig. 2 to Fig. 4.
  • the manufacturing method of the flexible wheel for the harmonic reducer provided in this example adopts a step by step to produce gold with high precision requirement. Belonging to the ring gear 1, and then through nano-processing, and finally injecting the plastic cup bottom 2 on the metal ring gear 1 by means of in-mold injection, finally obtaining a flexible wheel; using the manufacturing method according to an embodiment of the invention, on the one hand, It guarantees the dimensional accuracy and service life of the flexible wheel for harmonic reducers. On the other hand, the process is very simple, which can shorten the processing time of a single piece, increase production efficiency, and reduce production costs to maximize benefits.

Abstract

一种用于谐波减速器的柔轮及其制造方法，所述用于谐波减速器的柔轮包括金属齿圈（1）和塑胶杯底（2）；所述金属齿圈（1）上设有纳米结合部（11），所述纳米结合部（11）的内、外表面上经纳米处理；所述塑胶杯底（2）经模内注塑成型；所述金属齿圈（1）的纳米结合部（11）嵌在所述塑胶杯底（2）上。所述用于谐波减速器的柔轮，其具有对尺寸精度要求更高的金属齿圈和对尺寸精度要求相对较低的塑胶杯底两部分；如此，一方面可以保证用于谐波减速器的柔轮的尺寸精度和使用寿命，另一方面可简化制作工艺，缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化。

Description

用于谐波减速器的柔轮及其制造方法
相关申请的交叉引用
本申请要求比亚迪股份有限公司于2016年6月30日提交的、发明名称为“一种谐波减速器柔轮及其制造方法”的、中国专利申请号“201610510665.6”的优先权。
技术领域
本发明涉及一种谐波减速器技术领域，尤其涉及谐波减速器中的柔轮及其制造工艺。
背景技术
谐波减速器是一种利用柔性组件产生可控弹性变形，并与刚性组件相啮合来传递动力和运动的一种传动装置，其工作过程称为“谐波齿轮传动(简称谐波传动)”。谐波减速器主要包含有三个组件：一个具有内齿的刚轮、一个具有外齿的柔轮，以及一个波发生器。谐波减速器具有体积小、重量轻、传动效率高、寿命长、传动平稳、无冲击、无噪音、运动精度高等特点，因此是一种应用十分广泛的减速器。
由于柔轮在减速传动过程中需要承受较大的交变负荷，致使柔轮较容易损坏，因而对柔轮材料的抗疲劳强度、加工和热处理技术要求较高，制程技术也较复杂。
然而，现有柔轮一般采用合金钢材通过机加工的方式制作而成(具体指通过车削和滚齿相结合的工艺制作而成)；该种加工工艺存在单件加工时间长，生产效率低，且柔轮精度和寿命均难以保证的问题。
技术人员在研发过程中发现，用于谐波减速器的柔轮的结构可以分为上下两部分，其下端形成杯状结构，上端为环状的齿圈；下端为杯状结构；在装配过程中，对齿圈的传动精度要求很高(需达到0.005MM以上)，然而下端的杯状结构的精度可以要求低些(一般在0.01mm)。基于此思路，技术人员发现了可在保证柔轮精度和使用寿命前提下，简化制作工艺，缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化的柔轮及其制造方法。
发明内容
本发明旨在至少在一定程度上解决相关技术中的技术问题之一。为此，本发明提供了一种用于谐波减速器的柔轮及其制造方法。
本发明一方面提供了一种用于谐波减速器的柔轮，包括金属齿圈和塑胶杯底；
所述金属齿圈上设有纳米结合部，所述纳米结合部的内、外表面上经纳米处理；
所述塑胶杯底经模内注塑成型；所述金属齿圈的纳米结合部嵌在所述塑胶杯底上。
本发明提供的用于谐波减速器的柔轮，其具有对尺寸精度要求更高的金属齿圈和对尺寸精度要求相对较低的塑胶杯底两部分。如此，一方面可以保证柔轮的精度和使用寿命，另一方面可简化制作工艺，缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化。
进一步地，所述塑胶杯底注塑成型时，其上形成与所述金属齿圈的纳米结合部相配合的环形槽；所述金属齿圈嵌在所述环形槽内。
进一步地，所述金属齿圈的材料为金属合金。
进一步地，为满足柔轮需要的表面硬度、尺寸精度、抗疲劳强度及屈服强度的金属合金。
进一步地，所述金属合金为铬锰弹簧钢、合结钢或非晶合金中的一种。
进一步地，所述非晶合金为锆基合金。
进一步地，所述塑胶杯底的材料为PEEK、NYLON、PBT、PPA或PPS中的一种。
本发明第二方面提供了一种用于谐波减速器的柔轮的制造方法，包括如下步骤：
获得金属齿圈；
在所述金属齿圈上设置纳米结合部，所述纳米结合部的内、外表面上进行纳米处理；
将经纳米处理后的金属齿圈置于塑胶模具内后注塑，在所述纳米结合部上成型出塑胶杯底。
本发明提供的用于谐波减速器的柔轮的制作方法，其采用分步骤先制作精度要求高的金属齿圈，然后再通过纳米处理，最后采用模内注塑的方式，在金属齿圈上注塑成型塑胶杯底，最终获得该柔轮；采用该种制造方法，一方面，其可以保证用于谐波减速器的柔轮的精度和使用寿命。另一方面，其工艺非常简单，可缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化。
进一步地，所述“获得所述金属齿圈”具体包括如下步骤：经机加工、压铸、热锻或挤出工艺加工获得所述金属齿圈。
进一步地，所述金属齿圈具体通过挤出成型工艺加工获得。
进一步地，所述纳米处理具体包括如下步骤：
将金属齿圈的纳米结合部进行T处理，在所述纳米结合部的内、外表面上形成纳米微孔。采用T液进行T处理，可增加塑胶杯底与所述金属齿圈的结合强度。
进一步地，所述T处理包括如下步骤：
先进行清洗；然后采用T液浸泡，进行若干次T处理，并经烘干。
进一步地，所述T液为弱酸性溶液。
进一步地，所述清洗包括如下步骤：依次经水洗、碱洗、水洗、酸洗及水洗。
进一步地，所述纳米微孔的孔径为6～12纳米。
附图说明
图1a是本发明具体实施方式中提供的金属齿圈的剖面示意图；
图1b是本发明具体实施方式中提供的塑胶杯底的剖面示意图；
图2是本发明具体实施方式中提供的用于谐波减速器的柔轮剖面示意图；
图3是本发明具体实施方式中提供的用于谐波减速器的柔轮立体示意图；
图4是本发明具体实施方式中提供的用于谐波减速器的柔轮主视示意图；
图5是本发明具体实施方式中提供的用于谐波减速器的柔轮的制造方法的流程图。
其中，1、金属齿圈；2、塑胶杯底；11、纳米结合部；12、外齿轮；21、环形槽。
具体实施方式
为了使本发明所解决的技术问题、技术方案及有益效果更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
实施例1
如图1a-图4所示，本例中公开的用于谐波减速器的柔轮，包括金属齿圈1和塑胶杯底2；
所述金属齿圈1上设有纳米结合部11，所述纳米结合部11的内、外表面上经纳米处理；
所述塑胶杯底2经模内注塑成型；所述金属齿圈1的纳米结合部11嵌在所述塑胶杯底2上。
上述纳米处理及注塑成型的过程，是将金属材料与塑胶材料利用纳米技术相结合的体现，经纳米处理以后的纳米结合部11在进行注塑过程中，可以获得更稳定的接着力。
其中，“金属齿圈1的纳米结合部11嵌在所述塑胶杯底2上”并不是预先通过注塑的方式单独成型塑胶杯体，而是将金属齿圈1置于塑胶模具内，进行模内注塑，注塑的结果是将金属齿圈1嵌在塑胶杯体上，将金属齿圈1和塑胶杯体形成一体件。从结果上看，如图1b所示，所述塑胶杯底2注塑成型时，其上形成与所述金属齿圈1的纳米结合部11相 配合的环形槽21；所述金属齿圈1嵌在所述环形槽21内。
其中，所述金属齿圈1的材料为金属合金。该金属合金满足柔轮对表面硬度(硬度在HRC30～HRC40之间)、尺寸精度(±0.005)、抗疲劳强度、及屈服强度等要求即可。比如，金属合金可以为铬锰弹簧钢(如50CrMn，其疲劳极限610MPa，屈服极限1100MPa)、合结钢(如40CrNiMoA，其疲劳极限530MPa，屈服极限950MPa)或非晶合金等。优选地，所述金属合金为非晶合金(锆基合金)。比如，本例中提供的锆基合金为Zr63AL3.5Cu25Ni5.5，余量为不可避免的杂质，或者如下表所示成分的锆基合金：
Figure PCTCN2017085403-appb-000001
其中，所述塑胶杯底2的材料要满足柔轮对尺寸精度、抗疲劳强度、可实现可控的弹性变形等性能的要求。比如，所述塑胶杯底2的材料为PEEK(英文名称：polyetheretherketone，中文名称：聚醚醚酮)、NYLON(尼龙)、PBT(英文名称：polybutylene terephthalate，中文名称：聚对苯二甲酸丁二醇酯)、PPA(英文名称：Polyphthalamide，中文名称：聚邻苯二甲酰胺)或PPS(英文名称：Polyphenylene sulfide，中文名称：聚苯硫醚)中的一种。
其中，如图3所示，金属齿圈1整体呈环状结构，其外侧壁上设有外轮齿12，外轮齿12的齿数等根据需要设定。该金属齿圈1的下端设置一定高度的纳米结合部11，其高度并不特别限定，比如可以为3～5mm。塑胶杯底2整体也呈环状结构，金属齿圈1纳米结合部11被注塑在塑胶杯体2内的上端。
其中，上述金属齿圈1和塑胶杯底2的具体结合可以采用本领域技术人员所公知的结构，其具体参数也可根据需要设计，比如，通过选用不同的塑胶材质来计算并设计出适合的侧壁厚度(可以大于0.5mm)和结构参数(过渡圆角等影响疲劳数量的结构参数)，以使其满足柔轮所需的尺寸精度和抗疲劳强度。同样的，通过选用不同的金属合金等来计算并设计出金属齿圈1的结构参数，以使其满足柔轮所需的尺寸精度和抗疲劳强度。显然，塑胶杯体的侧壁厚度大于金属齿圈1的厚度(金属齿圈1内表面到外轮齿12的齿顶圆之间的径向距离)。
本例提供的用于谐波减速器的柔轮，其具有对尺寸精度要求更高的金属齿圈1和对尺寸精度要求相对较低的塑胶杯底2两部分。如此，其一方面可以保证用于谐波减速器的柔 轮的尺寸精度和使用寿命。另一方面可简化制作工艺，缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化。
实施例2
本例将对上述实施例1中提供的用于谐波减速器的柔轮的制造方法进行具体解释说明，如图5所示，包括如下步骤：
S1，金属齿圈获得步骤：如图1a所示，获得金属齿圈1；其中，该金属齿圈1可以通过机加工、压铸、热锻或挤出工艺加工获得所述金属齿圈1。其中，作为优选的方式，本例中，所述金属齿圈1具体通过挤出成型工艺加工获得，挤出加工难度较低，加工效率高。
S2、金属齿圈纳米处理步骤：如图1a所示，在所述金属齿圈1上设置纳米结合部11，所述纳米结合部11的内、外表面上进行纳米处理；纳米处理的目的是在纳米结合部11外表面上形成纳米微孔，以增强金属齿圈1和塑胶杯体之间的结合力。
具体的，所述纳米处理具体包括如下步骤：
将金属齿圈1的纳米结合部11进行T处理，在所述纳米结合部11的内、外表面上形成纳米微孔。
具体的，所述T处理包括如下步骤：
先进行清洗，其清洗包括水洗、酸洗和碱洗等过程，比如，具体的，先经水洗、再进行碱洗(20-100g/L碱液、浸泡约30-60秒)、然后进行水洗、酸洗(100-200g/L酸液、浸泡40-90秒中和)、水洗等，碱洗时去除金属齿圈1表面的油脂等杂质。酸洗时，会预先形成大尺寸的纳米孔洞；
然后采用T液进行若干次T处理，比如将其浸于8个T液处理槽中，每次浸泡约3分钟；并经烘干水分，使T液存储在纳米微孔之中，可增加塑胶杯底2与所述金属齿圈1的结合强度。T处理结束后，可以在纳米结合部11表面形成具有直径为6～12nm的纳米微孔的蜂窝状孔层。
其中，所述T液为弱酸性溶液，其成分为本领域技术人员所公知，其根据要进行T处理的金属材料进行具体调配。
S3、模内注塑步骤：将经纳米处理后的金属齿圈1置于塑胶模具内后注塑，在所述纳米结合部11上成型出塑胶杯底2。该注塑过程即为公众所熟知的模内注塑。即将经纳米处理后的金属齿圈1置于塑胶模具内，并定位，使其在注塑时，仅在纳米结合部11上注塑成型出塑胶杯体2。具体的模内注塑方法为公众所知，不再赘述。其中，注塑后的塑胶杯体2如图1b所示，其用于谐波减速器的柔轮整体如图2-图4所示。
本例提供的用于谐波减速器的柔轮的制作方法，其采用分步骤先制作精度要求高的金 属齿圈1，然后再通过纳米处理，最后采用模内注塑的方式，在金属齿圈1上注塑成型塑胶杯底2，最终获得柔轮；采用根据本发明实施例的制造方法，一方面，其可以保证用于谐波减速器的柔轮的尺寸精度和使用寿命。另一方面，其工艺非常简单，可缩短单件加工时间，提高生产效率，降低生产成本，以实现效益最大化。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (14)

  1. 一种用于谐波减速器的柔轮，其特征在于，包括：
    金属齿圈，所述金属齿圈上设有纳米结合部，所述纳米结合部的内、外表面上经纳米处理；和
    塑胶杯底，所述塑胶杯底经模内注塑成型；
    所述金属齿圈的纳米结合部嵌在所述塑胶杯底上。
  2. 根据权利要求1所述的用于谐波减速器的柔轮，其特征在于，所述塑胶杯底注塑成型时，其上形成与所述金属齿圈的纳米结合部相配合的环形槽，所述金属齿圈嵌在所述环形槽内。
  3. 根据权利要求1所述的用于谐波减速器的柔轮，其特征在于，所述金属齿圈的材料为满足柔轮对表面硬度、尺寸精度、抗疲劳强度及屈服强度等要求的金属合金。
  4. 根据权利要求3所述的用于谐波减速器的柔轮，其特征在于，所述金属合金为铬锰弹簧钢、合结钢或非晶合金中的一种。
  5. 根据权利要求4所述的用于谐波减速器的柔轮，其特征在于，所述非晶合金为锆基合金。
  6. 根据权利要求1所述的用于谐波减速器的柔轮，其特征在于，所述塑胶杯底的材料为PEEK、NYLON、PBT、PPS或PPA中的一种。
  7. 一种用于谐波减速器的柔轮的制造方法，其特征在于，包括如下步骤：
    获得金属齿圈；
    在所述金属齿圈上设置纳米结合部，所述纳米结合部的内、外表面上经纳米处理；
    将经纳米处理后的金属齿圈置于塑胶模具内注塑，在所述纳米结合部上成型出塑胶杯底。
  8. 根据权利要求7所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述获得所述金属齿圈具体包括如下步骤：
    经机加工、压铸、热锻或挤出工艺加工获得所述金属齿圈。
  9. 根据权利要求8所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述金属齿圈具体通过挤出成型工艺加工获得。
  10. 根据权利要求7所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述纳米处理具体包括如下步骤：
    将金属齿圈的纳米结合部进行T处理，在所述纳米结合部的内、外表面上形成纳米微孔。
  11. 根据权利要求10所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述T处理包括如下步骤：
    先进行清洗；然后采用T液浸泡，进行若干次T处理，并经烘干。
  12. 根据权利要求11所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述T液为弱酸性溶液。
  13. 根据权利要求11所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述清洗包括如下步骤：依次经水洗、碱洗、水洗、酸洗及水洗。
  14. 根据权利要求10所述的用于谐波减速器的柔轮的制造方法，其特征在于，所述纳米微孔的孔径为6～12纳米。
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