Harmonic Drive CSD-2A Component Sets Dimension Guide

11019659 11/2014
QUICKLINK
www.harmonicdrive.de/3060
Engineering Data
CSD-2A Component Sets

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Contents
1. General ....................................................................................................................................................03
1.1 Description of Safety Alert Symbols ......................................................................................................................................04
1.2 Disclaimer and Copyright ........................................................................................................................................................04
2. Safety and Installation Instructions......................................................................................................05
2.1 Hazards ....................................................................................................................................................................................05
2.2 Intended Purpose ....................................................................................................................................................................06
2.3 Non Intended Purpose.............................................................................................................................................................06
2.4 Declaration of Conformity....................................................................................................................................................... 07
3. Technical Description..............................................................................................................................08
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........................................................................................................................................14
3.3.4 Accuracy.........................................................................................................................................................................14
3.3.5 Torsional Stiness ........................................................................................................................................................14
4. Actuator Selection Procedure.................................................................................................................15
4.1 Selecting Harmonic Drive® Gears............................................................................................................................................. 17
4.1.1 Torque Based Dimensioning.........................................................................................................................................18
4.1.2 Life of the Wave Generator Bearing............................................................................................................................ 20
4.1.3 Stiness Based Dimensioning.....................................................................................................................................21
4.2 Calculation of the Torsion Angle............................................................................................................................................. 23
4.3 Eciency Versus Load ............................................................................................................................................................ 24
4.3.1 Eciency Calculations................................................................................................................................................. 24
4.3.2 Eciency Tables........................................................................................................................................................... 25
4.4 Free Load Torques ................................................................................................................................................................... 26
4.4.1 No Load Running Torque ............................................................................................................................................. 26
4.4.2 No Load Starting Torque...............................................................................................................................................27
4.4.3 No Load Back Driving Torque........................................................................................................................................27
4.5 Lubrication ............................................................................................................................................................................... 28
4.5.1 Grease Lubrication ....................................................................................................................................................... 28
4.5.2 Oil Lubrication ..............................................................................................................................................................30
4.6 Axial Forces at the Wave Generator........................................................................................................................................ 31
5. Installation and Operation..................................................................................................................... 32
5.1 Transportation and Storage .................................................................................................................................................... 32
5.2 Gear Conditions at Delivery..................................................................................................................................................... 32
5.3 Assembly Instructions............................................................................................................................................................. 33
5.4 Recommended Tolerances for Assembly ................................................................................................................................37
5.5 Lubrication ............................................................................................................................................................................... 38
5.5.1 Grease Lubrication .......................................................................................................................................................38
5.5.2 Grease Reservoir ..........................................................................................................................................................40
5.5.3 Grease Change..............................................................................................................................................................40
5.5.4 Oil Lubrication ...............................................................................................................................................................41
5.6 Preparation .............................................................................................................................................................................. 42
5.7 Assembly.................................................................................................................................................................................. 43
5.7.1 Assembly of the Circular Spline (CS)........................................................................................................................... 43
5.7.2 Assembly of the Flexspline (FS)..................................................................................................................................44
5.7.3 Assembly of the Wave Generator (WG) to the Input Shaft ...................................................................................... 45
5.7.4 Check before Assembly of the Wave Generator......................................................................................................... 45
5.7.5 Assembly of the Wave Generator (WG) into the Flexspline (FS) .............................................................................. 45
5.7.6 Assembly Control......................................................................................................................................................... 45

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1. General
About this documentation
This document contains safety instructions, technical data and operation rules for servo actuators and servo motors 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 servo actuators and servo motors 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: [e-mail]
6. Glossary...................................................................................................................................................46
6.1 Technical Data..........................................................................................................................................................................46
6.2 Labelling, Guidelines and Regulations ................................................................................................................................... 52

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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
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.
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 protected by copyright. In addition to the copyright, logos,
fonts, company and product names can also be protected 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 mis-
takes 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.
DANGER
WARNING
ATTENTION
INFORMATION
ADVICE

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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
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.
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.
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.
The successful and safe operation of gears, products requires proper transport, storage and assembly as well as correct
operation and maintenance.
The surface temperature of gears, motors and actuators can exceed 55 degrees Celsius. The hot surfaces should not be touched.
DANGER
DANGER
DANGER
ATTENTION
WARNING

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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.
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
Movement and lifting of products with a mass > 20 Kg should only be carried out with suitable lifting gear.
Cables must not come into direct contact with hot surfaces.
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.
ADVICE
ADVICE
ADVICE
INFORMATION

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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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CSD-2A Series Component Sets are available in seven sizes with gear ratios of 50, 100 and 160:1 oering repeatable peak
torques from 12 to 823 Nm and a power density of up to 512 Nm/kg.
If required, the Component Sets are available as specific configurations tailoredto your application. Consisting of just three
individual components, they are very lightweight and the series with the shortest axial length. The 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.
3. Technical Description
3.1 Product Description
The short series

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3.2 Ordering Code
Explanation of the technical data can be found in the Glossary.
Table 9.1
Table 9.2 Table 9.3
Series Size Ratio 1) Version Flexsplinetype Special design
CSD
14 50 100
2A-R
According to
customer requirements
17 50 100
20 50 100 160
2A-GR
-
BB
25 50 100 160
32 50 100 160
40 50 100 160
50 50 100 160
Ordering code
CSD 25 100 2A-GR BB SP
- --- -
Flexsplinetype
Ordering code Description
- Standard
BB Flexspline with enlarged bore
Version
Ordering code Description
2A-R Component Set
2A-GR
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 the chapter 4 “Ratio”.

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3.3 Technical Data
3.3.1 General Technical Data
Table 10.1
Unit CSD-14-2A CSD-17-2A
Ratio i [ ] 50 100 50 100
Repeatable peak torque TR[Nm] 12 19 23 37
Average torque TA [Nm] 4.8 7.7 18 27
Rated torque TN[Nm] 3.7 5.4 11 16
Momentary peak torque TM[Nm] 24 31 48 55
Maximum input speed (oil lubrication) nin (max) [rpm] 14000 10000
Maximum input speed (grease lubrication) nin (max) [rpm] 8500 7300
Average input speed (oil lubrication) nav (max) [rpm] 6500 6500
Average input speed (grease lubrication) nav (max) [rpm] 3500 3500
Moment of inertia Jin [x10-4 kgm²] 0.021 0.054
Weight m [kg] 0.06 0.1
Table 10.2
Unit CSD-20-2A CSD-25-2A
Ratio i [ ] 50 100 160 50 100 160
Repeatable peak torque TR[Nm] 39 57 64 69 110 123
Average torque TA [Nm] 24 34 34 38 75 75
Rated torque TN[Nm] 17 28 28 27 47 47
Momentary peak torque standard TM[Nm] 69 76 76 127 152 152
Momentary peak torque with enlarged Flexspline bore (BB) TM[Nm] 64 64 64 127 135 135
Maximum input speed (oil lubrication) nin (max) [rpm] 10000 7500
Maximum input speed (grease lubrication) nin (max) [rpm] 6500 5600
Average input speed (oil lubrication) nav (max) [rpm] 6500 5600
Average input speed (grease lubrication) nav (max) [rpm] 3500 3500
Moment of inertia Jin [x10-4 kgm²] 0.090 0.282
Weight m [kg] 0.13 0.24

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3.3.2 Dimensions
Illustration 11.1 Illustration 11.2[mm] [mm]
CSD-14-2A CSD-17-2A
Illustration 11.3 Illustration 11.4 [mm] [mm]
CSD-20-2A CSD-25-2A
QUICKLINK
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Table 12.1
Unit CSD-32-2A CSD-40-2A
Ratio i [ ] 50 100 160 50 100 160
Repeatable peak torque TR[Nm] 151 233 261 281 398 453
Average torque TA [Nm] 75 151 151 137 260 316
Rated torque TN[Nm] 53 96 96 96 185 206
Momentary peak torque standard TM[Nm] 268 359 359 480 696 696
Momentary peak torque with enlarged Flexspline bore (BB) TM[Nm] 268 331 331 480 578 578
Maximum input speed (oil lubrication) nin (max) [rpm] 7000 5600
Maximum input speed (grease lubrication) nin (max) [rpm] 4800 4000
Average input speed (oil lubrication) nav (max) [rpm] 4600 3600
Average input speed (grease lubrication) nav (max) [rpm] 3500 3000
Moment of inertia Jin [x10-4 kgm²] 1.09 2.85
Weight m [kg] 0.51 0.92
Table 12.2
Unit CSD-50-2A
Ratio i [ ] 50 100 160
Repeatable peak torque TR[Nm] 500 868 823
Average torque TA[Nm] 247 466 590
Rated torque TN[Nm] 172 329 370
Momentary peak torque standard TM[Nm] 1000 1440 1560
Momentary peak torque with enlarged Flexspline bore (BB) TM[Nm] 1000 1320 1320
Maximum input speed (oil lubrication) nin (max) [rpm] 4500
Maximum input speed (grease lubrication) nin (max) [rpm] 3500
Average input speed (oil lubrication) nav (max) [rpm] 3000
Average input speed (grease lubrication) nav (max) [rpm] 2500
Moment of inertia Jin [x10-4 kgm²] 8.61
Weight m [kg] 1.9

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Illustration 13.3 [mm]
CSD-50-2A
Illustration 13.1 Illustration 13.2[mm] [mm]
CSD-32-2A CSD-40-2A
QUICKLINK
www.harmonicdrive.de/CAD3060

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3.3.3 Minimum Housing Clearance
3.3.5 Torsional Stiness
3.3.4 Accuracy
Table 14.3
Table 14.1
Size 14. 17 ≥ 20
Transmission accuracy < 1.5 < 1
Hysteresis loss < 2 < 2
Lost Motion < 1
Repeatability < ±0.1
Table 14.4
Size 14 17 20 25 32 40 50
x 12 13.5 15.5 18.5 24 29.5 36.5
y 0000000
Øz 38 45 53 66 86 106 133
[mm]
Illustration 14.2
Size 14 17 20 25 32 40 50
T1[Nm] 2.0 3.9 7.0 14 29 54 108
T2[Nm] 6.9 12 25 48 108 196 196
i = 50
K3[x103Nm/rad] 5.7 13 23 44 98 180 540
K2[x103Nm/rad] 4.7 11 18 34 78 140 440
K1[x103Nm/rad] 3.4 8.1 13 25 54 100 310
i > 50
K3[x103Nm/rad] 7.1 16 29 57 12 230 710
K2[x103Nm/rad] 6.1 14 25 50 11 200 610
K1[x103Nm/rad] 4.7 10 16 31 67 130 400

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4. Actuator Selection Procedure
A variety of dierent driving arrangements is possible with Harmonic Drive® gears.
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 15.2.
Ratio i = Input speed
Output speed
Equation 15.1
Illustration 15.2
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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FS WG
CS
Ratio = -
Reduction gearing
CS Fixed
WG Input
FS Output
Reduction gearing
FS Fixed
WG Input
CS Output
Reduction gearing
WG Fixed
FS Input
CS Output
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.
Input and output rotate in opposite directions. Input and output rotate in same direction. Input and output rotate in same direction.
Equation 16.1
Equation 16.4
1) 2) 3)
Equation 16.2
Equation 16.5
Equation 16.3
Equation 16.6
Speed increaser gearing
WG Fixed
CS Input
FS Output
Speed increaser gearing
CS Fixed
FS Input
WG Output
Speed increaser gearing
FS Fixed
CS Input
WG Output
Input and output rotate in same direction. Input and output rotate in opposite directions. Input and output rotate in same direction.
4) 5) 6)
7)
Ratio
i
1Ratio = i+1
1Ratio= i +1
1
Ratio = i
i+1 Ratio = -1
i Ratio = 1
i+1

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4.1 Selecting Harmonic Drive® Gears
When choosing a gear, you should take into account both torque as well as stiness requirements. In robot applications, for
example, the necessary torque is the more crucial factor for the gear size, while the process related torsional stiness is often
decisive in machine tool manufacture. We therefore recommend that you always take both criteria into account according to the
following procedures.
Gear preselection
Application
Gear size sucient?
Gear size
sucient?
Selection of
a bigger size
Yes
Yes
No
No
Selection of
a bigger size
End of gear selection
Torque based dimensioning
according to selection procedure
on page 18
Stiness based dimensioning
according to selection procedure
on page
21

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4.1.1 Torque Based Dimensioning
Output Data
Time
n1
n2
t2
T2
t3
np
tpt1
T1
n1
n3
t1
T1
Torque Speed
T3
Time
Torques T1...Tn[Nm]
during the load phases t1...tn[s]
during the pause time tp[s]
and output speeds n1...nn[rpm]
Emergency stop/
momentary peak torque Tk[Nm]
at output speed nk[rpm]
and duration tk[s]
Equation 18.2
Illustration 18.1
Permissible maximum input speed
nin max = nout max · i ≤Maximum input speed (see Technical Data)
Load limit 2, TR
Tmax ≤ TR
Operating life
L50 = Ln*· Rated input speed ·(Rated torque TN)3
nin av Tav
nout av =
|n1|· t1+ |n2|· t2+ ... + |nn|· tn
t1+ t2+ ... + tn+ tp
Equation 18.4
Equation 18.6
Equation 18.8
Equation 18.11
Equation 18.9 Equation 18.10
Equation 18.5
Equation 18.7
Selection of a bigger size
No
Equation 18.3
Load limit 3, TM
Tk≤ TM
Allowable number of momentary peak torques
Nk max = 104
2· nk ·i·tk
60
Permissible average input speed
nin av ≤ Limit for average input speed
(see Technical Data)
Values for TA see Technical Data
Tav ≤ TA
Calculation of the average output speed
Load limit 1,
Calculation of the Average Output Torque Tav
3 |n1· T13| · t1+|n2· T23| · t2+ ... + |nn· Tn3 |· tn
|n1| · t1+|n2|·t2+ ... + |nn|· tn
Tav =
Average input speed
nin av = i · nout av
< 104
Values for Lnsee table 20.1

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Output Data
T1= 400 Nm t1= 0.3 s n1= 7 rpm
T2= 320 Nm t2= 3.0 s n2= 14 rpm
T3= 200 Nm t3= 0.4 s n3= 7 rpm
Tk=500 Nm tk= 0.15 s nk=14 rpm
tp= 0.2 s np=0 rpm
Ratio i = 120
Operating life L50 = 30000 h (required)
Load limit 1,
calculation of the average output torque Tav
Tav = 319 Nm ≤TA= 451 Nm Selected size
HFUC-40-120-2A-GR
Calculation of the average output speed
Average input speed
nin av = 120 · 12.0 rpm = 1440 rpm
nout av =7rpm · 0.3 s + 14 rpm · 3 s + 7 rpm · 0.4 s =12.0 rpm
0.3 s + 3 s + 0.4 s + 0.2 s
Permissible maximum input speed
nin max = 14 rpm · 120 = 1680 rpm ≤4000 rpm
Permissible average input speed
nin av = 1440 rpm ≤3000 rpm
Load limit 2, TRLoad limit 3, TM
Allowable number of
momentary peak torques
Tmax = 400 Nm ≤TR= 617 Nm Tk= 500 Nm ≤TM= 1180 Nm
104
14 · 120
2 · 60 · 0.15
Operating life
HFUC-40-120-2A-GR: L50 = 35000 h · 2000 rpm ·(294 Nm )3
1440 rpm 319 Nm L50 = 38054 h > 30000 h
3 7 rpm · (400 Nm)3 · 0.3 s + 14 rpm · (320 Nm)3 ·3 s + 7 rpm · (200 Nm)3 · 0.4 s
7 rpm · 0.3 s + 14 rpm · 3 s + 7 rpm · 0.4 s
Tav =
Nk max = = 1190 < 104

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Harmonic Drive® series Ln
CobaltLine, CSG, SHG 50000
HFUC, HFUS, CSD, CPU, CSF, SHD 35000
PMG gearbox 15000
[h]
L50 = Ln
nN
nin av
TN
Tav
( )3
L10 ≈1 –
5•L50
nN= Rated input speed [rpm]
nin av = Average input speed [rpm] (Equation 18.5)
TN= Rated output torque at rated speed [Nm]
Tav = Average output torque [Nm] (Equation 18.2)
Ln= See table 20.1
4.1.2 Life of the Wave Generator Bearing
Given that the Harmonic Drive® Gear is rated to provide infinite fatigue life for the Flexspline, the life expectancy is based on
the average life of the Wave Generator bearing. The rated torque at the rated speed given in the rating table is based on the
mean L50 bearing life.
The life expectancy of a component set or an unit operating at an input speed n (rpm) and output torque T (Nm) may be
estimated from equation 20.2.
Table 20.1
Equation 20.2
Equation 20.3