空间润滑谐波减速器失效机理及其加速寿命试验方法研究
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摘要
课题来源于民用航天预研项目及国家自然科学基金重点项目“新型高性能传动件及系统的可靠性设计理论与方法”。随着航天技术的发展，空间驱动机构正向长寿命、高精度、高可靠、高功率密度及高稳定度技术方向发展。但空间驱动机构的可靠性和工作寿命直接受相关基础理论研究的影响，尤其在复杂空间环境综合应力作用下的动态服役行为和失效机理还没得到深入分析和研究，也没有建立一套科学合理的寿命试验方法和规范以经济有效地验证研制产品的在轨寿命，这些问题已经成为空间驱动机构长寿命技术发展中的薄弱环节，也是造成近年来空间驱动机构在轨故障频发的主要深层次原因，极大地制约着后续航天器长寿命技术的发展。
针对上述问题，本课题以空间驱动机构中最典型的关键部件谐波减速器为研究对象，采用混合润滑相关理论对其失效机理进行深入研究，并建立失效模型，在此基础上提出了加速寿命试验方法，最后搭建空间润滑谐波减速器综合性能测试系统并进行了相关的试验验证。主要研究内容包括：
（1）制备了空间润滑谐波减速器，刚轮与柔轮齿面采用类金刚石碳膜（WC-DLC:H）与PFPE基润滑脂（Braycote601）复合润滑，柔性轴承采用MoS2-Ti复合固体润滑薄膜与聚四氟乙烯保持器进行润滑，柔轮与波发生器间的接触面单独采用Braycote601进行润滑。并对各润滑材料进行了力学与摩擦学性能试验。
（2）为建立混合润滑模型以研究油脂润滑部位的失效机理，首先推导了等温条件下的Reynolds方程，在此基础上建立了考虑表面粗糙度的线接触统一膜厚方程，同时考虑了润滑剂的黏—压、黏—温、密—压及非牛顿流体特性。分析柔轮内壁—柔性轴承外圈，柔轮—刚轮齿面两对接触副的相对运动及载荷分布情况，并建立了等效润滑模型。在此基础上以膜厚比（λ）、微凸体接触承担的载荷比例（Wc）以及所占接触面积比例（Ac）作为混合润滑状态表征量，对其进行混合润滑仿真分析。
（3）基于混合润滑仿真分析结果，探讨了油脂润滑接触区域的失效机理，转速、载荷、温度对其润滑状态的影响规律及作用机制。发现转速对润滑状态的影响效果最为明显，载荷与温度影响相对较小。且低速运转时温度与载荷对微凸体接触程度的影响效果较为明显，随着转速的增大温度与载荷对其影响逐渐减小，该理论分析结果为加速寿命试验的加速应力与加速因子选择提供了理论依据。
（4）分析了谐波减速器回差、扭转刚度与传动精度的影响因素及其作用规律，建立了减速器内部各摩擦副之间磨损产生的间隙与其回差、扭转刚度及传动精度的计算公式。
（5）通过磨损试验拟合了MoS2-Ti复合薄膜与聚四氟乙烯两种材料的磨损模型，基于磨损模型判断了两种固体润滑材料的可加速性。分析了混合润滑状态下，微凸体接触程度对摩擦系数的影响规律，并基于Johnson—Williamson的混合润滑模型与Archard的黏着磨损模型提出了以摩擦系数为主要表征量的混合润滑状态下的黏着磨损模型。基于该磨损模型与线接触弹流润滑的膜厚方程，分别提出了全膜润滑与混合润滑两种状态下摩擦副的加速寿命试验准则。进一步提出了空间润滑谐波减速器的加速寿命试验方法，包括加速应力与加速因子的选择以及加速寿命与正常寿命间的外推关系建立。
（6）研究了谐波减速器传动精度、传动效率、回差与扭转刚度的精密测试方法，搭建了热真空环境下谐波减速器各传动性能指标在线、原位测试的实验系统。对空间润滑谐波减速器进行5000小时的热真空寿命试验，相关试验结果验证了理论分析的正确性。
Present work is based on the Civil Aerospace Advance Research Program and theproject “The theory and method of reliability design of a new model drive componentsand the systematic” which had been supported by National Natural Science Foundationof China. Due to the development of aerospace technology, long-life, high-precision,high-reliability, high-power density and high-stability become fundamentalperformances for modern space driving mechanisms. However, the reliability andservice life of space drive mechanism is directly influenced by fundamental theoreticalresearch, especially for the dynamic service behavior and failure mechanism of themechanism under complex space environment, there still lack of complete theoreticalframework and experimental study for them. All these issues have become the weakpoints during the development process of long-life space drive mechanism, andconstituted the major causes of frequent on-orbit malfunctions of space drivemechanism, furthermore, become the stumbling block for the development of modernspacecraft.
Therefore, this paper takes lubricated harmonic drive, the most typical componentsin space drive mechanism, as the research object, applying mixed lubrication theory,conducts simulation analysis on the failure mechanism of the harmonic drive,establishes the failure model and based on above, proposes the optimal acceleratedlife testing method. At last, the comprehensive performance testing system of spacelubricated harmonic drive is set up and the relevant tests are carried on to verify theeffectiveness of the proposed method. The main research content is composed of thefollowing six parts:
(1) Lubricated harmonic drives for space application are prepared for testing, thetooth surfaces of circular spline and flexspline are lubricated by mixed diamond-likecarbon films (WC-DLC:H) and PFPE-based grease (Braycote601). The wave generatorbearing is lubricated by MoS2-Ti composite films and polytetrafluoroethylene retainer,the contact surface between flexspline and wave generator is lubricated only byBraycote601. Meanwhile, the mechanical and tribological properties of the lubricatingmaterial are tested.
(2) In order to obtain proper mixed lubrication model to study the failuremechanism of the lubricated parts, Reynolds equation is first deduced under isothermal condition. Then, film thickness equation of line contact taking surface roughness intoconsideration is established and in which the relationships of viscosity–pressure,viscosity–temperature, density–pressure and no Newtonian fluid property for thelubricant are considered. The relative motions and load distributions of contact surfacesbetween the inner flexspline and wave generator bearing, circular spline and flexsplinetooth surface are analyzed, and the equivalent lubrication model is established. Basedon above, the mixed lubrication simulation is conducted with the film thickness ratio (λ),load distributed generated by asperity contact (Wc) and relative contact area (Ac) as therepresentative variables.
(3) After obtain the mixed lubrication simulation results, the failure mechanism ofthe grease lubricated contact parts and the effects of rotation speed, load, temperature ontheir lubrication status is discussed. The results release that the rotation speed has themost significant effect comparing to load and temperature. Moreover, the effects of thetemperature and load on asperity contact are more serious at a lower speed while theeffects decrease with increase in the rotation speed. The analysis results become thetheoretical basis for the determination of accelerated stress and accelerated factor duringaccelerated life test.
(4) The factors effect backlash, torsional stiffness and transmission accuracy of theharmonic drive and how they generate those effects are analyzed. The computationalformulas for calculating backlash, torsional stiffness, transmission accuracy and wearclearances between friction pairs in the harmonic drive are presented.
(5) The wear model of MoS2-Ti composite film and polytetrafluoroethylene werefitted through the data obtained from wear tests, and the possibility for conductingaccelerated test for the two lubricating materials are analyzed based on the wear model.The effect of asperity distribution on friction coefficient during contact in mixedlubrication is investigated. And then the adhesive wear model characterized by frictioncoefficient in mixed lubrication is proposed based on Johnson-Williamson mixedlubrication model and Archard adhesive wear model. Furthermore, based on the wearmodel and film thickness equation of line contact elastohydrodynamic lubrication, theaccelerated life test schemes for full film lubrication and mixed lubrication are proposed,respectively. Finally, accelerated life test scheme for the harmonic drive is obtained,including the choice of accelerated stress and accelerated factor and establishment of theextrapolation relationship between accelerated life and regular life.
(6) A precisely testing method for transmission accuracy, transmission efficiency, backlash and torsional stiffness of the harmonic drive is studied and correspondingexperimental system for in-circuit and in-situ test of harmonic drive under thermalvacuum environment is set up. A serial of5000-hours thermal vacuum life tests arecarried out, and the test results verifies the validity of the proposed theory.
针对上述问题，本课题以空间驱动机构中最典型的关键部件谐波减速器为研究对象，采用混合润滑相关理论对其失效机理进行深入研究，并建立失效模型，在此基础上提出了加速寿命试验方法，最后搭建空间润滑谐波减速器综合性能测试系统并进行了相关的试验验证。主要研究内容包括：
（1）制备了空间润滑谐波减速器，刚轮与柔轮齿面采用类金刚石碳膜（WC-DLC:H）与PFPE基润滑脂（Braycote601）复合润滑，柔性轴承采用MoS2-Ti复合固体润滑薄膜与聚四氟乙烯保持器进行润滑，柔轮与波发生器间的接触面单独采用Braycote601进行润滑。并对各润滑材料进行了力学与摩擦学性能试验。
（2）为建立混合润滑模型以研究油脂润滑部位的失效机理，首先推导了等温条件下的Reynolds方程，在此基础上建立了考虑表面粗糙度的线接触统一膜厚方程，同时考虑了润滑剂的黏—压、黏—温、密—压及非牛顿流体特性。分析柔轮内壁—柔性轴承外圈，柔轮—刚轮齿面两对接触副的相对运动及载荷分布情况，并建立了等效润滑模型。在此基础上以膜厚比（λ）、微凸体接触承担的载荷比例（Wc）以及所占接触面积比例（Ac）作为混合润滑状态表征量，对其进行混合润滑仿真分析。
（3）基于混合润滑仿真分析结果，探讨了油脂润滑接触区域的失效机理，转速、载荷、温度对其润滑状态的影响规律及作用机制。发现转速对润滑状态的影响效果最为明显，载荷与温度影响相对较小。且低速运转时温度与载荷对微凸体接触程度的影响效果较为明显，随着转速的增大温度与载荷对其影响逐渐减小，该理论分析结果为加速寿命试验的加速应力与加速因子选择提供了理论依据。
（4）分析了谐波减速器回差、扭转刚度与传动精度的影响因素及其作用规律，建立了减速器内部各摩擦副之间磨损产生的间隙与其回差、扭转刚度及传动精度的计算公式。
（5）通过磨损试验拟合了MoS2-Ti复合薄膜与聚四氟乙烯两种材料的磨损模型，基于磨损模型判断了两种固体润滑材料的可加速性。分析了混合润滑状态下，微凸体接触程度对摩擦系数的影响规律，并基于Johnson—Williamson的混合润滑模型与Archard的黏着磨损模型提出了以摩擦系数为主要表征量的混合润滑状态下的黏着磨损模型。基于该磨损模型与线接触弹流润滑的膜厚方程，分别提出了全膜润滑与混合润滑两种状态下摩擦副的加速寿命试验准则。进一步提出了空间润滑谐波减速器的加速寿命试验方法，包括加速应力与加速因子的选择以及加速寿命与正常寿命间的外推关系建立。
（6）研究了谐波减速器传动精度、传动效率、回差与扭转刚度的精密测试方法，搭建了热真空环境下谐波减速器各传动性能指标在线、原位测试的实验系统。对空间润滑谐波减速器进行5000小时的热真空寿命试验，相关试验结果验证了理论分析的正确性。
Present work is based on the Civil Aerospace Advance Research Program and theproject “The theory and method of reliability design of a new model drive componentsand the systematic” which had been supported by National Natural Science Foundationof China. Due to the development of aerospace technology, long-life, high-precision,high-reliability, high-power density and high-stability become fundamentalperformances for modern space driving mechanisms. However, the reliability andservice life of space drive mechanism is directly influenced by fundamental theoreticalresearch, especially for the dynamic service behavior and failure mechanism of themechanism under complex space environment, there still lack of complete theoreticalframework and experimental study for them. All these issues have become the weakpoints during the development process of long-life space drive mechanism, andconstituted the major causes of frequent on-orbit malfunctions of space drivemechanism, furthermore, become the stumbling block for the development of modernspacecraft.
Therefore, this paper takes lubricated harmonic drive, the most typical componentsin space drive mechanism, as the research object, applying mixed lubrication theory,conducts simulation analysis on the failure mechanism of the harmonic drive,establishes the failure model and based on above, proposes the optimal acceleratedlife testing method. At last, the comprehensive performance testing system of spacelubricated harmonic drive is set up and the relevant tests are carried on to verify theeffectiveness of the proposed method. The main research content is composed of thefollowing six parts:
(1) Lubricated harmonic drives for space application are prepared for testing, thetooth surfaces of circular spline and flexspline are lubricated by mixed diamond-likecarbon films (WC-DLC:H) and PFPE-based grease (Braycote601). The wave generatorbearing is lubricated by MoS2-Ti composite films and polytetrafluoroethylene retainer,the contact surface between flexspline and wave generator is lubricated only byBraycote601. Meanwhile, the mechanical and tribological properties of the lubricatingmaterial are tested.
(2) In order to obtain proper mixed lubrication model to study the failuremechanism of the lubricated parts, Reynolds equation is first deduced under isothermal condition. Then, film thickness equation of line contact taking surface roughness intoconsideration is established and in which the relationships of viscosity–pressure,viscosity–temperature, density–pressure and no Newtonian fluid property for thelubricant are considered. The relative motions and load distributions of contact surfacesbetween the inner flexspline and wave generator bearing, circular spline and flexsplinetooth surface are analyzed, and the equivalent lubrication model is established. Basedon above, the mixed lubrication simulation is conducted with the film thickness ratio (λ),load distributed generated by asperity contact (Wc) and relative contact area (Ac) as therepresentative variables.
(3) After obtain the mixed lubrication simulation results, the failure mechanism ofthe grease lubricated contact parts and the effects of rotation speed, load, temperature ontheir lubrication status is discussed. The results release that the rotation speed has themost significant effect comparing to load and temperature. Moreover, the effects of thetemperature and load on asperity contact are more serious at a lower speed while theeffects decrease with increase in the rotation speed. The analysis results become thetheoretical basis for the determination of accelerated stress and accelerated factor duringaccelerated life test.
(4) The factors effect backlash, torsional stiffness and transmission accuracy of theharmonic drive and how they generate those effects are analyzed. The computationalformulas for calculating backlash, torsional stiffness, transmission accuracy and wearclearances between friction pairs in the harmonic drive are presented.
(5) The wear model of MoS2-Ti composite film and polytetrafluoroethylene werefitted through the data obtained from wear tests, and the possibility for conductingaccelerated test for the two lubricating materials are analyzed based on the wear model.The effect of asperity distribution on friction coefficient during contact in mixedlubrication is investigated. And then the adhesive wear model characterized by frictioncoefficient in mixed lubrication is proposed based on Johnson-Williamson mixedlubrication model and Archard adhesive wear model. Furthermore, based on the wearmodel and film thickness equation of line contact elastohydrodynamic lubrication, theaccelerated life test schemes for full film lubrication and mixed lubrication are proposed,respectively. Finally, accelerated life test scheme for the harmonic drive is obtained,including the choice of accelerated stress and accelerated factor and establishment of theextrapolation relationship between accelerated life and regular life.
(6) A precisely testing method for transmission accuracy, transmission efficiency, backlash and torsional stiffness of the harmonic drive is studied and correspondingexperimental system for in-circuit and in-situ test of harmonic drive under thermalvacuum environment is set up. A serial of5000-hours thermal vacuum life tests arecarried out, and the test results verifies the validity of the proposed theory.
引文
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