An improved transmission efficiency prediction method for nonlinear characteristics of the cycloid reducer

This study aims to accurately predict the nonlinear characteristics of transmission efficiency of cycloid reducers under different operating conditions. Firstly, equivalent modeling of the multi-source errors (MSEs) in the designed cycloid reducer is conducted. Force analysis algorithms considering MSEs are proposed for the cycloid drive mechanism, the output mechanism, and the bearings. Secondly, mathematical models are established for the load-dependent power losses, while an equivalent test is used for modeling load-independent power losses. Subsequently, an improved transmission efficiency prediction (TEP) method for cycloid reducers is proposed, which is then applied to the performance prediction of a prototype under different operating conditions. The advantages of the improved TEP method over the conventional method are discussed, and the influences of MSEs and load-independent power losses on the nonlinear characteristics of transmission efficiency are summarized. Finally, tests are conducted for the reducer prototype, and the test results are found to be in good agreement with the results obtained by the proposed TEP method. The main contribution of this study is to establish a solid algorithmic and modeling foundation for the optimal design of nonlinear transmission efficiency in cycloid reducers and provide reliable guidance for their engineering applications.