Determination of Surface Singularities of A Cycloidal Gear Drive With Inner Meshing

Mathematical and Computer Modelling 45 (2007) 340354
www.elsevier.com/locate/mcm
Determination of surface singularities of a cycloidal gear drive with
inner meshing
Yii-Wen Hwang
, Chiu-Fan Hsieh
Department of Mechanical Engineering, National Chung-Cheng University, 168 San-Hsing, Ming-Hsiung, Chia-Yi 621, Taiwan, ROC
Received 10 January 2006; received in revised form 17 May 2006; accepted 23 May 2006
Abstract
The cycloidal gear drive is widely used in industrial applications, such as gerotor pump, speed reducer, transmission apparatus
and so on. In this paper, the prole of inner rotor is with equidistance to an epitrochoidal (or extended epicycloid) curve, and
the mathematical model of the internal cycloidal gear with tooth difference is created by the theory of gearing. The proposed
mathematical model can simulate not only gerotor pump but also cycloidal speed reducer. The design of outer rotor depends on
different applications. Being applied to the speed reducer, the outer rotor will be a pin wheel (outer rotor arc teeth). Besides, for
a better design of the gerotor pump, the mathematical model of the generated shape between outer rotor arc teeth will also be
proposed. Lastly, a simpler dimensionless equation of undercutting will be derived from the proposed mathematical model. And a
more explicit procedure to determine the feasible design region without undercutting on the tooth prole or interference between
the pins will be developed and demonstrated by some numerical examples.
c 2006 Elsevier Ltd. All rights reserved.
Keywords: Cycloidal gear drive; Speed reducer; Gerotor pump; Undercutting; Pump efciency
1. Introduction
The cycloidal gear drives can be applied to gerotors. The gerotor is a positive displacement pump mechanism,
which delivers a known, predetermined quantity of uid in proportion to speed. It can be applied to both uid powers
and uid transmissions. Because the inner gerotor advances only one tooth space per revolution, gerotor elements
revolve in the same direction at low relative speed. Thus, the gerotor can be made to pump in the same direction
regardless of rotation direction. Additionally, it provides a relatively pulseless ow, high volumetric and mechanical
efciency, and balanced and quiet operation.
Besides, the cycloidal gear drives can also be applied to many other elds such as cycloid speed reducers and
air motors [1,2]. Cycloid reducers use rolling elements and a multilobate cam to transmit torque and provide speed
reduction. These reducers provide high reduction ratios with low backlash, high accuracy, and high stiffness. They
contribute much to the renovation and replacement of the directional products of the mine hoist, cement equipment,
rod and bar mill train, lifting machines, sugarcane extraction mills, crushers and power generation equipment.
Corresponding author. Tel.: +886 5 272 0411x33308.

E-mail addresses: imeywh@ccu.edu.tw (Y.-W. Hwang), naturaltom@gmail.com (C.-F. Hsieh).
0895-7177/$ - see front matter c 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mcm.2006.05.010
Y.-W. Hwang, C.-F. Hsieh / Mathematical and Computer Modelling 45 (2007) 340354 341
Nomenclature
c center distance between the outer rotor and inner rotor
R pin radius of the outer rotor
r center distance between the circular-arc pin and the outer rotor
m the tooth numbers difference between the outer rotor and the inner rotor
N the tooth number of the outer rotor
S
i
coordinate system i where i = 1, 2, f
O
i
origin of the coordinate system S
i
, i = 1, 2, f
i
,
i
rotation angle, i = 1, 2
prole parameter of the circular-arc pin of the outer rotor
M
i j
coordinate transformation matrix from system j to system i
i
pitch radius of the outer rotor when i = 1, pitch radius of the inner rotor when i = 2
r
i
position vector represented in S
i
, i = 1, 2, i = a, b
P the eccentric ratio parameter
Q the pin radius ratio parameter
Q
u
the minimum value Q of undercutting
1 min
the meshing point is located at the tooth bottom of the inner rotor
1 max
the meshing point is located at the tooth top of the inner rotor
Q
c
the maximum value of the pin radius ratio
With regard to the researches concerning the cycloidal gear drives, Tsay and Yu [3] proposed an analytical
method for gerotors with the outer rotor arc teeth and inner rotor trochoid teeth. The relations among design variable
of the traditional design method and the proposed analytical method had also been studied and compared. Yang
and Blanche [4] investigated the characteristics of the backlash and torque ripple and analyzed the relationships
among the machining tolerance, drive parameters (namely, gear ratio, pitch diameter and normalized tooth heights)
and drive performance indices (namely, backlash and torque ripple). They found that, as a gerotor cannot be
adjusted to compensate for wear, the contact forces should be kept to a minimum and the curvature of the lobes
decreased to reduce the wear rate. Subsequently, Beard et al. [5] derived relationships that show the inuence of
the trochoid ratio, the pin size ratio and the radius of the generating pin on the curvature of the epitrochoidal
gerotor.
Drawing on the theory of the envelope, Shung and Pennock [6] presented a unied and compact equation describing
the geometry, the geometric properties of the different types of trochoid and the geometric properties of a conjugate
envelope. Mimmi and Pennacchi [7] dealt with a general method showing the analytical condition for avoiding
undercutting using the concept of the limit curve. From the same perspective, Vecchiato et al. [8] applied the rotor
proles of a cycloidal pump as a circular arc and a conjugated epicycloidal curve. They investigated the formation of
an envelope by branches and discussed the determination of singularities and computerized pump design with rotor
proles free of singularities. Litvin et al. [9] investigated the envelopes relation to surface family by considering
envelopes formed by several branches for cycloidal pumps and conventional worm gear drives. Demenego et al. [10]
developed a tooth contact analysis (TCA) computer program and discussed avoidance of tooth interference and rapid
wearing through modication of the rotor prole geometry of a cycloidal pump whose one pair of teeth is in mesh at
every instant.
Of particular interest for this paper, Fong and Tsay [11] proposed a dimensionless equation of non-undercutting
to study the feasible design region without undercutting for the internal cycloidal gear with a small tooth difference.
They solved the undercutting curve using a xed eccentric ratio parameter and showed the impact of tooth difference
on the feasible design region. Specically, when the tooth number difference is equal to 1, the feasible design region
falls only under the lowest point of the undercutting curve, but when the tooth number difference is equal to or greater
than 2, the feasible design region is determined by considering the undercutting curve and
max
curve simultaneously.
However, not only is their dimensionless equation of non-undercutting extremely complicated, but the authors did not
take into consideration interference between the pins. Therefore, the result for the speed reducer may not point clearly
to a feasible design region.
342 Y.-W. Hwang, C.-F. Hsieh / Mathematical and Computer Modelling 45 (2007) 340354
Fig. 1. Traditional design of gerotors.
Therefore, in this paper, the mathematical model with tooth difference is derived by the theorem of gearing and the
operation of the coordinate transformation for the prole of the internal gear. The proposed mathematical model can
be applied to simulate not only the gerotor pump but also the cycloidal speed reducer. A better geometry design is also
presented in gerotor pump design. According to the proposed mathematical model, a simpler dimensionless equation
of non-undercutting will be derived and a design region of non-undercutting will be presented in the following
sections.
2. Geometric design
As shown in Fig. 1, the traditional design of gerotors has carryover phenomenon between inner and outer rotors.
That is, when the outer and inner rotors rotate at the location shown in Fig. 1, the inability to completely discharge the
liquid reduces pump efciency. In this paper, the prole of inner rotor will be designed rst and then the outer rotor
generated according to the inner rotor, so that the carryover may thus be improved. The mathematical model of rotors
will be created in the following.
2.1. Mathematical model
One method for generating the internal cycloidal gear is shown in Fig. 2. Circles 1 and 2 are in internal tangency,
and their radius are radii
1
and
2
separately. Point I is the instantaneous center of rotation. When circle 1 rotates
counterclockwise around the circumference of circle 2 in a pure rolling motion, the eccentric throw r is the distance
between point p and the center of circle 1, and point p generates an extended epicycloid path. This path could be
the center of rollers and then the prole of inner cycloidal rotor (or cycloidal wheel) would be generated by the inner
envelope methods.
The coordinate systems are created as shown in Fig. 3, where the coordinate systems S
1
, S
2
and S
f
are rigidly
attached to the outer rotor, inner rotor and frame, respectively. The ratio of the inner rotors rotation angle to that of
the outer rotor is inversely proportional to the ratio of the tooth number. Therefore, the relationship between rotation
angle
2
and
1
is represented as follows:
2
=
N
N m
1
(1)
where N is the tooth number of the outer rotor, m is the tooth number difference between the inner rotor and the outer
rotor. Thus, the tooth number of the inner rotor is N m.
If the circular arc pin tooth of the outer rotor is represented in S
1
as
r
1
() =
_
_
x
1
()
y
1
()
1
_
_
=
_
_
R sin
r R cos
1
_
_
. (2)
The equation of the inner rotor can be determined by the following coordinate transformation:
r
2
(,
1
) = M
21
(
1
)r
1
() (3)
Fig. 2. Generation of the extended epicycloidal curve.
Fig. 3. Applied coordinate system.
where
M
21
(
1
) =
_
_
cos(
1

2
) sin(
1

2
) c sin
2
sin(
1

2
) cos(
1

2
) c cos
2
0 0 1
_
_
.
The mathematical equation of the inner rotor can be yielded by Eq. (3) as follows:
r
2
(,
1
) =
_
_
x
2
(,
1
)
y
2
(,
1
)
1
_
_
=
_
_
r sin(
1

2
) + R sin( +
1

2
) c sin
2
r cos(
1

2
) R cos( +
1

2
) c cos
2
1
_
_
. (4)
The equation of meshing is represented as [12,13]:
f
1
(,
1
) =
_
r
2
k
_
r
2
1
= 0 (5)
where k is the unit vector in the z direction. Substituting Eq. (4) into Eq. (5) yields
f
1
(,
1
) = mr sin + cN sin( +
1
) = 0. (6)
Eqs. (4) and (6) considered simultaneously determine the generated tooth prole of the inner rotor.
Fig. 4. The basic ideal of generated shape.
Fig. 5. Coordinate system for generating outer rotor.
The above mathematical model is applicable for a cycloidal speed reducer. However, if the application is a gerotor
pump, the carryover shown in Fig. 1 can be improved by generating the outer rotor prole using the envelope of the
inner rotor prole. This basic concept is illustrated in Fig. 4.
For the coordinate system shown in Fig. 5, the equation of the inner rotor (Eq. (4)) in S
a
is written as r
a
(,
1
), the
relationship between the rotation angle
2
and
1
is represented as:
2
=
N m
N

1
. (7)
Operating the coordinate transformation as in Eq. (3) then yields
r
b
(,
1
,
1
) = M
ba
(
1
)r
a
(,
1
)
=
_
_
r sin(
1

2
+
1

2
) + R sin( +
1

2
+
1

2
) c[sin
2
sin(
1

2

2
)]
r cos(
1

2
+
1

2
) R cos( +
1

2
+
1

2
) c[cos
2
+ cos(
1

2

2
)]
1
_
_
(8)
where
M
ba
(
1
) =
_
_
cos(
1

2
) sin(
1

2
) c sin
2
sin(
1

2
) cos(
1

2
) c cos
2
0 0 1
_
_
in which the inner rotor tooth prole is obtained by considering simultaneously the equation of meshing:
f
2
(,
1
,
1
) =
_
r
b
1
k
_
r
b
1
= 0. (9)
Substituting Eqs. (1) and (7) into Eq. (8) and operating Eq. (9) yields
f
2
(,
1
,
1
) = mr
_
sin
1
+ sin
_
1

m
N m
1
__
+ mR
_
sin( +
1
) + sin
_
+
1

m
N m
1
__
+cN sin
_
1
+
N
N m
1
_
= 0. (10)
Simultaneous consideration of Eqs. (6), (8) and (10) then allows determination of the generated shape between the
outer rotor arc teeth.
3. Equation of undercutting and design constraints
For the generated rotor prole, if a singular point exists on the tooth prole, then undercutting will occur and the
relative velocity denition can be represented by the theory of gearing [12,13]:
V
(2)
r
= V
(1)
r
+ V
(12)
= 0 (11)
where, V
(1)
r
and V
(2)
r
represent the velocities of the contact point displacement along the tooth shape in coordinate
system S
1
and the generated shape in coordinate system S
2
, respectively. V
(12)
is the sliding velocity. Eq. (11) implies
that the following two determinants are equal to zero [12,13]:
x
1
V
(12)
x1
f
1
d
1
dt
y
1
V
(12)
y1
f
1
d
1
dt
= 0. (12)
Eq. (12) is the equation of undercutting. And the sliding velocity is represented as:
V
(12)
1
= V
(12)
x1
+ V
(12)
y1
=
_
(
(1)
1

(2)
1
) r
1
_
(R
1

(2)
1
) (13)
where
(1)
1
=

k (14)
(2)
1
=
N
N m
k (15)
R
1
= c sin
1
i +c cos
1
j . (16)
Substituting Eqs. (2) and (14)(16) into Eq. (13) and transforming it into a dimensionless equation by dividing r yields
_
_
V
(12)
x1
=
1
N m
(m mQ cos PN cos
1
)
V
(12)
y1
=
1
N m
(mQ sin + PN sin
1
)
(17)
where P =
c
r
denotes the eccentric ratio parameter; Q =
R
r
denotes the pin radius ratio parameter.
Letting
1
=
x
1
V
(12)
x1
f
1
d
1
dt
,
2
=
y
1
V
(12)
y1
f
1
d
1
dt
(18)
and setting the angular velocity of the outer rotor to unit
d
1
dt
=
1
= 1, a dimensionless equation can also be obtained
from Eq. (6) by dividing r:
f = m sin + PN sin( +
1
) = 0. (19)
Operating Eq. (18) yields the following dimensionless equation:
1
=
1
N m
[m cos (m + mQ cos + N P cos
1
) + N P cos( +
1
)(m NQ cos N P cos
1
)] (20)
2
=
1
N m
[m cos (mQ sin N P sin
1
) + N
2
P cos( +
1
)(Q sin + P sin
1
)] (21)
where
r
1
=
x
1
i +
y
1
j = Q(cos
i +sin
j )
f
=
f
= m cos + PN cos( +
1
)
f
1
=
f
1
= PN cos( +
1
).
According to the theory of gearing, the singularity exists when both determinants are equal to zero,
1
=
2
= 0,
the coordinates of the singular point can be solved as follows:
2
1
+
2
2
= 0. (22)
The rotation angle
1
of the outer rotor at the singular point is denoted as
u
and can be solved by simultaneous
consideration of Eqs. (19) and (22). If the undercutting value
u
is in the range of
1 max

u

1 max
, undercutting
will occur on the tooth prole. However, we solve the values (Q) by xed eccentric ratio parameter P. If the minimum
value of the undercutting is denoted as Q
u
, the following equations are helpful to obtain the minimum value of the
undercutting as:
_
1
_
2
+
_
1
_
2
= 0 (23)
where
1
=
1
N m
{N P[m sin( +
1
) + cos (m sin
1
+ NQ sin( +
1
)) + N P sin( + 2
1
)]}
1
=
1
N m
{N P[m cos cos
1
+ N P cos( + 2
1
) + NQ sin sin( +
1
)]}.
Eq. (19) can yield the following:
= tan
1
_
PN sin
1
m + PN cos
1
_
. (24)
Substituting Eq. (24) into Eqs. (22) and (23) then produces the minimum value of undercutting Q
u
.
When the lower bound of the eccentric ratio parameter P is equal to zero, the upper boundary values of eccentric
ratio parameter P may be derived from the differentiation of Eq. (19) and written as follows:
d f ((
1
),
1
)
d
1
=
f
d
d
1
+
f
1
= 0. (25)
Thus, the transformation yields:
d
d
1
=
f
1
f
=
N P(N P + m cos
1
)
m
2
+ (N P)
2
2mN P cos
1
. (26)
In Eq. (26), when
f
1
= 0 then
d
d
1
= 0, the function (
1
) will reach its extreme value. Therefore, to obtain the
condition of extreme value of parameter P, the numerator of Eq. (26) must be zero, and then we can yield as follows:
1
N P
m
1. (27)
Fig. 6. The tooth top and tooth bottom radii of the outer rotor for m = 1.
It should be noted that the denominator of Eq. (26) must not be zero. Finally, the design constraint of P can be
determined as follows:
0 < P <
m
N
. (28)
When the difference of the tooth number is equal to 1 (m = 1) and the meshing point is located at the tooth bottom
of the inner rotor when
1 min
= 0 but at the tooth top when
1 max
= , the tooth depth (
t 1

b1
) is equal to the
difference between the radius of tooth top
t 1
and the radius of tooth bottom
b1
. However, if the difference of tooth
number is larger than 1 (m 2) and the meshing point is located at the tooth top of the inner rotor when
1
=
1 max
,
the angle
1 max
can be solved by considering the following equation and Eq. (4), simultaneously:
x
2
cos
_

N m
_
y
2
sin
_

N m
_
= 0 (29)
where, x
2
and y
2
are calculated from Eq. (4). Substituting Eq. (4) into Eq. (29) yields:
r sin
_

N m
+
1

2
_
R sin
_

N m
+ +
1

2
_
c sin
_

N m

2
_
= 0. (30)
This can also be transformed into a dimensionless equation by dividing by r:
sin
_

N m
+
1

2
_
Q sin
_

N m
+ +
1

2
_
P sin
_

N m

2
_
= 0. (31)
Eq. (30) or Eq. (31) can then be used to solve the maximum meshing rotation angle
1 max
. Next, they can be
substituted back into Eq. (4) to calculate the x and y coordinates of the tooth top. As shown in Figs. 6 and 7, the
tooth number differences are m = 1 and m = 2, respectively. Anyway, the radii of the tooth bottom and tooth top can
be determined by the following equations:
bi
=
_
x
2
(
1 min
)
2
+ y
2
(
1 min
)
2
, i = m
ti
=
_
x
2
(
1 max
)
2
+ y
2
(
1 max
)
2
, i = m
(32)
where,
1 min
= 0
.
For the cycloidal speed reducer design, to avoid contact or interference between either of the two neighbor pins,
the maximum value of the pin radius ratio is denoted as Q
c
and the radius of the pin or the pin radius ratio may be
Fig. 7. The tooth top and tooth bottom radii of the outer rotor for m = 2.
Table 1
Designed parameters for gerotor
Parameters given Design constraint
Case 1 m = 1, N = 5, P = 0.1333, Q = 0.5, r = 30 0 < Q < Q
u
= 0.527
Case 2 m = 1, N = 7, P = 0.1, Q = 0.3667, r = 30 0 < Q < Q
u
= 0.402
constrained by the following equations:
0 < R < r sin
_
N
_
0 < Q < Q
c
= sin
_
N
_
.
(33)
However, Eq. (33) only determines the design range of the pin size. Therefore, to determine the feasible design
region, the design constraint must be considered simultaneously using the equations of undercutting, Eqs. (20)(24).
The details of such determination are illustrated by the following examples.
4. Numerical examples and discussion
4.1. Gerotor design
For gerotor design, the tooth number difference must be equal to 1, whose given parameters and design constraints
are presented in Table 1. According to Eq. (28), the design constraints of P are 0 < P < 0.2 and 0 < P < 0.1429 for
case 1 and case 2 respectively. Therefore, the value of P must be designed in the feasible range. For example, based
on Eqs. (20)(24), for case 1, the value Q
u
= 0.527 is solved by the xed eccentric ratio parameter P = 0.1333 and
that for case 2, Q
u
= 0.402, by the xed eccentric ratio parameter P = 0.1. These two cases have no undercutting on
the proles because the designed values of Q are lower than their values of Q
u
. The design results of case 1 and 2 are
shown in Figs. 8 and 9, respectively. Thus both cases can achieve an improved carryover phenomenon. Besides, the
design constraints shown in Table 1 is a feasible design range without undercutting by xed eccentric ratio parameter.
Specically, a given value of P would correspond to a constraint value Q
u
. Thus, the feasible design range of Q can
be determined as 0 < Q < Q
u
. To achieve the condition of non-undercutting, the design value of Q must also be in
the feasible design range. If the value of Q is larger than its Q
u
then the undercutting will occur. When we change the
value of Q into 0.53 in case 1, the undercutting is as demonstrated in Fig. 10.
Fig. 8. Design result of case 1 for gerotor.
Fig. 9. Design result of case 2 for gerotor.
Fig. 10. Undercutting example of case 1 for gerotor.
Lastly, a feasible design region of parameters P and Q is shown in the lower part of the undercutting curve in
Fig. 11. So the design values can be determined without undercutting. Fig. 11 also illustrates that when the tooth
number is larger, the curve of undercutting would be lower.
Fig. 11. Feasible design region of gerotor.
Fig. 12. Feasible design region for m = 1 and N = 10.
4.2. Design of cycloidal speed reducer
According to Eqs. (20)(24), (28) and (33), when we x the parameter N = 10, the tooth number difference m
is given as 1, 2 and 3, whose design regions are calculated and shown in Figs. 12, 13 and 14, respectively. In these
gures, the designs without undercutting are under the curve of undercutting, but determining a feasible design region
within the lower part of the undercutting curve requires additional consideration of the maximum pin radius ratio,
which is the line of Q
c
= 0.309. Thus, the design curve can be determined and the lower part of that is the feasible
design region. And it becomes possible to design the parameters in this feasible design region without undercutting of
the tooth prole and interference between the adjacent pins.
For example, the given parameters and calculations are in Table 2. Where, when m 2 the rotation angle
1 max
is solved by consideration of Eqs. (24) and (31), then the radii of tooth bottom and tooth top would be calculated by
Eqs. (4), (24) and (32). The design results of these three cases are shown in Figs. 1517.
If the parameters are designed above the curve of design then the undercutting of tooth prole or interference
between the pins may occur. Taking one example in case 1, we change the value of Q into 0.32 that is above the line
of Q
c
= 0.309 and the curve of design, then the undercutting of tooth prole and the interference between the pins
are demonstrated in Fig. 18.
Table 2
Designed parameters for speed reducer
Parameters given Design constraints
1 max

b

t
0 < P < 0.1
m = 1, N = 10, r = 50
Case 1 0 < Q < Q
u
= 0.305 180
40.5 47.5
P = 0.07, Q = 0.12
0 < Q < Q
c
= 0.309
0 < P < 0.2
m = 2, N = 10, r = 50
Case 2 0 < Q < Q
u
= 0.3725 112.74
35.5 48.3561
P = 0.17, Q = 0.12
0 < Q < Q
c
= 0.309
0 < P < 0.3
m = 3, N = 10, r = 50
Case 3 0 < Q < Q
u
= 0.3835 87.4761
30.5 45.9935
P = 0.27, Q = 0.12
0 < Q < Q
c
= 0.309
Fig. 15. Design result of case 1 of speed reducer.
5. Conclusion
In this paper, the prole of inner rotor is designed by equidistance to an epitrochoidal (or extended epicycloid)
curve. The mathematical model in parametric form and simpler dimensionless equations of non-undercutting are
derived. The paper also suggests a better design for improving the carryover phenomenon of the gerotor pump. The
numerical results show that even with one difference of tooth number and the tooth number of the outer rotor, this
model can determine the feasible design region from the undercutting analysis. Thus, this simpler design procedure is
of great practical value to designers.
Specically, designers should consider two applications the gerotor and cycloidal speed reducer. For gerotor,
the feasible design region only needs to consider the lower part of undercutting curve. Besides, a better design for
improving the carryover phenomenon of gerotor pump is also presented in this paper. In contrast, for cycloidal speed
reducer, the feasible design region should consider not only the undercutting curve but also the line of maximum
pin radius ratio V
c
. Once this design curve is determined, its lower part can be identied as a feasible design region.
Overall, the proposed procedure is very helpful for designing the parameters, the eccentric ratio parameter, P, and
Fig. 18. Undercutting and interference example of case 1 for speed reducer.
the pin radius ratio parameter, Q, all of which are available within the feasible region without the occurrence of
undercutting on the tooth prole or interference between the pins.
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Determination of Surface Singularities of A Cycloidal Gear Drive With Inner Meshing

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Determination of Surface Singularities of A Cycloidal Gear Drive With Inner Meshing

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Mathematical and Computer Modelling 45 (2007) 340354

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