Accelerated Life Test and Performance Degradation Test of Harmonic Drive with Failure Analysis

Harmonic drive is susceptible to strength failure and performance degradation failure during operation. Given the long life test cycles, limited sample size, and incomplete understanding of degradation laws, this study conducted comprehensive life test and performance degradation test research to enable future failure prediction and reliability assessment for harmonic drive. Building upon established test rigs for a HD life test and performance degradation test, a step-down accelerated life test methodology was developed. Life tests under step-down accelerated conditions were executed, with a concurrent performance degradation test throughout the life test. Key datasets acquired include vibration signal histories, degradation data for critical performance indicators such as stiffness, precision, transmission efficiency, and backlash. Test results show that the predominant strength failure in the atmospheric environment is flexspline fatigue fracture, while significant degradation occurred in stiffness, precision, and backlash across all test conditions; transmission efficiency showed gradual degradation before strength failure followed by a marked decline post-failure. Finally, the failure mechanism of strength and performance degradation is analyzed, and the mechanism consistency of the two failures is verified by Hilbert envelope spectrum analysis and degradation trajectory shape consistency, respectively. The results from this paper provide critical data support and a reference foundation for the proactive maintenance of the harmonic drive.