Robert Schuller ^1* Jens Reinecke ¹ Henry Maurenbrecher ¹ Christian Ott ² Alin Albu-Schäffer ¹ Bastian Deutschmann ^1* Fred Buettner ³ Jens Heim ³ Frank Benkert ³ Stefan Glueck ³

• ¹ Institute of Robotics and Mechatronics, German Aerospace Center (DLR), Weßling, Germany
• ² Vienna University of Technology, Vienna, Vienna, Austria
• ³ Schaeffler Technologies AG & Co. KG, Schweinfurt, Germany

The idea of sensorizing a strain wave gear to measure the transmitted torque has been reported since the 1980s. The strain in the elastic flex spline is typically measured by strain gauges attached to it. The resulting voltages relate to the transmitted torque in the gear. However, periodic inaccuracies in the measured torque signal (sensing ripple), resulting from positioning inaccuracies of the strain gauges on the flex spline, prevented this technology from being used outside a lab environment. Regardless of these difficulties, measuring the torque directly in the strain wave gear would bring many advantages, especially in robotic applications, where design space is highly limited. Traditionally, robotic joints are equipped with link-sided torque sensors, which reduce the available volume, lower the joint stiffness, and require complex cable routing. This paper presents an experimental study of a novel sensorized strain wave gear named RT1-T which was developed by Schaeffler Technologies. The study is implemented on a joint testbed, including a high-resolution reference torque sensor at the link side. In addition to the measurement accuracy and linearity, a torque ripple analysis is performed. The joint torque control capabilities are determined along dynamic trajectories and compared to the performance achieved with a link-sided reference sensor. The sensor performed in the testbed with a static torque error of 0.42 Nm and an average closed-loop torque control error of 0.65 Nm above the reference sensor.