What's the real-world efficiency loss through a harmonic drive stage?

[karen.chen3]

This has been on my mind since a conversation I had last week. Torque sensing is frequently integrated directly into the actuator housing via strain gauges near the output flange or spring element, rather than bolted on as an external sensor, to save weight and reduce noise from mechanical slop. Series elastic actuators add a spring element in series with the drivetrain, which gives cheap, precise torque sensing (measure spring deflection) and passive shock absorption, at the cost of reduced control bandwidth and added complexity. Feel free to tell me I'm overthinking this.

[diego.moore6]

@karen.chen3 Not sure I fully agree here. It's common for a single humanoid to mix actuator types by joint - harmonic drives or hybrid geared actuators at the hips and shoulders where sustained torque matters most, and lower-ratio QDD-style actuators at ankles and knees where backdrivability and impact tolerance matter more.

[samuel.adams]

@diego.moore6 From what I've seen: Reflected inertia is what a limb 'feels like' to the outside world through the gearbox - a high-ratio harmonic drive reflects a lot of the rotor's inertia back to the joint, making the limb feel stiffer and less forgiving on unexpected impacts.

[scott21]

@samuel.adams From what I've seen: Field-oriented control (FOC) tuning directly affects how smooth torque output feels - poorly tuned current loops show up as audible whine and jerky low-speed motion, while well-tuned FOC can make even a geared actuator feel fairly fluid.

[ethan17]

@scott21 Just to be precise about one thing: Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables.

[niklassantos]

@ethan17 This is exactly the kind of context I was looking for. Quasi-direct drive (QDD) actuators use lower gear ratios (roughly 6:1 to 10:1) paired with high-torque-density motors, trading some peak force density for backdrivability and low reflected inertia, which matters a lot for impact tolerance and fall recovery.

[elarsen69]

Same conclusion I've come to. Also worth noting: For dynamic walking and recovery, joint control bandwidth in the tens of Hz range is typically necessary to react to a stumble before the center of mass gets too far outside the support polygon.

[karen.chen3]

@elarsen69 Minor factual note: Harmonic drives use high reduction ratios (often around 100:1), which gives excellent force density, stiffness, and thermal endurance for continuous-duty lifting - the tradeoff is low backdrivability and some backlash.

[forgesve15]

This lines up with my experience. Anti-backlash techniques in production actuators range from mechanical preloading (spring-loaded gear meshes) to purely software compensation that models and corrects for known backlash in the control loop. Boston Dynamics' commercial electric Atlas switched fully from hydraulic to QDD-style electric actuation, ending up quieter and lighter with comparable or better dynamic performance than the old hydraulic platform.

[sarah.santos3]

@forgesve15 Can I ask a dumb follow-up - Backdrivability is the property that lets an external force move a joint without destroying the gearbox or the motor - it's central to both safe human-robot contact and to letting a leg comply naturally when the robot stumbles.