Gear-Ratio Spectrum for Robotic Joint Motor Drive Systems: Multiphysics Coupling and Design Trade-Offs

Abstract

Robotic joint motor drive systems must combine torque density and dynamic response with low mechanical impedance, safe interaction, and thermal robustness. This review treats gear ratio as a system-level design coordinate realized jointly by the motor, transmission, thermal path, sensing, and control. It synthesizes how ratio selection changes torque–speed capability, reflected inertia, losses, thermal duty, reducer nonidealities, backdrivability, and control bandwidth. The proposed spectrum uses nominal ratio as its primary coordinate while treating reducer topology, application domain, integration level, and compliance as distinct, overlapping descriptors. Mechanism-level conclusions are based on peer-reviewed studies; manufacturer specifications, open-source structures, and model-based engineering examples are identified and interpreted within narrower evidence boundaries. Representative robotic-joint cases connect these mechanisms to application demands, and an iterative framework translates the synthesis into checks on the task envelope, motor–reducer matching, thermal feasibility, transmission nonlinearity, sensing, and control. Relative to gearbox-centered reviews and task-specific motor–transmission optimization studies, this review provides a cross-domain decision map rather than a product ranking or universal predictive model.