Sensing, driving and controlling integrated joint module

Abstract

The invention discloses a sensing, driving and controlling integrated joint module which comprises a shell used for installing a harmonic reducer, a power module, a power module rear cover, a braking module, a fixing flange, a driving module, a control module, a sensing module and a main shaft. The main shaft is rotationally supported on the shell and the power module rear cover; the power module is used for driving the main shaft to rotate in an electromagnetic excitation mode; the power module rear cover is provided with a wiring groove, and a gap is formed between the power module rear cover and the power module; the braking module is used for generating braking force to lock the main shaft; the fixed flange is provided with a wiring groove and is used for positioning the driving module and the control module; the sensing module is used for detecting temperature, vibration and position signals of the joint module and transmitting the temperature, vibration and position signals to the control module; the control module is used for controlling the power module and the brake module and regulating and controlling the position, the speed and the torque of the joint module; the stability, the response speed and the safety of the joint module are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of drive control equipment, and in particular to a sensor drive control integrated joint module. Background Art

[0002] The sensor-driven-control integrated joint module is widely used in various intelligent robots, undertaking comprehensive tasks such as motion generation, precise positioning and drive control. In the fields of rescue robots, industrial robotic arms and service robots, the module not only needs to integrate multiple functional components in a limited space, but also needs to achieve high-efficiency power transmission and precise motion execution to meet diverse application requirements. Its performance has a crucial impact on the overall flexibility, load capacity and intelligent operation of the robot.

[0003] At present, the mainstream integrated joint modules usually adopt the combination design of planetary gear reducer and DC brushless motor, with internal integrated driver and controller to achieve basic motion control. This type of joint module provides a stable reduction ratio and high transmission efficiency through the planetary gear reducer, while the DC brushless motor provides a relatively stable output for motion drive.

[0004] Although joint modules based on planetary gear reducers and brushless DC motors have made breakthroughs in performance, they still have obvious shortcomings. First, the overall structure of such modules is bulky and occupies a large space, making it difficult to achieve efficient integration in a compact robotic arm design. Secondly, its torque output capacity is limited and cannot meet high-load tasks or instantaneous high torque requirements. Thirdly, due to the low degree of modularity of the system, the collaborative efficiency and integration level between components are insufficient, making it difficult to achieve smooth control and intelligent operation. In addition, the poor dynamic response capability in complex environments limits its application in high-sensitivity and high-flexibility scenarios. These problems make it difficult for existing technologies to fully meet the diverse needs of modern robots in terms of intelligence, flexibility and high performance.

[0005] Therefore, there is an urgent need for a technical solution that can effectively improve the power output performance, response speed and intelligent control capability of the joint module to solve the problem of insufficient stability of the existing module under high load and complex working conditions, thereby meeting the needs of smooth and reliable operation of the robot in a variety of scenarios. Summary of the invention

[0006] The purpose of the present invention is to provide an integrated sensing, driving and controlling joint module to improve the stability, response speed and safety of the joint module, and significantly enhance the intelligence level through real-time perception of the module's operating status by the perception module, thereby meeting the needs of high-performance equipment driving scenarios.

[0007] The technical solution to achieve the purpose of the present invention is:

[0008] A sensor-driven-controlled integrated joint module, comprising:

[0009] A housing for mounting a harmonic reducer, a power module, a power module rear cover, a brake module, a fixing flange, a drive module, a control module, a sensing module and a main shaft;

[0010] A main shaft, rotatably supported on the housing and the rear cover of the power module;

[0011] A power module, used for driving the rotation of the main shaft by means of electromagnetic excitation;

[0012] The power module rear cover is provided with a wiring slot and a gap between the power module;

[0013] A brake module, used to generate a braking force to lock the main shaft;

[0014] A fixed flange with wiring slots and positioning for the drive module and control module;

[0015] The sensing module is used to detect the temperature, vibration and position signals of the joint module and transmit them to the control module;

[0016] The control module is used to control the power module, the brake module and realize the regulation of the position, speed and torque of the joint module;

[0017] The harmonic reducer is connected to the main shaft, passes the power module through the main shaft and increases the output torque for output.

[0018] Compared with the prior art, the present invention has the following significant advantages:

[0019] Improve torque output density: By adopting high-torque-density harmonic reducers and power modules, efficient torque transmission and driving performance are achieved, effectively improving the load capacity and motion efficiency of the joint module. This improvement significantly enhances the power output performance of the joint module, enabling it to meet the needs of high-load, high-dynamic performance scenarios.

[0020] Enhanced structural compactness: The harmonic reducer, power module, brake module, drive module, control module and perception module are integrated into one, and the optimized space layout design is adopted to greatly reduce the volume and weight of the joint module. The highly compact structure lays the foundation for the lightweight design of the joint module and improves the overall design freedom and adaptability.

[0021] Realize multifunctional modularization: Through modular design, multiple functions such as drive, control, and perception are integrated into a unified joint module, ensuring that each functional module operates independently and collaboratively. This multifunctional modular design significantly improves the scalability and versatility of the joint module and meets the needs of diverse application scenarios.

[0022] Improve drive control accuracy: The perception module provides high-precision motion state feedback, combined with the advanced algorithm in the control module and the high-performance drive module, to achieve precise control of joint position, speed and torque. High-precision drive control ensures stable operation of the module under the driving requirements of high-performance equipment, providing technical support for the realization of intelligent precision equipment.

[0023] Optimize the wiring layout: Through the reasonable layout between modules and the design of wiring troughs, signal interference and cable redundancy are minimized, and the electrical reliability and maintenance convenience inside the module are improved. The optimization of the wiring layout not only improves the overall operating efficiency of the system, but also provides technical support for the maintainability and long-term reliability of the module. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a two-dimensional cross-sectional view of the structure of an embodiment of the present invention;

[0025] Figure 2 is a two-dimensional cross-sectional view of a harmonic reducer according to an embodiment of the present invention;

[0026] Figure 3 is a three-dimensional structural diagram of a power module according to an embodiment of the present invention;

[0027] Figure 4 is a three-dimensional structural diagram of a rear cover of a power module according to an embodiment of the present invention;

[0028] Figure 5 is a three-dimensional structural diagram of a brake module according to an embodiment of the present invention;

[0029] Figure 6 is a three-dimensional structural diagram of a fixed flange according to an embodiment of the present invention;

[0030] Figure 7 This is a working principle diagram of a long short-term memory network according to an embodiment of the present invention;

[0031] Figure 8 is a flow chart of an adaptive empirical mode decomposition algorithm according to an embodiment of the present invention;

[0032] Fig. 9 is a three-dimensional structural diagram of an encoder according to an embodiment of the present invention;

[0033] Fig.10 This is a workflow diagram of the sensor-driven-controlled integrated joint module according to an embodiment of the present invention;

[0034] Fig.11 is a two-dimensional cross-sectional view of a housing according to an embodiment of the present invention;

[0035] Markings in the figure: 1- harmonic reducer, 11- wave generator, 111- elliptical cam, 112- flexible bearing, 12- flexible wheel, 121- external gear, 122- connecting flange, 13- rigid wheel, 131- rigid gear ring, 132- rigid wheel fixing seat, 2- housing, 21- joint housing, 22- joint rear cover, 23- first bearing, 3- power module, 31- stator, 32- rotor, 33- integrated circuit board, 331- power terminal, 332- Hall sensor, 333- thermal sensor, 4- power Module back cover, 41-wiring groove, 42-second bearing, 43-fixed frame, 5-brake module, 51-electromagnet, 511-coil, 512-spring, 52-armature, 53-friction plate, 54-brake seat, 55-brake housing, 6-fixed flange, 61-wiring groove, 7-drive module, 8-control module, 9-sensing module, 91-temperature sensor, 92-acceleration sensor, 93-encoder, 931-optical encoder disk, 932-signal processing unit, 933-interface module, 10-spindle. DETAILED DESCRIPTION

[0036] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0037] The present invention and its implementation methods are described below, which are not restrictive and the actual implementation methods are not limited thereto. In short, if ordinary technicians in the field are inspired by it and design structural methods and embodiments similar to the technical solution without creativity without departing from the purpose of the invention, they should all fall within the protection scope of the present invention.

[0038] like Figure 1 As shown, this embodiment discloses a sensor-driven-control integrated joint module, including a harmonic reducer 1, a housing 2, a power module 3, a power module back cover 4, a brake module 5, a fixing flange 6, a drive module 7, a control module 8, a sensing module 9 and a spindle 10. The harmonic reducer 1 is fixed to the housing 2, the spindle 10 is arranged in the housing 2, and the power module 3, the power module back cover 4, the brake module 5, and the fixing flange 6 are all sleeved with the spindle 10.

[0039] like Figure 2As shown, the harmonic reducer 1 is composed of a wave generator 11, a flexible wheel 12 and a rigid wheel 13, wherein the wave generator 11 is composed of an elliptical cam 111 and a flexible bearing 112, the flexible wheel 12 is composed of an external gear 121 and a connecting flange 122, and the rigid wheel 13 includes a rigid gear ring 131 and a rigid wheel fixing seat 132. The wave generator 11 is connected with the flexible wheel 12 by interference fit, and is firmly connected to the main shaft 10 by a flat key, driving the power transmission between the flexible wheel 12 and the rigid wheel 13. In a specific embodiment, the elliptical cam 111 is sleeved with the main shaft 10 and connected by a flat key, the elliptical cam 111 is supported in the rigid gear ring 131 by the flexible bearing 112, the rigid gear ring 131 is fixed in the rigid wheel fixing seat 132, and the rigid wheel fixing seat 132 is connected to the housing 2 by bolts; the elliptical cam 111 and the flexible bearing 112 are clearance-fitted. The outer gear 121 is fixed to the connection flange 122, rotatably supported in the rigid wheel fixing seat 132, and used in conjunction with the rigid gear ring 131. The engagement and disengagement between the outer gear 121 of the flexible wheel 12 and the rigid gear ring 131 realizes differential transmission. The connection flange 122 is connected to the external load through eight evenly distributed threaded holes, thereby completing the torque output of the joint module. The rigid wheel fixing seat 132 is firmly connected to the joint housing 21 through eight evenly distributed screws to ensure the stability of the overall structure.

[0040] In terms of working principle, when the main shaft 10 rotates, the wave generator 11 applies radial deformation to the flexible bearing 112 through the cooperation of the elliptical cam 111 and the flexible bearing 112, thereby driving the flexible wheel 12 and the rigid wheel 13 to engage and disengage at specific positions. The difference in the number of teeth between the flexible wheel 12 and the rigid wheel 13 causes differential transmission, thereby realizing precise torque transmission between the external gear 121 and the rigid gear ring 131. Power is input to the wave generator 11 through the main shaft 10, and torque output is realized through the connecting flange 122, ensuring efficient operation of the system.

[0041] The harmonic reducer 1 converts the high-speed, low-torque output of the power module 3 into a low-speed, high-torque output through the periodic meshing of the flexible wheel 12 and the rigid wheel 13. The transmission ratio is determined by the difference in the number of teeth of the flexible wheel 12 and the rigid wheel 13. The specific calculation formula is:

[0042]

[0043] Among them, Z g and Z f They represent the number of teeth of the rigid wheel 12 and the flexible wheel 13 respectively. When the number of teeth of the rigid wheel 13 is greater than that of the flexible wheel 12, a high transmission ratio and high-precision control can be achieved. Through the tooth difference principle, the harmonic reducer 1 not only gives the joint precise motion control capability, but also significantly improves the torque density of the joint, making it suitable for a variety of complex robot working scenarios.

[0044] like Figure 3 As shown, the power module 3 is a high-efficiency drive device with various forms. Here, an inner rotor frameless torque motor is used as an example for explanation. The module is mainly composed of a stator 31, a rotor 32 and an integrated circuit board 33. The integrated circuit board 33 includes a power terminal 331, a Hall sensor 332 and a thermal sensor 333. The stator 31 is firmly fixed to the inner hole of the joint housing 21 by an adhesive or mechanical assembly. The rotor 32 is placed inside the stator 31 and firmly fixed to the main shaft 10 by an adhesive or mechanical assembly. The axial positioning of the rotor 32 is based on the shoulder surface of the main shaft 10, while maintaining a spacing of 3 to 5 mm with the left end surface of the power module rear cover 4, so as to avoid leakage of the power module 3. The integrated circuit board 33 is bonded to the right end surface of the stator 31 with an adhesive. The power terminal 331, the Hall sensor 332 and the thermal sensor 333 are all welded to the integrated circuit board 33. In terms of working principle, the stator 31 is responsible for generating a rotating magnetic field to drive the rotor 32 to rotate. The rotor 32 interacts with the stator 31 through electromagnetic induction, and generates torque under the action of the magnetic field of the stator 31. The integrated circuit board 33 provides power control and signal processing functions for the power module 3. The integrated circuit board 33 is provided with a power terminal 331 for connecting to an external power supply to provide power supply. At the same time, the integrated circuit board 33 also includes a Hall sensor 332 and a thermistor 333, which are respectively used to monitor the position of the rotor 32 and the temperature of the power module 3 in real time. The Hall sensor 332 provides accurate information on the position of the rotor 32 by detecting changes in the magnetic field, so as to achieve closed-loop control; the thermistor 333 monitors the operating temperature of the power module 3 in real time and feeds back the temperature data to the control module 8. Once it is detected that the temperature exceeds the safety threshold, the control module 8 will automatically adjust the power output or start the cooling mechanism, thereby ensuring that the power module 3 always operates within a safe temperature range, effectively avoiding failures or performance degradation caused by overheating. The design structure of the power module 3 is simple and compact, which can effectively improve the transmission efficiency and control performance.

[0045] like Figure 4As shown, the power module rear cover 4 includes a wiring groove 41, a second bearing 42 and a fixing frame 43. The wiring groove 41 is located on the end face of the fixing frame 43. The second bearing 42 and the inner hole in the center of the fixing frame 43 are connected by interference fit to support the main shaft 10. The fixing frame 43 is firmly fixed to the joint housing 21 by three circumferentially evenly distributed protrusions on its outer circle. A wiring groove 41 is provided inside the power module rear cover 4, which optimizes the line layout between the power module 3 and the temperature sensor 91, avoids line crossing, interference and wear, and further improves the stability and durability of the system. In addition, a second bearing 42 is also installed inside the power module rear cover 4, which effectively shares the radial and axial loads generated by the power module 3 when running at high speed, reduces the vibration and friction generated by the rotation, and thus improves the operating stability of the power module 3 and the reliability of the power output. While improving the system accuracy, the second bearing 42 also ensures the smooth movement and long-term stable operation of the sensor-driven integrated joint module.

[0046] like Figure 5 As shown, the brake module 5 is composed of an electromagnet 51, an armature 52, a friction plate 53, a brake seat 54 and a brake housing 55. The electromagnet 51 includes a coil 511 and a spring 512. The electromagnet 51 is fixed to the right end face of the rear cover 4 of the power module by three evenly distributed screws, and is connected to the drive module 7 by two shielded communication lines, one of which is connected to the positive pole of the drive module 7, and the other is connected to the negative pole. The spring 512 is bonded to the right end face of the coil 511 with an adhesive. The left end face of the armature 52 is welded to the spring 512. A friction plate 53 is placed between the armature 52 and the brake housing 55. An interference fit is adopted between the square outer wall of the brake seat 54 and the square inner hole of the friction plate 53 to ensure that the friction plate 53 and the brake seat 54 start and stop synchronously. The inner hole of the brake seat 54 is reliably connected to the main shaft 10 through a flat key, and the axial direction is limited by retaining rings for the left and right shafts. The brake housing 55 is fixed to the right end face of the electromagnet 51 by three circumferentially evenly distributed screws. When the power is turned on, the coil 511 generates magnetic force, attracts the armature 52, and compresses the spring 512. At this time, the friction plate 53 and the brake seat 54 rotate with the main shaft 10. When the power is disconnected, the coil 511 loses the electromagnetic force, and the armature 52, pushed by the spring 512, presses the friction plate 53 against the brake housing 55, generates braking force through friction, quickly locks the main shaft 10, and realizes the braking of the power module 3. The advantage of the brake module 5 is that it responds quickly and can achieve smooth start and stop, ensuring the dynamic safety and operational stability of the joint module.

[0047] like Figure 6As shown, the fixed flange 6 includes eight circumferentially evenly distributed wiring grooves 61. The fixed flange 6 is fixed to the inner hole of the joint housing 21 through a hole-matching retaining ring, thereby ensuring its stable positioning and preventing axial movement. The installation method of the flange provides reliable structural support, ensuring that the encoder 93 always maintains the correct position during operation. A wiring groove 61 is provided inside the fixed flange 6. The design of the groove not only optimizes the layout of the power module 3 and the temperature sensor 91 circuit, but also effectively avoids interference between cables and other components, ensuring that the electrical connection of the entire system is stable, neat and reduces interference, thereby improving the overall performance and reliability of the joint module.

[0048] The drive module 7, control module 8 and encoder 93 are fixed to each other by three studs evenly distributed along the circumference. This design not only shows a high degree of structural compactness in reducing the axial size of the joint module and optimizing the wiring layout, but also ensures the precise alignment and mechanical stability of each module during the assembly process through evenly distributed studs, thereby effectively reducing the vibration and signal delay caused by installation errors. Furthermore, the integration of the drive module 7 and the control module 8 significantly shortens the signal transmission path, reduces redundant wiring and electromagnetic interference, and improves the system response speed and control accuracy, providing a solid technical guarantee for the optimization of the overall performance.

[0049] The core function of the drive module 7 is to control the electromagnetic excitation of the power module 3, and to achieve accurate output and dynamic adjustment of the torque of the power module 3. The drive module 7 provides a stable power drive foundation for the joint module with its high-efficiency power transmission and high-precision signal processing capabilities. Through integrated design, the drive module 7 reduces the modular size while optimizing energy efficiency, providing a guarantee for overall performance improvement.

[0050] The control module 8 is responsible for analyzing the data from the drive module 7 and the perception module 9 and executing a high-precision closed-loop control strategy. The control module 8 adjusts the speed and position of the power module 3 through real-time calculation and signal processing to ensure that the movement of the joint module meets the expected trajectory and achieves accurate and fast response under complex working conditions, further enhancing the intelligence level of the system.

[0051] The sensing module 9 is used to realize the all-round state perception of the joint module, and is composed of a temperature sensor 91, an acceleration sensor 92 and an encoder 93. The encoder 93 includes an optical encoder disk 931, a signal processing unit 932 and an interface module 933. The temperature sensor 91 is firmly bonded to the left end face of the rear cover 4 of the power module by an adhesive, and the acceleration sensor 92 is pasted on the right end face of the fixed flange 6. The encoder 93 firmly fixes the optical encoder disk 931 on the spindle 10 through three circumferentially evenly distributed set screws, and the axial direction is also fixed to the right end face of the fixed flange 6 by three screws. The temperature sensor 91 monitors the temperature of the joint module in real time to prevent the performance of the equipment from deteriorating or the damage of key components due to abnormal temperature. The acceleration sensor 92 uses micro-electromechanical system (MEMS) technology to realize high-precision acceleration signal acquisition, providing important data for motion state analysis. The encoder 93 provides high-precision position and velocity feedback to ensure the accuracy and real-time performance of motion control. Through the coordinated work of these three, the perception module 9 can accurately and comprehensively reflect the operating status of the joint module and ensure the stability and reliability of the joint module operation.

[0052] The temperature sensor 91 has various forms. The present invention takes a patch temperature sensor as an example, and other types of temperature sensors can also be selected according to actual needs. Since the working environment of the power module 3 is usually a closed space, when the temperature is too low, the system may have problems such as material embrittlement and lubricant solidification, resulting in the mechanical moving parts not being able to work normally; when the temperature is too high, it may cause electrical components to overheat, and even cause short circuits or fires. Therefore, through real-time monitoring of the temperature sensor 91, the system can detect abnormal temperature fluctuations in time and automatically trigger protection mechanisms, such as adjusting the workload or stopping operation, to prevent component damage or performance degradation caused by overheating, thereby effectively improving the safety and stability of the system. The patch temperature sensor is based on the characteristic that resistance changes with temperature. It reflects temperature changes by measuring resistance changes. It has the characteristics of high precision, low noise and a wide measurement range, and is particularly suitable for accurate temperature monitoring in high temperature environments. The temperature sensor 91 adopts a three-wire circuit connection method, in which two shielded communication lines are used for current input, and the third shielded communication line feeds back resistance value signals to ensure high precision and low temperature drift performance.

[0053] The temperature sensor 91 is used to measure the temperature of the integrated joint module of the sense-drive-control, and the specific method is as follows. First, the temperature sensor 91 performs real-time temperature sampling on the left end face of the rear cover 4 of the power module. Subsequently, the collected temperature data is input into the control module to generate a corresponding weight feature sequence. Finally, these feature sequences are passed to the LSTM (Long Short-Term Memory Network) to reconstruct the temperature distribution of the left end face of the rear cover 4 of the power module. LSTM shows significant advantages in processing temperature data. By introducing a gating mechanism, LSTM effectively overcomes the limitations of traditional RNN in dealing with long-term dependencies and avoids the problem of gradient vanishing or exploding. This feature enables LSTM to capture richer long-term dynamic features in the time series data of temperature changes, thereby providing stronger time-dependent modeling capabilities and higher accuracy in temperature monitoring.

[0054] Figure 7 This is a diagram of the working principle of LSTM (Long Short-Term Memory Network). By introducing four key mechanisms, namely forget gate, input gate, output gate and cell state, LSTM neural network significantly enhances its ability to process long-term dependencies in feature sequences.

[0055] In the joint module, the cell state C t Represents the long-term memory of all historical temperature data. It stores the temperature evolution of the joint module and adds the current temperature change information at each time step update. In this way, the LSTM network can dynamically adjust the temperature control of the joint module based on the current input and long-term temperature memory.

[0056] Hidden state h t It is the output of each time step, which contains the temperature change information of the joint module at the current moment and integrates the cell state at the previous moment. In the joint module, the hidden state is equivalent to the instant feedback of the current temperature change of the joint module, which helps the system respond to the current temperature change and provides the necessary input in the next calculation. The hidden state and the cell state work together through the gating mechanism to ensure that LSTM can capture the dynamic characteristics of temperature changes over a long time span and respond to short-term temperature fluctuations in a timely manner.

[0057] The Sigmoid activation function is a smooth nonlinear function whose output value ranges from 0 to 1. It compresses the weighted sum of the input so that the output value of the forget gate can be adjusted between 0 (completely forgotten) and 1 (completely retained). In temperature monitoring, this function helps determine which temperature data is most important for the current decision and which can be ignored. For example, in the temperature monitoring process of the joint module, some historical temperature data (such as temperature changes in distant time steps) may be irrelevant to the current decision. They can be "forgotten" through the forget gate, while more relevant temperature data can be retained, thereby optimizing the system's responsiveness to temperature changes.

[0058] The forget gate is used in LSTM to determine which temperature information should be forgotten from the cell state. This mechanism enables LSTM to effectively suppress the accumulation of unnecessary historical information, thereby enhancing the stability and expressiveness of the network when processing long time series data. In the temperature monitoring application of the joint module, the forget gate uses a sigmoid activation function to calculate the current temperature input x. t and the hidden state h at the previous moment t-1 The calculation outputs a value between 0 and 1. This value represents the forget gate's response to the cell state C t The degree of retention of temperature information in is expressed as follows.

[0059] f t =σ(W f ·[h t-1 ,x t ]+b f ) (2)

[0060] Among them, f t Indicates the amount of temperature information retained, 0 means completely discarded, 1 means completely retained. σ represents the sigmoid activation function. W f h represents the weight matrix of the forget gate, which determines how the system adjusts its dependence on historical temperature data based on the previous temperature state and the temperature change of the current input. t-1 and x t Represents the hidden state at the previous moment and the temperature input at the current moment. f It represents the bias term of the forget gate, which provides adjustment for the output of the forget gate, so that the forget gate can further optimize its temperature data processing logic according to specific application requirements.

[0061] The input gate in LSTM is responsible for controlling the influence of the current input information when updating the cell state. In the temperature monitoring application of the joint module, the input gate uses a sigmoid activation function to input the current temperature x t and the hidden state h at the previous moment t-1A weighted sum is performed to produce a value between 0 and 1. This value determines which temperature information will be written into the cell state C t , that is, the degree of influence of the current temperature data on the long-term temperature memory of the joint module. Specifically, a higher value means that more temperature information will be retained, and a lower value means that the current temperature data contributes less to the system state.

[0062] This value is then compared to a candidate cell state processed by a tanh activation function By multiplying the candidate cell state, it represents the new temperature information extracted from the current input and the state at the previous moment, which is a prediction of the future temperature change trend. By multiplying it with the sigmoid output, LSTM decides how much new information to add to the cell state C t This process ensures the effective update of temperature data, allowing the joint module to make reasonable temperature adjustment decisions based on current and historical data.

[0063]

[0064] Among them, i t Represents the activation value of the input gate, which determines the current input temperature x t In updating the cell state C t In the temperature monitoring of the joint module, the input gate ensures the effective transmission of temperature information by controlling the weight of the input temperature information in the long-term temperature memory. i Represents the weight matrix of the input gate, which is used to transform the hidden state h of the previous moment t-1 and the current temperature input x t Converted into a weighted value for the input gate, determining the contribution of each temperature sensor signal to the current state of the system. i It is the bias term of the input gate, which is added to the weighted summation result to adjust the response of the model to the input gate, so as to make appropriate adjustments when the temperature data fluctuates greatly. Represents the candidate value of the cell state, which is obtained by the current input temperature information x t and the hidden state h at the previous moment t-1 The candidate value provides potential update information about the temperature change at the current moment and determines which new temperature information will be written into the current cell state to update the long-term temperature memory. The tanh activation function performs a nonlinear transformation on the input so that the output value is between -1 and 1, controlling the flow of information in the LSTM and ensuring a smooth transition of temperature information. C Represents the weight matrix of cell state candidates, similar to W i, used to transform the hidden state h of the previous moment t-1 and the current temperature input x t Convert to cell state candidate value. b C It is the bias term of the cell state candidate, which is added to the weighted sum result to adjust the model's response to the cell state candidate value to ensure adaptability and accuracy to temperature changes.

[0065] The output gate in LSTM is responsible for determining the hidden state h at the current moment t What information should be output? In the temperature monitoring application of the joint module, the output gate adjusts the cell state C t and the hidden state h at the previous moment t-1 , to achieve the screening and transmission of temperature information, the formula is as follows. Specifically, the output gate generates the hidden state h t When the temperature is controlled by the output gate, it plays a role of filtering and selection, ensuring that only valid temperature information in the cell state is passed to the next layer or as the final system output. In this way, the output gate ensures that only the temperature data that is most critical to temperature control can affect the next decision, enhancing the system's responsiveness and stability to temperature changes.

[0066]

[0067] Among them, t Indicates the current hidden state h t In the temperature monitoring application of the joint module, the output gate is used to adjust the cell state C t The temperature information in the W ensures that only data meaningful for temperature control can be passed to the next layer or output. o Represents the weight matrix of the output gate, which controls the hidden state h at the previous moment t-1 and the current input temperature data x t Impact on the output gate. Through weighted summation, the weight matrix determines the importance of historical temperature information and current temperature input in adjusting the output. o Represents the bias term of the output gate, which adjusts the output of the output gate to ensure that the system can better fit the actual temperature data changes during network training. This adjustment process helps the model optimize its response to temperature data and ensures that the temperature changes of the system are accurately captured.

[0068] The fixed flange 6 is far from the output end. Since the joint module often generates large dynamic impact and vibration when running at high speed, the acceleration sensor 92 is pasted at this position, which can more accurately perceive these mechanical changes and timely feedback the dynamic state of the joint module. The acceleration sensor 92 is based on micro-electromechanical system (MEMS) technology and uses the capacitive principle. The deformation of its cantilever beam causes the resistance value to change, thereby changing the analog voltage and realizing the acquisition of the acceleration signal of the fixed flange 6. The acceleration signal is transmitted to the control module 8 through the digital interface for real-time monitoring of the dynamic motion state and external vibration of the joint. The acceleration sensor 92 is connected to the control module 8 through the I2C or SPI protocol to transmit the acceleration signal to the control module 8. The acceleration sensor 92 can accurately perceive impact and vibration, and help the control system to quickly adjust the operation strategy through the feedback signal, reduce the impact of external disturbances on the system, thereby significantly improving the dynamic response capability and operation stability of the module.

[0069] In the process of the acceleration sensor 92 collecting acceleration signals, in order to improve the sampling accuracy of the signal, the control module 8 first uses adaptive empirical mode decomposition (EMD) to decompose the original acceleration signal. The original signal refers to the vibration data collected by the acceleration sensor during the operation of the joint module. These signals reflect the vibration conditions of the various components of the joint module, including impact, friction and other factors. During the decomposition process, the EMD algorithm decomposes the acceleration signal into several intrinsic mode functions (IMFs), each of which represents the local vibration mode of the joint module on different time scales. For example, rapid impact vibrations may occur when components collide or operate violently, while continuous low-frequency vibrations may be caused by long-term operation or load. Through these IMFs, the different working states of the various components of the joint module and potential abnormal vibrations can be effectively identified.

[0070] EMD decomposes the input signal into several eigenmode functions and a residual, which is Formula 5.

[0071]

[0072] Where X(t) represents the input vibration signal, IMF m (t) represents the eigenmode function of the mth input vibration signal, r M (t) represents the residual, and M represents the total number of input vibration signals. The process of extracting IMF is as follows: Figure 8 shown.

[0073] (1) Signal preprocessing: De-noise and normalize the raw acceleration signal collected from the acceleration sensor to ensure that the signal quality is suitable for subsequent analysis. In the joint module, this process removes irrelevant information caused by sensor noise or external environmental interference. Common preprocessing methods include high-pass filtering to remove low-frequency noise (such as equipment drift); low-pass filtering to remove high-frequency noise (such as electrical interference); and wavelet denoising to remove noise from instantaneous impact or short-term vibration.

[0074] (2) Local extreme point extraction: All local maximum points and local minimum points are extracted from the preprocessed acceleration signal. These points represent the key peaks in the vibration signal of the joint module, such as the start or end position of the vibration impact. To ensure the accurate extraction of these extreme values, cubic spline interpolation can be used to smooth the local extreme points in the signal to further enhance the accuracy and stability of the signal. By extracting extreme points, abnormal vibration or impact of the joint module can be effectively identified, helping to diagnose potential faults or abnormal operating conditions.

[0075] (3) Constructing the envelope: By calculating the local maximum point e upper (t) and the local minimum point e lower (t) Spline interpolation is performed respectively to construct the upper envelope and lower envelope of the signal. In the acceleration signal processing of the joint module, the upper envelope and the lower envelope reflect the upper and lower limits of the oscillation amplitude of the signal. Through the construction of the envelope, the vibration trend of the signal can be clarified and the range of change of the vibration amplitude in the module can be identified. The upper envelope and the lower envelope provide clear boundaries for subsequent signal analysis, helping to monitor the dynamic response of the joint module, especially the detection of changes in vibration intensity and sudden impact.

[0076] (4) Calculate the envelope average m(t): Calculate the average of the upper envelope and the lower envelope to obtain the local average envelope of the signal. The formula is as follows. In the acceleration signal processing of the joint module, the local average envelope reflects the low-frequency trend of the acceleration signal and helps capture the main change mode of the joint module in normal operation. By calculating the envelope average, the overall fluctuation trend of the signal and the long-term dynamic response of the system can be identified.

[0077]

[0078] (5) Envelope removal: Subtract the local average envelope from the original acceleration signal to obtain the intermediate signal h(t), which is the high-frequency part of the signal, as shown in Formula 7. The process of removing the envelope helps to remove the low-frequency trend components in the signal and highlight the transient vibration characteristics in the joint module. This process allows high-frequency vibration signals to be clearly displayed, which helps to analyze the dynamic changes caused by impact or rapid vibration.

[0079] h(t)=X(t)-m(t) (7)

[0080] Among them, the original signal X(t) represents the vibration data collected by the acceleration sensor, the mean signal m(t) is obtained by calculating the envelope average value, which reflects the low-frequency trend of the signal, and the intermediate signal h(t) is the signal after removing the trend, highlighting the high-frequency vibration components of the joint module, helping to identify rapidly changing vibration patterns or impacts.

[0081] (6) Iteration: If the intermediate signal h(t) does not meet the definition of IMF, then h(t) is used as the new input signal g(t) and steps (2) to (5) are repeated. If the intermediate signal h(t) meets the definition of IMF, then h(t) is extracted as an IMF component. Then X(t)-h(t) is used as the new input signal g(t) and steps (2) to (5) are repeated. If the intermediate signal h(t) is a monotonic function or a signal below the set frequency, then h(t) is assigned to r M (t), and the iteration process ends at the same time.

[0082] (7) Decomposition results: After multiple decompositions, the original acceleration signal is finally decomposed into multiple intrinsic mode functions (IMFs) and a residual term. Each IMF represents the oscillation component of the acceleration signal in different frequency bands, reflecting the vibration mode of the joint module under different working conditions. For example, low-frequency IMFs may correspond to continuous low-frequency vibrations of the joint module, while high-frequency IMFs may correspond to high-frequency vibrations caused by impacts or sudden events. The residual term represents the components in the signal that cannot be classified into any IMF, usually containing long-term trends or noise in the signal. By decomposing these IMFs, the dynamic characteristics of the joint module can be effectively analyzed and fault diagnosis can be performed.

[0083] (8) Subsequent analysis: Each IMF can be further processed through time-frequency analysis (such as Hilbert transform) to extract the frequency characteristics, energy distribution and time-frequency localization information of the acceleration signal. In the application of joint modules, the Hilbert transform can calculate the instantaneous frequency and amplitude of each IMF, revealing the frequency change and energy distribution of the vibration signal. This analysis provides more detailed time-frequency characteristics for the diagnosis, analysis and monitoring of impact vibration, enabling the system to accurately identify abnormal conditions caused by impact or vibration in the joint module, thereby optimizing the fault diagnosis and early warning mechanism.

[0084] like Fig. 9As shown, the encoder 93 adopts the absolute value encoding principle and samples the rotation displacement in real time through the optical encoder disk 931. The optical encoder disk 931 works in conjunction with the signal processing unit 932 to convert the collected optical signal into a digital signal to achieve high-precision detection of the rotation angle. The signal is then transmitted to the control module 8 through the interface module 933 to ensure accurate position information feedback.

[0085] like Fig.10 As shown, after the external power supply is turned on, the control module 8 is powered on and sends a control command to the drive module 7. If the drive current output by the drive module 7 is not zero, the current drives the power module 3 to rotate. If the drive current output by the drive module 7 is zero, the brake module 5 receives a power-off command and then achieves precise braking of the power module 3 through an electromagnetic attraction mechanism. The power module 3 outputs mechanical motion to the harmonic reducer 1 through the main shaft 10, achieving large torque output and ensuring stable operation of the system under high load conditions.

[0086] The driving module 7, the control module 8 and the perception module 9 work together precisely to realize the efficient operation of the sensor-driven integrated joint module. The control module 8 plays a core role in this process, and performs analysis and adjustment based on real-time feedback data. By integrating the LSTM algorithm, the control module 8 can predict and analyze the long-term dependence of temperature data and accurately control the dynamic response of the joint module. At the same time, combined with the adaptive empirical mode decomposition (EMD) algorithm, the control module can effectively decompose the acceleration signal and identify the key vibration mode in the signal, thereby adjusting the output of the driving module in real time to cope with the rapid changes in the system. Through these advanced algorithms, the control module can more accurately adjust the behavior of the driving module 7, achieve efficient and stable motion control, and ensure the optimal performance of the joint module under various working environments. According to the instructions of the control module 8, the driving module 7 accurately controls the output and torque transmission of the power module 3, thereby optimizing the operating efficiency of the joint module and ensuring efficient and stable operation under different working conditions. The perception module 9 includes a temperature sensor 91, an acceleration sensor 92 and an encoder 93, which respectively monitor the temperature change, vibration and motion state of the joint module in real time and provide key feedback information. The temperature sensor 91 is responsible for monitoring the temperature changes in the entire joint module space, and provides real-time feedback on the temperature status of the system to prevent the performance of the equipment from being degraded or key components from being damaged due to abnormal temperature. In contrast, the thermistor 333 integrated in the power module 3 is specifically used to monitor the temperature of the stator 31 coil, and feeds the data back to the control module 8, providing an important basis for local thermal management. The two temperature sensors work together to ensure the global and local thermal stability of the joint module. The acceleration sensor 92 is used to monitor whether the joint module has abnormal vibrations, and provides real-time impact and vibration data to ensure that the system is not subject to abnormal external interference during operation, thereby ensuring the stability of the system. The encoder 93 provides high-precision position and velocity feedback to ensure that the motion trajectory of the joint module is accurate and meets the predetermined motion requirements.

[0087] Through this precise collaborative work, the perception module 9 provides real-time data support for the control module 8, and the control module 8 adjusts the output of the drive module 7 based on this data, thereby achieving high-precision control, dynamic response and intelligent operation of the joint module under complex working conditions. The efficient collaboration of each module significantly improves the response speed, stability and intelligence level of the system, ensuring the accuracy and safety of the joint module in high-load and high-speed operation.

[0088] like Fig.11As shown, the housing 2 is composed of a joint housing 21, a joint rear cover 22 and a first bearing 23. Among them, the joint housing 21 is located on the left side, and the joint rear cover 22 is located on the right side, and the two are fastened together by four evenly distributed screws. The first bearing 23 is connected to the joint housing 21 by interference fit. The joint housing 21 and the joint rear cover 22 form an integral support structure to ensure that the sensor-driven-control integrated module has sufficient strength and rigidity to withstand the mechanical loads under various working environments. An observation hole is provided on the joint rear cover 22, which is convenient for the user to check the operating status inside the joint module in real time, promptly discover and respond to potential emergencies, and further enhance the reliability and safety of the overall system. On the left side of the joint housing 21, a first bearing 23 is arranged near the wave generator 11, which effectively supports the main shaft 10 to ensure that the power is smoothly and accurately transmitted to the harmonic reducer 1.

[0089] Each functional module is reasonably configured according to the principles of compact structure, optimized performance and convenient maintenance. The harmonic reducer 1 is located at the leftmost end of the module, and high-precision torque transmission is achieved through the meshing of the flexible wheel 12 and the rigid wheel 13. The stator 31 of the power module is bonded to the inner wall of the joint housing 21, and the rotor 32 is fixed on the main shaft 10, which is closely linked with the harmonic reducer 1 to ensure efficient and stable power output. The brake module 5 is installed on the right side of the power module 3, and precise stop control is achieved through electromagnetic braking. The drive module 7 and the control module 8 are coaxially arranged, and the axial dimension is effectively shortened through close combination, while optimizing the internal space utilization. The encoder 93 in the perception module 9 is located at the rear end of the main shaft 10 to provide high-precision position feedback; the temperature sensor 91 is bonded to the left end face of the power module rear cover 4 for real-time monitoring of the operating temperature; the acceleration sensor 92 is fixed to the right end face of the fixed flange 6 to monitor impact and vibration. The circuits of each module adopt a layered routing scheme, and the signal line and the power line are arranged separately, which not only reduces signal interference but also improves electrical reliability. The design of the wiring trough 41 ensures reasonable distribution and efficient management of the lines, thereby achieving organic integration between modules and optimal coordination of functions.

[0090] As described above, the present invention can be better implemented. The above embodiments are only preferred embodiments of the present invention and are not intended to limit the scope of implementation of the present invention; that is, all equivalent changes and modifications made according to the content of the present invention are covered by the scope of protection required by the claims of the present invention.

Claims

1. A sensor-driven-controlled integrated joint module, characterized in that: include: A housing for mounting a harmonic reducer, a power module, a power module rear cover, a brake module, a fixing flange, a drive module, a control module, a sensing module and a main shaft; A main shaft, rotatably supported on the housing and the rear cover of the power module; A power module, used for driving the rotation of the main shaft by means of electromagnetic excitation; The power module rear cover is provided with a wiring slot and a gap between the power module; A brake module, used to generate a braking force to lock the main shaft; A fixed flange with wiring slots and positioning for the drive module and control module; The sensing module is used to detect the temperature, vibration and position signals of the joint module and transmit them to the control module; The control module is used to control the power module, the brake module and realize the regulation of the position, speed and torque of the joint module; The harmonic reducer is connected to the main shaft, passes the power module through the main shaft and increases the output torque for output.

2. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The harmonic reducer consists of a wave generator, a flexible wheel and a rigid wheel; the rigid wheel is fixed to the housing, the wave generator is connected to the main shaft and supported in the steel wheel; the flexible wheel is supported in the rigid wheel and cooperates with the rigid wheel.

3. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The wave generator is composed of an elliptical cam and a flexible bearing; the flexible wheel is composed of an external gear and a connecting flange, and the rigid wheel includes a rigid gear ring and a rigid wheel fixing seat; the elliptical cam is sleeved with the main shaft, the elliptical cam is supported in the rigid gear ring through a flexible bearing, the rigid gear ring is fixed in the rigid wheel fixing seat, the rigid wheel fixing seat is connected to the housing, the external gear is fixed to the connecting flange, and is used in conjunction with the rigid gear ring.

4. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The power module consists of a stator, a rotor and an integrated circuit board; the stator is fixed to the housing, and the rotor is fixed to the main shaft; the integrated circuit board provides power control and signal processing functions for the power module, and is provided with a Hall sensor and a thermistor; they are respectively used to monitor the position of the rotor and the temperature of the power module in real time.

5. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The power module rear cover includes a second bearing and a fixing frame; the fixing frame is provided with a wiring groove, and the second bearing and the inner hole in the center of the fixing frame are connected by an interference fit to support the main shaft.

6. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The brake module consists of an electromagnet, an armature, a friction plate, a brake seat and a brake housing; the electromagnet is fixed to the rear cover of the power module and is connected to the drive module through two shielded communication lines; the electromagnet includes a coil and a spring, the armature is connected to the spring, and the friction plate is placed between the armature and the brake housing; an interference fit is adopted between the square outer wall of the brake seat and the square inner hole of the friction plate, and the inner hole of the brake seat is connected to the main shaft.

7. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The sensing module is composed of a temperature sensor, an acceleration sensor and an encoder; the temperature sensor is fixed on the end face of the rear cover of the power module. The control module processes the temperature data based on the LSTM neural network algorithm to provide real-time feedback on the temperature change of the joint module. The LSTM neural network includes: The forget gate is used to decide which temperature information should be forgotten from the cell state; Input gate, used to control the influence of current input information on updating cell state; The output gate is used to determine what information should be output from the hidden state at the current moment; The acceleration sensor is fixed on the end face of the fixed flange to detect the impact and vibration data of the joint module. The control module uses the empirical mode decomposition algorithm to analyze the vibration signal, including: (1) Signal preprocessing: denoising and normalizing the raw acceleration signal collected from the acceleration sensor; (2) Local extreme point extraction: extract all local maximum points and local minimum points from the preprocessed acceleration signal; (3) Constructing the envelope: By calculating the local maximum point e upper (t) and the local minimum point e lower (t) performing spline interpolation to construct the upper envelope and lower envelope of the signal; (4) Calculate the envelope average m(t): Calculate the average of the upper envelope and the lower envelope to obtain the local average envelope of the signal; (5) Envelope removal: Subtract the local average envelope from the original acceleration signal to obtain the intermediate signal h(t); (6) If the intermediate signal h(t) does not satisfy the definition of IMF, h(t) is used as the new input signal g(t) and steps (2) to (5) are repeated; If the intermediate signal h(t) satisfies the definition of IMF, h(t) is extracted as an IMF component, and X(t)-h(t) is used as the new input signal g(t), and steps (2) to (5) are repeated; If the intermediate signal h(t) is a monotonic function or a signal below the set frequency, h(t) is assigned to the residual and the iteration process ends; (7) Decomposition results: The original acceleration signal is finally decomposed into multiple IMFs and a residual term. Each IMF represents the oscillation component of the acceleration signal in different frequency bands, reflecting the vibration mode of the joint module under different working conditions; (8) Each IMF can be further processed by time-frequency analysis to extract the frequency characteristics, energy distribution and time-frequency localization information of the acceleration signal; The encoder is fixed to the spindle and is responsible for measuring the position and speed of the spindle.

8. The sensor-driven-controlled integrated joint module according to claim 1, characterized in that: The driving module, the control module and the encoder are fixed to each other by three studs evenly distributed along the circumference.

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