Sensor integrated intelligent harmonic reducer and flexible robot joint system

Abstract

The invention relates to the technical field of precision transmission and robot joints, and particularly discloses a sensor integrated intelligent harmonic reducer and a flexible robot joint system.The sensor integrated intelligent harmonic reducer comprises a rotating shaft, a wave generator, a flexible wheel assembly, a steel wheel assembly, a bearing pack and an integrated sensor module; the rotating shaft is used for being connected with a motor output shaft; the wave generator comprises a cam part and a mounting part; the flexible wheel assembly comprises a flexible wheel and a mounting disc, the flexible wheel is provided with a thin-wall tooth part, a thick-wall tooth part and a rigid connecting part, and the thick-wall tooth part and the rigid connecting part are in transition connection to the two sides of the thin-wall tooth part respectively; the steel wheel assembly comprises a rigid wheel, an inner gear and a flange plate. The bearing pack comprises a first flexible bearing, a second flexible bearing and a rigid bearing which are arranged in the axial direction of the rotating shaft, and the rigid bearing is located between the first flexible bearing and the second flexible bearing; and the integrated sensor module is arranged on the thick-wall tooth part or the rigid connecting part of the flexible gear assembly.

Description

Technical Field

[0001] The present invention relates to the technical field of precision transmission and robot joints, and in particular discloses a sensor-integrated intelligent harmonic reducer and a flexible robot joint system. Background Art

[0002] In the fields of modern industrial automation and robotics, as a core transmission component, the performance of a harmonic reducer directly affects the operation quality of equipment. Traditional harmonic reducers have problems such as insufficient transmission accuracy and poor structural stability. Single-stage reduction is difficult to meet the requirements of high precision and large torque, and there is a lack of effective monitoring means, making it impossible to real-time grasp the deformation and meshing state of the internal flexible gear, which easily leads to faults and delayed maintenance. At the same time, in a flexible robot joint system, the integration degree of each component is low, the control response is slow, the position detection error of a conventional encoder accumulates greatly, and the braking reliability of a brake system is poor, making it difficult to adapt to complex working environments. In addition, the existing system lacks the ability of adaptive adjustment and cannot dynamically optimize operation parameters according to load changes, resulting in high energy consumption and low efficiency. Therefore, there is an urgent need to develop a harmonic reducer and a flexible robot joint system with high precision, intelligent monitoring, and adaptive control functions to improve the overall performance and reliability and meet the increasing technical requirements of the industry. Summary of the Invention

[0003] In order to overcome the disadvantages and deficiencies existing in the prior art, the purpose of the present invention is to provide a sensor-integrated intelligent harmonic reducer and a flexible robot joint system.

[0004] To achieve the above purpose, a sensor-integrated intelligent harmonic reducer of the present invention includes a rotating shaft, a wave generator, a flexible gear assembly, a rigid gear assembly, a bearing group, and an integrated sensor module; the rotating shaft is used for connecting with the output shaft of a motor; the wave generator includes a cam portion and a mounting portion; the flexible gear assembly includes a flexible gear and a mounting disk, the flexible gear has a thin-wall tooth portion, a thick-wall tooth portion, and a rigid connection portion, and the thick-wall tooth portion and the rigid connection portion are respectively transitionally connected to both sides of the thin-wall tooth portion; the rigid gear assembly includes a rigid gear, an internal gear, and a flange disk; the bearing group includes a first flexible bearing, a second flexible bearing, and a rigid bearing arranged axially along the rotating shaft, and the rigid bearing is located between the first flexible bearing and the second flexible bearing; the thin-wall tooth portion abuts against the outer periphery of the cam portion, the thick-wall tooth portion abuts against the outer ring of the rigid bearing, and the rigid connection portion is axially fixed to the mounting disk and the mounting portion respectively; the rigid gear is axially fixed to the internal gear, the rigid gear is radially limited by the mounting disk and the flexible gear, the internal gear is axially fixed to the flange disk, and the flange disk abuts against the outer ring of the second flexible bearing; the integrated sensor module is arranged on the thick-wall tooth portion or the rigid connection portion of the flexible gear assembly for real-time monitoring of the deformation and meshing state of the flexible gear and signal connection with an external control system.

[0005] Furthermore, both the thin-walled tooth part and the thick-walled tooth part are cylindrical structures, and the wall thickness of the thick-walled tooth part is greater than that of the thin-walled tooth part. The rigid connection part is a disc-shaped structure radially extending outward circumferentially from one end of the cylindrical structure. The thick-walled tooth part is used to inhibit excessive deformation of the thin-walled tooth part during the meshing process.

[0006] Furthermore, the inner circumference of the cam part abuts against the outer ring of the first flexible bearing. The mounting part is a disc-shaped structure radially extending outward from one end of the cam part. The mounting part is fixedly connected to the motor output shaft to transmit torque.

[0007] Furthermore, external tooth structures are provided on the outer circumferences of both the thin-walled tooth part and the thick-walled tooth part, and internal tooth structures are provided on the inner circumferences of both the rigid wheel and the internal gear. The thin-walled tooth part meshes with the internal tooth structure of the rigid wheel to achieve the first-stage deceleration, and the thick-walled tooth part meshes with the internal tooth structure of the internal gear to achieve the second-stage deceleration.

[0008] Furthermore, the first flexible bearing is arranged close to the motor output shaft to bear the radial load, the second flexible bearing is arranged away from the motor output shaft to provide axial support, and the rigid bearing is located between the two.

[0009] Furthermore, the integrated sensor module communicates with the external control system through wireless transmission or wired connection.

[0010] A flexible robot joint system includes a joint body, a frameless motor, a brake assembly, an encoder disc assembly, a control system, and a carrier disc assembly. The carrier disc assembly has a first carrier disc and a second carrier disc mounted on the joint body. The frameless motor is arranged inside the joint body, and its output shaft is connected to the end of the rotating shaft. A transmission shaft is arranged inside the output shaft. One end of the transmission shaft is rotatably connected to the joint body, and the other end protrudes out of the output shaft of the frameless motor and is rotatably connected to the second carrier disc. The brake assembly includes a dynamic friction member, a static friction member, a disc spring, and a driver. The driver axially pushes the static friction member through a guide pin to drive the disc spring to abut against the dynamic friction member to achieve braking. The dynamic friction member is arranged between the first carrier disc and the disc spring. The first carrier disc is provided with a return spring that cooperates with the guide pin. The encoder disc assembly includes an input encoder disc arranged on the transmission shaft and a corresponding encoder. The encoder is signal-connected to the control system and is used to feedback the joint rotation angle position. The control system is integrated on the second carrier disc and is electrically connected to the integrated sensor module and the encoder to achieve synchronous calibration and closed-loop control of the flexible wheel deformation data and the joint position.

[0011] Further, the stator winding and the rotor of the frameless motor are integrated on the output shaft, the transmission shaft passes through the output shaft and is coaxially connected to the rotating shaft of the harmonic reducer; a shaft platform is provided on one side of the static friction member of the brake assembly, and an adjustable pressing force is formed with the dynamic friction member through a disc spring on the other side. The driver is arranged on the second bearing disc, and the driving guide pin pushes the static friction member to move axially to achieve braking and release.

[0012] Further, a bearing ring is installed on the other side of the shaft platform, and an annular gap is provided between the input code disc and the bearing ring. The encoder is a multi-turn absolute magnetic encoder, which detects the absolute rotation angle of the transmission shaft through magnetic poles and Hall sensors, and feeds the signal back to the control system; the integrated sensor module includes a strain gauge or a piezoelectric film, and its output signal is fused with the encoder data for dynamically adjusting the stiffness of the harmonic reducer and the joint output torque.

[0013] Further, the first bearing disc and the second bearing disc support the transmission shaft through rigid bearings to form a double-end fixed structure; the control algorithm of the control system includes model predictive control, and based on the deformation data of the harmonic reducer and the rotation angle signal fed back by the encoder, the torque output and the motion trajectory of the joint are optimized in real time.

[0014] Advantages of the present invention:

[0015] (1) High precision and stability: The harmonic reducer adopts two-stage reduction and optimized bearing layout. The thin-walled tooth part and the thick-walled tooth part cooperate to suppress excessive deformation. The bearing group is reasonably distributed to bear radial and axial loads. Combined with the double-end fixed structure, the transmission precision and structural stability are improved, vibration and noise are reduced, and the equipment life is prolonged.

[0016] (2) Intelligent monitoring and adaptive control: The integrated sensor module monitors the deformation and meshing state of the flexspline in real time, interacts with the control system through wireless or wired transmission, and combines the feedback data of the encoder to realize synchronous calibration and closed-loop control of the flexspline deformation and the joint position, dynamically adjust the stiffness and torque, and adapt to complex working conditions.

[0017] (3) High-efficiency integration and safety and reliability: The integrated design of the frameless motor simplifies the structure, improves the space utilization rate and the power transmission efficiency; the brake assembly provides precise braking to ensure safety; the multi-turn absolute magnetic encoder realizes high-precision position detection, and the model predictive control algorithm optimizes the torque output and the motion trajectory, enhancing the intelligent level and the overall performance of the system. Description of the drawings

[0018] Figure 1 It is an overall sectional view of an intelligent harmonic reducer and a flexible robot joint system with integrated sensors according to the present invention;

[0019] Figure 2 It is a schematic structural diagram of the present invention with the joint body removed;

[0020] Figure 3 Cross-sectional view of the harmonic reducer of the present invention;

[0021] Figure 4 Exploded view of the harmonic reducer of the present invention;[[ID=�]]

[0022] Figure 5 Schematic diagram of the partial structure of the present invention;

[0023] Figure 6 Partial cross-sectional view of the present invention;

[0024] Figure 7 Schematic diagram of the structure of the flexible wheel of the present invention.

[0025] Reference numerals include: 10, rotating shaft; 11, wave generator; 111, cam portion; 112, mounting portion; 12, flexspline assembly; 121, flexible wheel; 122, mounting disc; 123, thin-walled tooth portion; 124, thick-walled tooth portion; 125, rigid connection portion; 13, rigid wheel assembly; 131, rigid wheel; 132, internal gear; 133, flange; 14, bearing group; 141, first flexible bearing; 142, rigid bearing; 143, second flexible bearing; 20, joint body; 30, frameless motor; 31, stator winding; 32, rotor; 40, brake assembly; 41, dynamic friction member; 42, static friction member; 43, disc spring; 44, driver; 45, guide pin; 46, return spring; 50, code disc assembly; 51, input code disc; 52, encoder; 53, shaft table; 54, carrier ring; 60, control system; 70, carrier disc assembly; 71, first carrier disc; 72, second carrier disc; 80, transmission shaft. Detailed implementation manners

[0026] To further illustrate the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation manners, structures, features and their effects of the present invention as follows.

[0027] Please refer to Figures 1 to 6As shown in the figure, a sensor-integrated intelligent harmonic reducer of the present invention includes a rotating shaft 10, a wave generator 11, a flexspline assembly 12, a rigid gear assembly 13, a bearing group 14, and an integrated sensor module; the rotating shaft 10 is used to connect with the output shaft of the motor; the wave generator 11 includes a cam portion 111 and a mounting portion 112; the flexspline assembly 12 includes a flexible gear 121 and a mounting disk 122, the flexible gear 121 has a thin-wall tooth portion 123, a thick-wall tooth portion 124, and a rigid connection portion 125, and the thick-wall tooth portion 124 and the rigid connection portion 125 are respectively transitionally connected to both sides of the thin-wall tooth portion 123; the rigid gear assembly 13 includes a rigid gear 131, an internal gear 132, and a flange disk 133; the bearing group 14 includes a first flexible bearing 141, a second flexible bearing 143, and a rigid bearing 142 arranged axially along the rotating shaft 10, wherein the rigid bearing 142 is located between the first flexible bearing 141 and the second flexible bearing 143; the thin-wall tooth portion 123 abuts against the outer periphery of the cam portion 111, the thick-wall tooth portion 124 abuts against the outer ring of the rigid bearing 142, and the rigid connection portion 125 is axially fixed to the mounting disk 122 and the mounting portion 112 respectively; the rigid gear 131 is axially fixed to the internal gear 132, the rigid gear 131 is radially limited by the mounting disk 122 and the flexible gear 121, the internal gear 132 is axially fixed to the flange disk 133, and the flange disk 133 abuts against the outer ring of the second flexible bearing 143; the integrated sensor module is arranged on the thick-wall tooth portion 124 or the rigid connection portion 125 of the flexspline assembly 12, and is used to monitor the flexspline deformation and meshing state in real time, and is signal-connected to an external control system 60.

[0028] During actual use, the rotating shaft 10 is used to connect with the output shaft of the motor, which can effectively transmit power; the structural design of the cam portion 111 and the mounting portion 112 of the wave generator 11 is reasonable; the transitional connection of the thin-wall tooth portion 123, the thick-wall tooth portion 124, and the rigid connection portion 125 of the flexible gear 121 in the flexspline assembly 12 not only ensures the flexible deformation of the flexspline to achieve harmonic drive, but also provides certain rigidity and structural strength; the arrangement of the first flexible bearing 141, the second flexible bearing 143, and the rigid bearing 142 of the bearing group 14 axially along the rotating shaft 10, wherein the rigid bearing 142 is located between the first flexible bearing 141 and the second flexible bearing 143, optimizes the force distribution of the bearings and improves the overall stability and reliability.

[0029] The thin-walled tooth part 123 abuts against the outer periphery of the cam part 111, the thick-walled tooth part 124 abuts against the outer ring of the rigid bearing 142, the rigid connection part 125 is axially fixed to the mounting disc 122 and the mounting part 112 respectively, and in the steel wheel assembly 13, the rigid wheel 131 is axially fixed to the internal gear 132. The rigid wheel 131 is radially limited by the mounting disc 122 and the flexible wheel 121, the internal gear 132 is axially fixed to the flange disc 133, and the flange disc 133 abuts against the outer ring of the second flexible bearing 143. This connection method makes the assembly of each component compact and the positioning accurate, ensuring the accuracy and stability of the transmission; the integrated sensor module is arranged on the thick-walled tooth part 124 or the rigid connection part 125 of the flexspline assembly 12, which can monitor the deformation and meshing state of the flexspline in real time, and is signal-connected to the external control system 60, realizing the intelligent monitoring and control of the operation state of the harmonic reducer, facilitating the timely discovery of problems and adjustment, improving the operation efficiency and reliability of the equipment, and at the same time providing strong data support for the maintenance and fault diagnosis of the equipment.

[0030] Specifically, both the thin-walled tooth part 123 and the thick-walled tooth part 124 are cylindrical structures, and the wall thickness of the thick-walled tooth part 124 is greater than that of the thin-walled tooth part 123. The rigid connection part 125 is a disc-shaped structure radially extending from one end of the cylindrical structure to the outer periphery. The thick-walled tooth part 124 suppresses the excessive deformation of the thin-walled tooth part 123 during the meshing process through its enhanced rigidity.

[0031] In actual use, the thin-walled tooth part 123 and the thick-walled tooth part 124 adopt cylindrical structures, and the wall thickness of the thick-walled tooth part 124 is greater than that of the thin-walled tooth part 123. This structural design is reasonable and can give full play to their respective characteristics. The thick-walled tooth part 124 can effectively suppress the excessive deformation of the thin-walled tooth part 123 during the meshing process through its enhanced rigidity, ensuring that the thin-walled tooth part 123 works within the normal deformation range, thus ensuring the normal meshing transmission of the harmonic reducer and improving the transmission accuracy and stability; the rigid connection part 125 is designed as a disc-shaped structure radially extending from one end of the cylindrical structure to the outer periphery, which is beneficial to the connection and fixation of the flexspline assembly 12 with other components such as the mounting disc 122 and the mounting part 112, making the installation and positioning of the entire flexspline assembly 12 in the harmonic reducer more reliable, further enhancing the stability and reliability of the overall structure of the harmonic reducer, and improving the working performance and service life of the equipment.

[0032] Specifically, the inner periphery of the cam part 111 abuts against the outer ring of the first flexible bearing 141, the mounting part 112 is a disc-shaped structure radially extending from one end of the cam part 111 to the outer side, and the mounting part 112 is fixedly connected to the motor output shaft to transmit torque.

[0033] During actual use, the inner circumference of the cam portion 111 abuts against the outer circumference of the first flexible bearing 141. Through the elastic deformation and adaptation characteristics of the flexible bearing, it can effectively buffer the stress during the rotation of the cam, reduce wear, ensure the stable fit between the wave generator 11 and the bearing, and reduce vibration and noise during the transmission process. The installation portion 112 adopts a disc-shaped structure and extends radially outward from one end of the cam portion 111 and is fixedly connected to the motor output shaft. This structure increases the connection contact area, enhances the stability and reliability of torque transmission, can effectively avoid power transmission loss caused by connection looseness, and ensures that the motor torque can be efficiently and accurately transmitted to the wave generator 11, thereby driving the entire harmonic reducer to operate smoothly and improving the power transmission efficiency and overall performance of the harmonic reducer.

[0034] Specifically, external tooth structures are provided on the outer circumferences of both the thin-walled tooth portion 123 and the thick-walled tooth portion 124, and internal tooth structures are provided on the inner circumferences of both the rigid gear 131 and the internal gear 132. The thin-walled tooth portion 123 meshes with the internal tooth structure of the rigid gear 131 to achieve the first-stage reduction, and the thick-walled tooth portion 124 meshes with the internal tooth structure of the internal gear 132 to achieve the second-stage reduction.

[0035] During actual use, the thin-walled tooth portion 123 meshes with the internal tooth structure of the rigid gear 131, and the thick-walled tooth portion 124 meshes with the internal tooth structure of the internal gear 132 respectively to achieve two-stage reduction, which can greatly increase the reduction ratio of the harmonic reducer and meet the transmission requirements of high precision and large torque. The two-stage reduction structure disperses the load pressure of single-stage transmission, reduces the wear degree of a single meshing part, and extends the service life of the harmonic reducer. Through two-stage reduction, the output speed and torque can be more accurately controlled, improving the smoothness and transmission accuracy of the transmission system. The cooperation between the external tooth structure and the internal tooth structure increases the contact area between the gears, enhances the stability and reliability of the transmission, and can also effectively reduce the vibration and noise generated during the transmission process, improving the overall performance and use experience of the equipment operation.

[0036] Specifically, the first flexible bearing 141 is arranged close to the motor output shaft to bear the radial load, the second flexible bearing 143 is arranged away from the motor output shaft to provide axial support, and the rigid bearing 142 is located between the two.

[0037] In actual use, the first flexible bearing 141 is arranged close to the motor output shaft, which can directly bear the radial load brought by the motor output, give full play to the characteristics of the flexible bearing to adapt to deformation, and reduce the radial offset and vibration of the shafting; the second flexible bearing 143 is arranged away from the motor output shaft, which can effectively provide axial support, prevent the rotation shaft 10 from moving axially, and ensure the axial positioning accuracy of the transmission components; the rigid bearing 142 is located between the two, enhancing the rigidity of the entire bearing group 14, improving the structural stability of the harmonic reducer when bearing complex loads, effectively reducing the deformation risk caused by insufficient bearing rigidity. The three work together to optimize the bearing capacity of the bearing group 14 for radial and axial loads, improve the running stability, reliability and transmission accuracy of the harmonic reducer, and extend the service life of the equipment.

[0038] Specifically, the integrated sensor module communicates with the external control system 60 through wireless transmission or wired connection.

[0039] In actual use, the integrated sensor module communicates with the external control system 60 through wireless transmission or wired connection, greatly enhancing the flexibility and applicability of the harmonic reducer monitoring system. Wireless transmission gets rid of the cable restraint, facilitating the use of the equipment in complex environments or mobile working conditions, and reducing the installation and maintenance costs; wired connection has the advantages of stable transmission and strong anti-interference ability, ensuring accurate and reliable data transmission. Both can quickly and accurately feedback the data of the flexspline deformation and meshing state collected by the sensor in real time to the external control system 60, realizing the real-time monitoring of the running state of the harmonic reducer, and then realizing adaptive adjustment according to the data change, timely optimizing the equipment operation parameters, preventing faults from occurring, improving the operation efficiency, reliability and intelligent level of the equipment, and providing strong support for the full life cycle management of the equipment.

[0040] A flexible robot joint system includes a joint body 20, a frameless motor 30, a brake assembly 40, an encoder disk assembly 50, a control system 60 and a carrier disk assembly 70; the carrier disk assembly 70 has a first carrier disk 71 and a second carrier disk 72 mounted on the joint body 20, the frameless motor 30 is arranged inside the joint body 20, its output shaft is connected to the end of the rotating shaft 10, a transmission shaft 80 is arranged inside the output shaft, one end of the transmission shaft 80 is rotatably connected to the joint body 20, and the other end protrudes out of the output shaft of the frameless motor 30 and is rotatably connected to the second carrier disk 72; the brake assembly 40 includes a moving friction member 41, a static friction member 42, a disc spring 43 and a driver 44, the driver 44 axially pushes the static friction member 42 through a guide pin 45 to drive the disc spring 43 to abut against the moving friction member 41 to achieve braking, the moving friction member 41 is arranged between the first carrier disk 71 and the disc spring 43, and the first carrier disk 71 is provided with a return spring 46 that cooperates with the guide pin 45; the encoder disk assembly 50 includes an input encoder disk 51 arranged on the transmission shaft 80 and a corresponding encoder 52, the encoder 52 is signal-connected to the control system 60 and is used to feedback the joint rotation angle position; the control system 60 is integrated on the second carrier disk 72 and is electrically connected to the integrated sensor module and the encoder 52 to realize the synchronous calibration and closed-loop control of the deformation data of the flexible wheel 121 and the joint position.

[0041] During actual use, the setting of the first carrier disk 71 and the second carrier disk 72 in the carrier disk assembly 70 provides a stable installation foundation for each component of the system. The frameless motor 30 is arranged inside the joint body 20 and its output shaft is connected to the end of the rotating shaft 10. The unique design of the transmission shaft 80 enhances the stability and connection reliability of the transmission structure; in the brake assembly 40, the driver 44 pushes the static friction member 42 through the guide pin 45 to drive the disc spring 43 to abut against the moving friction member 41 to achieve braking. The return spring 46 of the first carrier disk 71 cooperates with the guide pin 45 to make the braking and releasing processes accurately controllable, ensuring the safe and reliable operation of the joint; the input encoder disk 51 and the encoder 52 of the encoder disk assembly 50 cooperate to accurately feedback the joint rotation angle position and provide accurate position information for the system; the control system 60 is integrated on the second carrier disk 72 and is electrically connected to the integrated sensor module and the encoder 52 to realize the synchronous calibration and closed-loop control of the deformation data of the flexible wheel 121 and the joint position, improving the accuracy and response speed of the joint motion control, being able to monitor and adjust the joint operation state in real time, enhancing the stability, reliability and intelligent level of the flexible robot joint system, and effectively meeting the high-precision operation requirements under complex working conditions.

[0042] Specifically, the stator winding 31 and the rotor 32 of the frameless motor 30 are integrated on the output shaft, and the transmission shaft 80 penetrates the output shaft and is coaxially connected to the rotating shaft 10 of the harmonic reducer; on one side of the static friction member 42 of the brake assembly 40, there is a shaft platform 53, and on the other side, an adjustable pressing force is formed with the dynamic friction member 41 through a disc spring 43. The driver 44 is arranged on the second bearing plate 72, and the driving guide pin 45 pushes the static friction member 42 to axially move to achieve braking and release.

[0043] During actual use, the frameless motor 30 integrates the stator winding 31 and the rotor 32 on the output shaft, simplifying the motor structure, reducing the overall volume of the joint system, improving the space utilization rate, enhancing the integration degree of the motor and the output shaft at the same time, reducing the energy loss in the transmission link, and improving the power transmission efficiency; the transmission shaft 80 penetrates the output shaft and is coaxially connected to the rotating shaft 10 of the harmonic reducer, ensuring the stability and accuracy of power transmission, reducing the transmission error, and making the joint movement smoother; the shaft platform 53 on one side of the static friction member 42 in the brake assembly 40 is designed for easy installation and positioning, and on the other side, an adjustable pressing force is formed with the dynamic friction member 41 through a disc spring 43, which can flexibly adapt to the braking requirements under different working conditions and ensure the braking effect; the driver 44 is arranged on the second bearing plate 72, and the driving guide pin 45 pushes the static friction member 42 to axially move to achieve braking and release. This layout makes the brake assembly 40 compact in structure, precise in control, and rapid in response, and can effectively ensure the rapid braking of the flexible robot joint in case of emergency, improving the system safety and reliability.

[0044] Specifically, a bearing ring 54 is installed on the other side of the shaft platform 53. There is an annular gap between the input code disc 51 and the bearing ring 54. The encoder 52 is a multi-turn absolute magnetic encoder 52. The absolute rotation angle of the transmission shaft 80 is detected through magnetic poles and Hall sensors, and the signal is fed back to the control system 60; the integrated sensor module includes a strain gauge or a piezoelectric film, and its output signal is fused with the data of the encoder 52 for dynamically adjusting the stiffness of the harmonic reducer and the joint output torque.

[0045] In actual use, a bearing ring 54 is installed on the other side of the shaft table 53, and an annular gap is provided between the bearing ring and the input code disk 51, which not only ensures the stability of the component installation but also provides a reasonable spatial layout for the detection of the encoder 52. The multi-turn absolute magnetic encoder 52 uses magnetic poles and Hall sensors to detect the absolute rotation angle of the transmission shaft 80. Compared with the traditional encoder 52, it does not require repeated calibration and can achieve high-precision and non-cumulative error position detection, ensuring the accuracy and real-time performance of the joint position feedback. The integrated sensor module uses strain gauges or piezoelectric films, which can sensitively sense state information such as the deformation of the flexspline, and fuse its output signal with the data of the encoder 52, which can more comprehensively reflect the operating state of the joint system. Then, according to the data, the stiffness of the harmonic reducer and the output torque of the joint are dynamically adjusted, enabling the joint system to adapt to different loads and working conditions, effectively improving the flexibility, accuracy, and load adaptability of the flexible robot joint system, and enhancing the intelligent level and overall performance of the system.

[0046] Specifically, the first bearing disk 71 and the second bearing disk 72 support the transmission shaft 80 through a rigid bearing 142 to form a double-end fixed structure. The control algorithm of the control system 60 includes model predictive control, which can optimize the torque output and motion trajectory of the joint in real time based on the deformation data of the harmonic reducer and the rotation angle signal feedback by the encoder 52.

[0047] In actual use, the first bearing disk 71 and the second bearing disk 72 support the transmission shaft 80 through a rigid bearing 142 to form a double-end fixed structure, significantly enhancing the structural rigidity and stability of the flexible robot joint system, effectively reducing the sway and offset of the transmission shaft 80 during movement, and improving the accuracy and reliability of joint transmission. The control system 60 uses an algorithm including model predictive control, which combines the deformation data of the harmonic reducer and the rotation angle signal feedback by the encoder 52, and can prospectively optimize the torque output and motion trajectory of the joint in real time. This not only makes the joint movement more accurate and smooth but also can quickly adjust the control strategy according to the actual working conditions, improving the adaptability of the joint to complex tasks, reducing energy consumption, and enhancing the anti-interference ability and robustness of the system, realizing the efficient, intelligent, and stable operation of the flexible robot joint system.

[0048] In this embodiment, the mounting disk 122 and the rigid connection part 125 are axially fixed by bolts or welding to ensure the structural stability of the flexspline assembly 12 during high-speed operation.

[0049] In actual use, the mounting disc 122 and the rigid connection part 125 are axially fixedly installed by bolts or welding, which can effectively enhance the structural stability of the flexure wheel assembly 12 during high-speed operation, avoid loosening or displacement of components caused by factors such as centrifugal force and vibration generated during high-speed rotation, reduce the shaking and deviation during operation, ensure the reliability and safety of the operation of the flexure wheel assembly 12, thereby improving the working performance of the entire robot joint system, extending the service life of the equipment, reducing the maintenance cost and failure risk caused by structural instability, and enabling the robot to still maintain precise motion control and good working conditions under high-speed operation.

[0050] The above is only a preferred embodiment of the present invention, and it does not impose any form of limitation on the present invention. Although the present invention has been disclosed above with a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to equivalent embodiments by using the technical content disclosed above within the scope of the technical solution of the present invention. However, as long as it does not depart from the content of the technical solution of the present invention, any brief modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. An integrated sensor intelligent harmonic reducer, characterized in that: It includes a rotating shaft (10), a wave generator (11), a flexspline assembly (12), a rigid gear assembly (13), a bearing group (14) and an integrated sensor module; the rotating shaft (10) is used to connect with the output shaft of the motor; the wave generator (11) includes a cam portion (111) and a mounting portion (112); the flexspline assembly (12) includes a flexspline (121) and a mounting disc (122), the flexspline (121) has a thin-wall tooth portion (123), a thick-wall tooth portion (124) and a rigid connection portion (125), the thick-wall tooth portion (124) and the rigid connection portion (125) are respectively transitionally connected to both sides of the thin-wall tooth portion (123); the rigid gear assembly (13) includes a rigid gear (131), an internal gear (132) and a flange disc (133); the bearing group (14) includes a first flexure bearing (141), a second flexure bearing (143) and a rigid bearing (142) arranged axially along the rotating shaft (10), wherein the rigid bearing (142) is located between the first flexure bearing (141) and the second flexure bearing (143); the outer periphery of the thin-wall tooth portion (123) abuts against the outer periphery of the cam portion (111), the outer periphery of the thick-wall tooth portion (124) abuts against the outer ring of the rigid bearing (142), and the rigid connection portion (125) is axially fixed to the mounting disc (122) and the mounting portion (112) respectively; the rigid gear (131) is axially fixed to the internal gear (132), the rigid gear (131) is radially limited by the mounting disc (122) and the flexspline (121), the internal gear (132) is axially fixed to the flange disc (133), and the flange disc (133) abuts against the outer ring of the second flexure bearing (143); the integrated sensor module is arranged on the thick-wall tooth portion (124) or the rigid connection portion (125) of the flexspline assembly (12) for real-time monitoring of the flexspline deformation and meshing state, and is signal-connected to an external control system (60).

2. The sensor-integrated intelligent harmonic reducer according to claim 1, characterized in that: Both the thin-wall tooth portion (123) and the thick-wall tooth portion (124) are cylindrical structures, and the wall thickness of the thick-wall tooth portion (124) is greater than that of the thin-wall tooth portion (123). The rigid connection portion (125) is a disc-shaped structure radially extending outward circumferentially from one end of the cylindrical structure. The thick-wall tooth portion (124) is used to inhibit excessive deformation of the thin-wall tooth portion (123) during meshing.

3. The integrated sensor intelligent harmonic reducer according to claim 1, characterized in that: The inner periphery of the cam portion (111) abuts against the outer ring of the first flexure bearing (141). The mounting portion (112) is a disc-shaped structure radially extending outward from one end of the cam portion (111), and the mounting portion (112) is fixedly connected to the output shaft of the motor to transmit torque.

4. The sensor-integrated intelligent harmonic reducer according to claim 1, characterized in that: External tooth structures are provided on the outer peripheries of the thin-wall tooth portion (123) and the thick-wall tooth portion (124), and internal tooth structures are provided on the inner peripheries of the rigid gear (131) and the internal gear (132); the thin-wall tooth portion (123) meshes with the internal tooth structure of the rigid gear (131) to achieve the first-stage speed reduction, and the thick-wall tooth portion (124) meshes with the internal tooth structure of the internal gear (132) to achieve the second-stage speed reduction.

5. The sensor-integrated intelligent harmonic reducer according to claim 1, wherein: The first flexible bearing (141) is arranged close to the motor output shaft to bear radial loads, the second flexible bearing (143) is arranged away from the motor output shaft to provide axial support, and the rigid bearing (142) is located between them.

6. The integrated sensor intelligent harmonic reducer according to claim 1, wherein: The integrated sensor module communicates with an external control system (60) by means of wireless transmission or wired connection.

7. A flexible robot joint system, comprising a sensor-integrated intelligent harmonic reducer according to any one of claims 1-6, characterized in that: It includes a joint body (20), a frameless motor (30), a brake assembly (40), an encoder disk assembly (50), a control system (60) and a carrier disk assembly (70); the carrier disk assembly (70) has a first carrier disk (71) and a second carrier disk (72) mounted on the joint body (20), the frameless motor (30) is arranged inside the joint body (20), its output shaft is connected to the end of the rotating shaft (10), a transmission shaft (80) is arranged inside the output shaft, one end of the transmission shaft (80) is rotatably connected to the joint body (20), and the other end protrudes from the output shaft of the frameless motor (30) and is rotatably connected to the second carrier disk (72); the brake assembly (40) includes a moving friction member (41), a static friction member (42), a disc spring (43) and a driver (44), the driver (44) axially pushes the static friction member (42) through a guide pin (45) to drive the disc spring (43) to press against the moving friction member (41) to achieve braking, the moving friction member (41) is arranged between the first carrier disk (71) and the disc spring (43), and a return spring (46) matching the guide pin (45) is arranged on the first carrier disk (71); the encoder disk assembly (50) includes an input encoder disk (51) arranged on the transmission shaft (80) and a corresponding encoder (52), the encoder (52) is signal-connected to the control system (60) and is used to feedback the joint rotation angle position; the control system (60) is integrated on the second carrier disk (72), is electrically connected to the integrated sensor module and the encoder (52), and realizes synchronous calibration and closed-loop control of the deformation data of the flexible wheel (121) and the joint position.

8. The flexible robot joint system according to claim 7, characterized in that: The stator winding (31) and the rotor (32) of the frameless motor (30) are integrated on the output shaft, the transmission shaft (80) penetrates the output shaft and is coaxially connected to the rotating shaft (10) of the harmonic reducer; a shaft platform (53) is arranged on one side of the static friction member (42) of the brake assembly (40), and an adjustable pressing force is formed between the other side and the moving friction member (41) through the disc spring (43), the driver (44) is arranged on the second carrier disk (72), and drives the guide pin (45) to push the static friction member (42) to move axially to achieve braking and release.

9. The flexible robot joint system according to claim 8, wherein: A carrier ring (54) is mounted on the other side of the shaft platform (53), an annular gap is provided between the input encoder disk (51) and the carrier ring (54), the encoder (52) is a multi-turn absolute magnetic encoder (52), the absolute rotation angle of the transmission shaft (80) is detected through magnetic poles and Hall sensors, and the signal is fed back to the control system (60); the integrated sensor module includes a strain gauge or a piezoelectric film, and its output signal is fused with the data of the encoder (52) and is used to dynamically adjust the stiffness of the harmonic reducer and the joint output torque.

10. The flexible robot joint system according to claim 7, wherein: The first carrier disk (71) and the second carrier disk (72) support a transmission shaft (80) through a rigid bearing (142) to form a double-ended fixed structure; the control algorithm of the control system (60) includes model predictive control, and based on the deformation data of the harmonic reducer and the rotation angle signal fed back by an encoder (52), the torque output and motion trajectory of the joint are optimized in real time.

Images