Multi-axis industrial robot

Abstract

The invention discloses a multi-shaft industrial robot which comprises a base module, a plurality of connecting arm modules, a tail end execution module, a flexible dustproof sleeve and pin shafts. A plurality of base stator discs are axially arranged on the surface of the base module, and a coil and a driving control structure are arranged in the base module; the first end part of the connecting arm module is provided with arm rotor discs which are sequentially arranged at intervals along the axial direction, the second end part of the connecting arm module is provided with arm stator discs which are arranged at intervals along the axial direction, and the connecting arm module is detachably connected with the adjacent module through a flange plate and a pin shaft; and the bottom of the tail end execution module is provided with a tail end rotor disc and a universal mounting flange. The flexible dustproof sleeve is used for joint protection, and a self-lubricating coating is arranged on the surface of the pin shaft. Independent magnetic circuit coupling driving is achieved through a multi-disc type axial magnetic flux direct drive structure, and the multi-disc type axial magnetic flux direct drive mechanism has high precision, high response, modular combination and excellent heat dissipation protection performance and is suitable for a multi-degree-of-freedom industrial robot.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial robots, in particular to a multi-axis industrial robot. Background Art

[0002] Industrial robots, as core equipment in modern intelligent manufacturing and automated production, are widely used in welding, handling, painting, assembly, and high-precision machining. Currently, common multi-axis industrial robots typically use a servo motor + reducer + spherical bearing combination to drive each joint. The servo motor provides power, while the harmonic reducer or RV reducer increases output torque and ensures joint positioning accuracy. However, traditional multi-axis robot structures generally have the following problems: Existing multi-axis industrial robots are often equipped with independent motors and reducers at each joint. They have many structural levels and long transmission chains. Mechanical friction and clearance lead to reduced transmission efficiency. At the same time, there is a delay in joint response, making it difficult to meet the needs of high-dynamic, high-precision flexible manufacturing.

[0003] Traditional multi-axis robots mostly have fixed structures in their joint design. If the number of degrees of freedom needs to be changed or the joint layout needs to be adjusted, the overall mechanical structure needs to be redesigned, which makes it difficult to achieve rapid assembly, disassembly and expansion, and is not conducive to multi-scenario adaptation and maintenance and upgrades.

[0004] Some existing direct-drive robots have attempted to utilize radial flux permanent magnet motors. However, due to the limited torque generated by a single stator and rotor set, achieving sufficient output often requires increasing the diameter or adding complex transmission mechanisms. This results in larger and heavier robot joints, and increases installation and maintenance costs. Traditional multi-jointed robots are susceptible to the intrusion of dust, oil, or cutting fluids during long-term operation. Without effective protective structures, joint bearings and motor components are susceptible to wear. Furthermore, lubrication and maintenance are complex, reducing the long-term stability of the robot system.

[0005] In summary, existing technologies struggle to achieve a balance between high-torque direct drive output, modular structure, lightweight design, and long-term reliability. Therefore, a new multi-axis industrial robot with multi-disk axial flux direct drive, modular assembly, high protection, and stable torque output is urgently needed to address the complex joint structure, sluggish response, and poor protection capabilities of existing robots, while also improving overall system performance. Summary of the Invention

[0006] The present invention aims to solve technical problems existing in existing industrial robots, such as complex structure, limited joint driving torque, poor joint topology flexibility, and insufficient heat dissipation and protection capabilities. It provides a multi-axis industrial robot with a modular multi-disc axial magnetic flux direct-drive joint to achieve high-precision, high-stability, and easy-to-maintain direct-drive motion control in multiple degrees of freedom.

[0007] To this end, the present invention provides a multi-axis industrial robot comprising a base module, multiple connecting arm modules, an end effector module, a flexible dust cover, and a pin assembly. This robot utilizes the multi-disk axial flux direct drive principle to form independent magnetic circuits, enabling modular direct-drive rotation of each joint. The overall structure offers high integration, strong adaptability, and excellent heat dissipation and protection.

[0008] The present invention provides a multi-axis industrial robot comprising a base module, multiple connecting arm modules, and an end effector module. The base module is provided with a plurality of axially spaced base stator discs, which are integrated with coils and a drive control structure for generating a drive magnetic field. Each connecting arm module comprises: a first end, with several arm rotor discs arranged axially and spaced apart on its surface. Permanent magnets are fixed to the surface, forming a magnetic coupling drive with adjacent stator discs; a second end, with several arm stator discs arranged axially and spaced apart on its surface. Coils are internally arranged, magnetically coupling with adjacent rotor discs to achieve drive output; both ends are detachably connected via flanges and pins, enabling modular assembly; and a terminal execution module, with several terminal rotor discs at its bottom, magnetically coupling with the final arm stator disc. A universal mounting flange is used to adapt to tools such as fixtures, welding machines, or spray heads. This achieves high-precision direct-drive motion with multiple degrees of freedom, eliminating the backlash and return errors associated with traditional reducer joints, and improving the robot's response speed and operational stability.

[0009] In a preferred example, the flange can be rotated around the axis of the connecting arm module and then locked during assembly, so that the axes of the arm stator disk and the arm rotor disk between adjacent modules can be selected to be parallel or vertical, thereby realizing a variety of joint topology layouts.

[0010] The present invention adopts a modular design and can realize robot combinations with different degrees of freedom by adding or reducing connecting arm modules.

[0011] Technical effect: Significantly improve the adaptability and scalability of robots in different work scenarios, and reduce manufacturing and maintenance costs.

[0012] In a preferred example, the base stator disc and the arm stator disc are connected to a cooling pipeline through an internal cavity of the flange, supporting liquid cooling or air cooling.

[0013] Furthermore, a cross roller bearing or a double row angular contact bearing is provided inside each connecting arm module to bear radial and axial loads and maintain coaxial accuracy.

[0014] Technical effect: Improve the stability and thermal management capabilities of the drive unit during long-term operation, while enhancing the joint's load-bearing performance under complex loads.

[0015] In a preferred example, a power module and a control module are provided inside the base module, and power supply and signal transmission of the base stator disk and the arm stator disk are achieved through a cable channel or slip ring structure inside the flange.

[0016] Furthermore, each connecting arm module and end execution module can be configured with an absolute encoder or a multi-turn position sensor to achieve real-time detection and closed-loop control of the joint angle position.

[0017] Technical effect: Realize high-precision real-time control and status feedback of the entire robot, and ensure the stability and safety of joint movement.

[0018] In a preferred embodiment, a flexible dustproof boot is installed between the base module and the connecting arm module and at each joint connection, and is composed of clamps at both ends and a rubber cover to prevent the intrusion of dust, oil mist and liquid; Furthermore, the surface of the pin is provided with a self-lubricating coating formed of polytetrafluoroethylene or an oil-containing copper-based material to reduce rotational friction and wear.

[0019] Technical effect: significantly improve joint durability and overall machine service life, and reduce maintenance frequency.

[0020] In a preferred example, a reasonable air gap is designed between adjacent stator disks and rotor disks, and a non-magnetic isolation ring can be optionally provided so that each disk group forms an independent magnetic circuit and adjacent magnetic fluxes do not interfere with each other.

[0021] Technical effect: Improve magnetic energy utilization and output torque stability, while avoiding the decrease in accuracy caused by magnetic field coupling interference.

[0022] The beneficial effects achieved by the present invention are: 1. In the present invention, by adopting a direct-drive structure with multi-disc axial flux stator disks and rotor disks alternately arranged in the base module, connecting arm module and end execution module, multi-degree-of-freedom high-torque output of the joints is achieved, and precise joint driving can be completed without the need for traditional reducers, which significantly improves the dynamic response performance and transmission efficiency of the industrial robot.

[0023] 2. In the present invention, each connecting arm module realizes modular expansion and rapid assembly through the detachable combination structure of the flange and the positioning pin shaft, and the parallel or vertical state of the joint axis can be selected by rotating the flange to form a variety of joint topologies; at the same time, the setting of the flexible dust cover and self-lubricating pin shaft improves the protection performance and long-term operation reliability of the robot joint.

[0024] 3. In the present invention, a reasonable air gap or non-magnetic spacer ring is provided between adjacent stator disks and rotor disks to construct an independent magnetic flux circuit to reduce magnetic interference. Combined with internal cooling pipes and high-precision bearing structures, a multi-axis robot joint system with high power density, low wear and low maintenance cost is realized, which can be flexibly adapted to multi-degree-of-freedom industrial robots and a variety of end-effector tools. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the assembly state of the connecting arm modules according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the connecting arm module and pin structure according to an embodiment of the present invention; Figure 4 This is a schematic structural diagram of a connecting arm module according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the surface structure of a base module according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the surface structure of an end-effector module according to an embodiment of the present invention; Figure 7 This is a schematic structural diagram of the base stator disk and the terminal rotor disk according to an embodiment of the present invention.

[0026] Reference numerals: 100. Base module; 110. Base stator disc; 200, connecting arm module; 210, first end; 220, arm rotor disk; 230, second end; 240, arm stator disk; 250, flange; 300, terminal execution module; 310, terminal rotor disk; 400, flexible dust cover; 500, pin; 510, self-lubricating coating. DETAILED DESCRIPTION

[0027] To make the purpose, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. It should be noted that the embodiments of the present invention and the features therein can be combined with each other without conflict.

[0028] It is to be understood that these descriptions are illustrative only and are not intended to limit the scope of the invention.

[0029] Example 1 A multi-axis industrial robot provided by some embodiments of the present invention will be described below with reference to the accompanying drawings.

[0030] Combine Figure 1-Figure 7As shown, the present invention provides a multi-axis industrial robot, comprising: a base module 100, a plurality of connecting arm modules 200, an end execution module 300, a flexible dust cover 400 and a pin shaft 500, wherein the structure and function of each part are described as follows.

[0031] The base module 100 is the fixed mounting unit of the multi-axis industrial robot, supporting the entire robot structure and providing drive for the first joint. Several base stator disks 110 are spaced along the axial direction of the base module 100. Each base stator disk 110 houses a coil and drive control structure, generating a driving magnetic field with axial magnetic flux, thereby achieving magnetic coupling and direct drive with the rotor disk of the adjacent module.

[0032] The base module 100 houses a power module and a control module, providing power and drive control signals to each base stator disc 110. A mounting flange and cable channel are provided on the base module 100. The cable channel connects to the connecting arm module 200 via a flange 250, enabling power and signal transmission. To ensure heat dissipation during continuous operation, cooling pipes can be connected between the base stator discs 110 through the cavity within the flange 250, forming a liquid or air cooling channel.

[0033] Each connecting arm module 200 is an intermediate joint unit used to achieve multi-degree-of-freedom rotation of the robot. Each connecting arm module 200 includes: First end portion 210: A plurality of arm rotor disks 220 are arranged on its surface in an axially spaced order. Permanent magnets are fixed to the surface of the arm rotor disks 220 to form magnetic coupling with the base stator disk 110 or the arm stator disk 240 of the adjacent module to achieve direct drive torque output; Second end portion 230: A plurality of arm stator disks 240 are arranged on its surface in sequence along the axial direction. Coils are provided inside the arm stator disks 240 for forming magnetic coupling drive with the arm rotor disks 220 or the terminal rotor disks 310 of the adjacent modules; Flange 250: Used to removably connect the first end 210 to the second end 230 of the adjacent connecting arm module 200 and securely lock the joint via a pin 500. During assembly, flange 250 can be rotated a certain angle around the axis of the connecting arm module 200 before being locked. This allows the axes of the arm rotor disc 220 and arm stator disc 240 to be parallel or perpendicular, creating different joint topologies and enhancing joint layout flexibility.

[0034] A cross roller bearing or a double row angular contact bearing that supports the arm rotor disk 220 and the arm stator disk 240 can be set inside each connecting arm module 200 to simultaneously bear radial and axial loads, thereby ensuring the coaxial accuracy and mechanical stability of the multi-disc magnetic flux direct drive structure during operation.

[0035] The end effector module 300 is mounted at the second end 230 of the final arm module 200 and is used to drive and operate the final tool. A plurality of axially spaced end rotor disks 310 are provided at the bottom of the end effector module 300. These magnetically couple with the arm stator disk 240 of the final arm module 200 to achieve direct-drive rotation of the end joint.

[0036] The EEM 300 features a universal mounting flange, compatible with common industrial robot end-of-line tools such as grippers, welders, and spray heads. Furthermore, EEM 300 incorporates internal through-hole wiring channels to facilitate the passage of air pipes, hydraulic lines, or electrical cables, enabling the expansion of end-of-line tool functionality.

[0037] In this embodiment, to improve the robot's reliability under complex working conditions, the present invention provides flexible dust boots 400 at each joint connection. These boots, consisting of clamps at both ends and a rubber cover that fits over each joint connection, effectively prevent dust, oil mist, or cutting fluid from entering the joint, reducing the risk of wear on the bearings, rotor discs, and stator discs.

[0038] In this embodiment, adjacent modules are precisely positioned and rotationally connected via a pin 500. The pin 500 is inserted into the axial holes of the base stator disc 110, the arm stator disc 240, the arm rotor disc 220, and the terminal rotor disc 310, forming a reliable mechanical pivot. The surface of the pin 500 is coated with a self-lubricating coating 510 compatible with the arm rotor disc 220 and the terminal rotor disc 310. This coating can be made of polytetrafluoroethylene or an oil-containing copper-based composite material to reduce rotational friction and long-term wear at the joints, thereby extending the service life of the entire unit.

[0039] To ensure that the magnetic flux of adjacent stator and rotor disks does not interfere with each other, the present invention provides appropriately designed air gaps between arm rotor disks 220 and 240, between base stator disks 110 and 220, and between terminal rotor disks 310 and 240. By controlling the air gap distance and optionally providing non-magnetic isolation rings, each disk assembly forms an independent magnetic circuit, thereby improving torque output stability and magnetic energy utilization efficiency.

[0040] Example 2 In this embodiment 2, the present invention is further optimized on the basis of embodiment 1 to realize the angle maintaining function of the multi-axis industrial robot.

[0041] The structures and connection methods of the base module 100 , connecting arm module 200 , end effector module 300 , flexible dust cover 400 and pin shaft 500 are the same as those in Example 1 and will not be described in detail.

[0042] The differences are: Stator disk constant magnetic flux control: A constant current is continuously supplied to the internal coils of the base stator disk 110 and the arm stator disk 240 through the control module to form a stable magnetic flux; when the robot is at the target angle position, the adjacent arm rotor disk 220 and the end rotor disk 310 are attracted by the constant magnetic flux through closed-loop control, thereby generating a holding torque to achieve angle maintenance of each joint of the robot without the need for continuous high-frequency dynamic drive.

[0043] Angle holding control logic: When the robot completes the preset movement, the control module switches to the angle holding mode. The magnetic flux generated by the base stator disk 110 and the arm stator disk 240 remains unchanged, and the magnetic flux amplitude is kept lower than the peak current during driving to reduce energy consumption and heat generation; the absolute encoder or multi-turn position sensor detects the rotor disk position in real time to ensure angle holding accuracy.

[0044] Through the above-mentioned constant magnetic flux adsorption method, the angles of each joint can be stably maintained when the robot has no motion instructions, reducing the offset caused by external force disturbances, while reducing the energy consumption of continuous motor drive, achieving high-precision angle maintenance and energy-saving operation.

[0045] Example 3: On the basis of Example 1 and Example 2, in order to improve the heat dissipation capability, a ducted fan is provided inside the first end portion 210 of the connecting arm module 200: The ducted fan is arranged along the module axis, with its air outlet aligned with the axial air gap formed between the adjacent arm stator discs 240 and arm rotor discs 220; The fan sends the airflow directly into the magnetic coupling gap through the air guide cover, forming local forced air convection heat dissipation; the control module automatically adjusts the speed of the ducted fan according to the stator disk temperature to ensure safety and reliability under long-term high-load operation.

[0046] The above solution can further improve the heat dissipation performance of the joint magnetic coupling structure, which complements the liquid cooling or air cooling pipeline described in claim 3.

[0047] The working principle and use process of the present invention: 1. Working Principle Principle of magnetically coupled direct-drive joint motion: The present invention forms a multi-axis robot system by connecting a base module 100, a multi-section connecting arm module 200 and an end execution module 300 in series. Each joint is composed of a stator disk and a rotor disk arranged relative to each other. The base stator disk 110 and the arm stator disk 240 are provided with a drive coil and a control module, and permanent magnets are fixed on the surface of the arm rotor disk 220 and the end rotor disk 310. When the stator disk is energized, a rotating magnetic field is generated, which forms a magnetic coupling torque with the permanent magnet of the corresponding rotor disk, realizing the direct-drive rotation of the joint without a reducer. Each joint segment can achieve different topological arrangements by changing the rotation angle of the flange 250, so that the robot has the ability to move in multiple degrees of freedom in space.

[0048] Torque Transmission and Motion Control: The rotating magnetic field generated by the base stator disk 110 drives the first arm rotor disk 220, which is then transmitted to each arm module 200 and end effector module 300 via magnetic coupling. A built-in absolute encoder or multi-turn position sensor collects real-time angle data from each joint. The control module implements closed-loop control, achieving high-precision multi-axis coordinated motion. The flange 250 is internally equipped with cable channels or slip rings for continuous power and signal transmission. Furthermore, the internal cavity can accommodate liquid or air cooling pipes to reduce heat generation in the stator coil.

[0049] Support and Protection Mechanism: Each connecting arm module 200 utilizes crossed roller bearings or double-row angular contact bearings to ensure the joints withstand radial and axial loads while maintaining coaxial precision. A pin 500 is inserted into each joint's axial hole, and its surface self-lubricating coating 510 reduces rotational friction and wear, ensuring long-term stable operation. A flexible dust cover 400 is installed between each joint, creating a seal with a clamp and rubber cover to prevent dust and impurities from entering the joint cavity.

[0050] 2. Usage Process 1. Module assembly and debugging: According to the required number of degrees of freedom, the base module 100, several connecting arm modules 200, and the end effector module 300 are modularly assembled using flanges 250 and locating pins 500. The rotation angle of the flange 250 is selected based on the task requirements, ensuring that the stator and rotor disc axes of adjacent joints are parallel or perpendicular. The cables and cooling pipes are connected, and the flexible dust cover 400 is installed.

[0051] 2. Power on and initialization: Connect the built-in power module and control module of the base module 100, and power each stator disc through the cable channel. The system automatically reads the initial position of the absolute encoder or multi-turn position sensor to achieve zero point calibration and posture initialization.

[0052] 3. Movement execution and task operation: The control module outputs drive current to each stator disk, creating a rotating magnetic field that drives the corresponding rotor disk. Each joint achieves coordinated motion. The end effector module 300, via a universal mounting flange, carries a fixture, welder, or spray head to perform gripping, welding, handling, or spraying operations. Sensor feedback and closed-loop control enable smooth and precise spatial trajectory control.

[0053] Through the above principles and processes, the present invention realizes a modular multi-axis industrial robot with multi-degree-of-freedom direct drive, high precision, and low maintenance cost, which is suitable for various industrial scenarios such as highly flexible production lines, spraying, handling, welding, etc.

[0054] Throughout this specification, terms such as "one embodiment," "some embodiments," and "specific embodiments" mean that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, illustrative uses of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0055] Although the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the claims and their equivalents.

Claims

1. A multi-axis industrial robot, characterized in that: include: A base module (100) is provided on its surface with a plurality of base stator discs (110) spaced apart in the axial direction, wherein a coil and a drive control structure are provided in the base stator discs (110) for generating a drive magnetic field; A plurality of connecting arm modules (200), each connecting arm module (200) comprising: a first end portion (210) provided with a plurality of arm rotor disks (220) sequentially spaced along the axial direction, a permanent magnet being fixed on the surface of the arm rotor disk (220) for forming a magnetic coupling drive with a stator disk of an adjacent module; a second end portion (230) provided with a plurality of arm stator disks (240) sequentially spaced along the axial direction, a coil being provided in the arm stator disk (240) for forming a magnetic coupling drive with a rotor disk of an adjacent module; the first end portion (210) and the second end portion (230) of the adjacent connecting arm module (200) are detachably connected via a flange (250) and a positioning pin shaft; The end execution module (300) has a plurality of end rotor disks (310) arranged at intervals along the axial direction at its bottom, which are used for magnetic coupling and driving with the arm stator disk (240) of the last connecting arm module (200), and a universal mounting flange is provided at the end of the end execution module (300); wherein the base stator disk (110), the arm stator disk (240), the arm rotor disk (220), and the end rotor disk (310) are magnetically coupled with each other to realize multi-degree-of-freedom joint direct drive motion, thereby forming a multi-axis industrial robot; A flexible dust cover (400) is sleeved between the connecting arm module (200) and the base (100) and at each joint connection, the flexible dust cover (400) comprising clamps at both ends and a rubber cover for sleeved at each joint connection; A pin shaft (500) has a surface provided with a self-lubricating coating (510) adapted to the arm rotor disc (220) and the terminal rotor disc (310).

2. The multi-axis industrial robot according to claim 1, characterized in that: The flange (250) can be locked after being rotated around the axis of the connecting arm module (200) during assembly, so that the axes of the arm stator disk (240) and the arm rotor disk (220) between adjacent modules can be selectively parallel or perpendicular to form different joint topologies.

3. The multi-axis industrial robot according to claim 1, characterized in that: The base stator disc (110) and the arm stator disc (240) are connected to a cooling pipeline via an internal cavity of the flange disc (250), and the cooling pipeline is used for liquid cooling or air cooling.

4. The multi-axis industrial robot according to claim 1, characterized in that: Each connecting arm module (200) is provided with a cross roller bearing or a double row angular contact bearing for carrying the arm rotor disc (220) and the arm stator disc (240), and is used to bear radial and axial loads and maintain coaxial accuracy.

5. The multi-axis industrial robot according to claim 1, characterized in that: The base module (100) is provided with a power module and a control module inside, and supplies power and transmits signals to the base stator disc (110) and the arm stator disc (240) through a cable channel or slip ring reserved inside the flange disc (250).

6. The multi-axis industrial robot according to claim 1, characterized in that: Each connecting arm module (200) and end execution module (300) is provided with an absolute encoder or a multi-turn position sensor for detecting the angular position of a multi-degree-of-freedom joint in real time.

7. The multi-axis industrial robot according to claim 1, characterized in that: The end execution module (300) is a universal structure and is provided with a through-hole wiring channel for the passage of signal lines, air pipes or hydraulic pipes.

8. The multi-axis industrial robot according to claim 1, characterized in that: The pin shaft (500) is inserted into the shaft holes of the correspondingly connected base stator disk (110), the arm stator disk (240), the arm rotor disk (220) and the terminal rotor disk (310), and the self-lubricating coating (510) is located on the surface of the pin shaft (500) at a position corresponding to the arm rotor disk (220) and the terminal rotor disk (310). The self-lubricating coating (510) is formed of polytetrafluoroethylene or an oil-containing copper-based material and is used to reduce rotational friction and wear.

9. The multi-axis industrial robot according to claim 1, characterized in that: A predetermined air gap or a non-magnetic isolation ring is provided between the base stator disk (110) and the arm rotor disk (220), between the arm stator disk (240) and the adjacent arm rotor disk (220), and between the arm stator disk (240) and the terminal rotor disk (310) to form a relatively independent magnetic flux circuit, reduce interference between adjacent magnetic circuits, and improve the stability of joint torque output.

10. The multi-axis industrial robot according to any one of claims 1 to 9, characterized in that: The robot has a modular structure, and the base module (100), the connecting arm module (200) and the end execution module (300) can realize a multi-axis robot combination with different degrees of freedom by increasing or decreasing the number of modules.

Images