Robot large-torque joint power-source-free intelligent temperature control integrated module

Abstract

The invention belongs to the technical field of robot thermal management, and particularly relates to a robot large-torque joint power-source-free intelligent temperature control integrated module. The module is designed based on a joint integrated module, efficient export of heat generated by a joint core heat source is achieved through independent phase change circulation of a working medium in the intelligent temperature control module, and the temperature stability and operation reliability of the joint under the high-load working condition are remarkably improved. The heat dissipation module does not need external power sources such as a fan and a pump completely, and is driven only by working medium phase change and natural heat dissipation, so that the system architecture is simplified fundamentally, the energy consumption is reduced, and the strict requirements of robot joints for compact space are met. According to the integrated module, the heat dissipation module is deeply integrated to the power unit, the external skin of the robot is ingeniously used as an ultimate heat dissipation interface, extremely high space utilization efficiency and structural compactness are achieved, and an efficient, passive and reliable intelligent temperature control solution is provided for the large-torque joint of the robot.

Description

Technical Field

[0001] This invention belongs to the field of robot thermal management technology, and in particular relates to an integrated intelligent temperature control module for robot high-torque joints without a power source. Background Technology

[0002] As the application fields of humanoid robots continue to expand, their joint modules, as the core components for realizing movements, are facing increasingly severe thermal management challenges. Joint modules typically integrate precision components such as motors, reducers, encoders, and drive controls, generating a significant amount of heat during operation, especially under high load and high torque conditions. Currently, high-power-density joint motors are developing towards smaller size and higher power; however, the structural contradiction between high power and small space leads to a sharp increase in the heat density of joint motors. The permanent magnets and insulating materials inside the motor are extremely sensitive to temperature. Excessive operating temperature rise can cause irreversible demagnetization of the permanent magnets and accelerate the aging and failure of the insulating materials, thereby directly reducing the motor's output performance, service life, and operational reliability.

[0003] To address joint heat dissipation, existing technologies primarily employ active cooling solutions such as air cooling or liquid cooling. While air cooling offers structural simplicity, its efficiency is limited within the confined, compact joint space, making it unsuitable for high-power cooling demands. Liquid cooling, though providing superior cooling capacity, typically requires additional pumps, piping, and heat sinks, leading to system complexity, increased size, and higher energy consumption. It also carries the risk of leakage, reducing the overall reliability of the joint module. Therefore, existing technologies suffer from structural redundancy, high energy consumption, and poor space adaptability, failing to meet the urgent needs of next-generation robot joints for lightweight design and efficient heat dissipation.

[0004] In summary, existing technologies lack an integrated temperature control solution that can be deeply integrated with the joint module, does not rely on external power, and achieves efficient and intelligent heat dissipation within an extremely compact space. Therefore, there is an urgent need for an integrated intelligent temperature control module for high-torque robot joints without a power source to solve the aforementioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated intelligent temperature control module for high-torque robot joints without a power source, in order to solve the above-mentioned problems.

[0006] To achieve the above objectives, the present invention provides the following solution:

[0007] A robot high-torque joint intelligent temperature control integrated module without power source includes:

[0008] A housing assembly, wherein a power mechanism, a transmission mechanism, and a heat dissipation mechanism are provided within the housing assembly;

[0009] The power mechanism and the transmission mechanism are in a transmission cooperation;

[0010] The heat dissipation mechanism is configured to exchange heat with the power mechanism and the outer casing assembly;

[0011] The heat dissipation mechanism includes an intelligent liquid storage container and a heat pipe heat dissipation section connected to the intelligent liquid storage container. One end of the heat pipe heat dissipation section and the intelligent liquid storage container are heat exchanged with the power mechanism, and the other end of the heat pipe heat dissipation section is heat exchanged with the outer shell assembly.

[0012] The intelligent liquid storage container includes:

[0013] A liquid storage container for storing refrigerant, the liquid storage container being coaxially fixed within the housing assembly;

[0014] The liquid storage container is connected to the heat pipe heat dissipation section via an adaptive regulating valve;

[0015] The adaptive regulating valve consists of a shape memory alloy and a valve core. The shape memory alloy is fixed to the valve core, and the valve core is movably disposed within the liquid storage container. The valve core is used to block the communication hole between the liquid storage container and the heat dissipation part of the heat pipe.

[0016] The shape memory alloy is heat exchanged with the power mechanism, and the shape memory alloy deforms when heated, causing the valve core to separate from the connecting hole.

[0017] Optionally, the heat pipe heat dissipation part includes an integrated motor housing, and a plurality of heat pipe grooves are formed inside the integrated motor housing. One end of an interconnected heat pipe is embedded in the heat pipe groove. The heat pipe includes an evaporation section, an insulation section and a condensation section. The evaporation section is heat-exchange configured with the power mechanism, and the condensation section is heat-exchange configured with the housing assembly.

[0018] The liquid storage container is located on the side of the heat pipe away from the condensation section;

[0019] The liquid storage container contains a refrigerant. After evaporating and absorbing heat from the power mechanism in the evaporation section, the refrigerant vaporizes. The vaporized refrigerant moves along the insulation section to the condensation section, where it is condensed into a liquid state by heat exchange with the outside through the outer shell assembly and flows back to the liquid storage container.

[0020] Optionally, the heat pipe is arranged around the outside of the power mechanism.

[0021] Optionally, the power mechanism includes components fixed within the housing assembly:

[0022] A high-power-density motor is configured to exchange heat with the evaporation section and the adaptive regulating valve;

[0023] The control unit is electrically connected to the high-power-density motor.

[0024] Optionally, the control unit includes a high-precision encoder and a drive board electrically connected to the high-power-density motor.

[0025] Optionally, the high power density motor includes a motor housing, the motor housing being fixedly connected to the inner wall of the outer casing assembly, and further includes a component disposed in the motor housing:

[0026] The stator is fixed inside the motor housing;

[0027] The rotor portion is rotatably mounted within the motor housing;

[0028] The stator section and the rotor section are in a driving engagement;

[0029] The stator portion is sleeved on the outside of the rotor portion;

[0030] The stator portion includes:

[0031] The stator core is fixed inside the housing assembly;

[0032] The stator winding is fixedly connected to the stator core;

[0033] The rotor portion includes:

[0034] The rotor core is coaxially and rotatably disposed inside the stator core;

[0035] A shaft is coaxially fixed inside the rotor core, and the shaft is rotatably engaged with the motor housing.

[0036] Several rotor ventilation openings are provided on the rotor core.

[0037] The shaft is connected to the input end of the transmission mechanism.

[0038] The rotor core is circumferentially and equally spacedly embedded with a number of permanent magnets, which together form a rotor winding. The permanent magnets are connected to the stator winding in a driving connection.

[0039] An end ring is fixed on the rotor core, and the end ring is used to constrain the axial displacement of the rotor core.

[0040] Optionally, the transmission mechanism includes an output device and a harmonic reducer. The fixed ends of the output device and the harmonic reducer are fixedly connected to the housing assembly. The input end of the harmonic reducer is connected to the shaft, and the output end of the harmonic reducer is connected to the input end of the output device.

[0041] Optionally, the harmonic reducer includes a wave generator, a rigid wheel, and a flexible wheel; the rigid wheel is fixedly connected to the housing assembly; the flexible wheel is rotatably disposed inside the rigid wheel, and the external teeth of the flexible wheel mesh with the internal teeth of the rigid wheel; the wave generator is coaxially disposed inside the flexible wheel, and the wave generator is fixedly connected to the shaft, and the wave generator is used to drive the flexible wheel to generate elastic deformation to achieve interlocking meshing transmission with the rigid wheel.

[0042] Optionally, the housing assembly includes:

[0043] The robot's external skin and a joint connection device coaxially fixed within the robot's external skin;

[0044] One end of the robot's external skin is equipped with a passive heat dissipation unit;

[0045] The passive heat dissipation section is configured to exchange heat with the condensation section.

[0046] Optionally, the passive heat dissipation unit includes:

[0047] A plurality of fin slots are arranged in a circular pattern. The fin slots are opened at one end of the robot's outer skin. Heat dissipation fins are fixed to the fin slots. The plurality of heat dissipation fins are fixed to the robot's outer skin by steel rings.

[0048] The heat dissipation fins are configured to exchange heat with the condensation section.

[0049] Compared with the prior art, the present invention has the following advantages and technical effects:

[0050] This module achieves efficient heat removal from the joint's core heat source—the power mechanism—through a highly efficient heat exchange system between the evaporation section and the power unit, and between the condensation section and the outer casing, as well as a rapid phase change cycle of the working fluid. This ensures the joint's temperature stability and operational reliability under high loads. Since the entire cooling cycle requires no external power source such as fans or pumps, relying solely on the working fluid's phase change and natural heat dissipation, it significantly simplifies the system structure, reduces energy consumption, and avoids the problems of increased size, noise, and potential failure points associated with adding active cooling components. This perfectly meets the application requirements of compact robot joints. Ultimately, this integrated module achieves extremely high space utilization efficiency and structural compactness by deeply integrating the cooling mechanism into the power unit's integrated motor housing and utilizing the outer casing as the final heat dissipation interface. It provides a highly efficient, passive, and reliable intelligent temperature control solution for high-torque robot joints. Attached Figure Description

[0051] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 This is a schematic diagram of the structure of the present invention;

[0053] Figure 2 This is a schematic diagram of the heat dissipation mechanism of the present invention;

[0054] Figure 3 This is a schematic diagram of the structure of the non-powered ring-shaped heat dissipation module of the present invention;

[0055] Figure 4 This is a schematic diagram of the heat pipe groove structure of the present invention;

[0056] Figure 5 This is a schematic diagram of the intelligent liquid storage container structure of the present invention;

[0057] Figure 6 This is a schematic diagram of the adaptive regulating valve structure and its principle of the present invention;

[0058] Figure 7 This is a schematic diagram of the high power density motor structure of the present invention;

[0059] Figure 8 This is a schematic diagram of the harmonic reducer structure of the present invention;

[0060] Figure 9 This is a schematic diagram of the external skin structure of the robot of the present invention;

[0061] Figure 10 This is a flowchart of the workflow of the present invention;

[0062] The components include: 1. Output device; 2. Harmonic reducer; 211. Wave generator; 212. Rigid wheel; 213. Flexible wheel; 3. Intelligent liquid storage container; 310. Adaptive regulating valve; 311. High-precision temperature sensor; 312. High-precision pressure sensor; 313. Liquid storage container; 4. Non-powered annular heat dissipation module; 420. Evaporation section; 430. Insulation section; 440. Condensation section; 450. Integrated motor housing; 451. Heat pipe groove; 5. High power density motor; 510. Stator core; 520. Stator winding; 530. Rotor winding; 540. End ring; 550. Shaft; 560. Rotor core; 570. Rotor vent; 6. High-precision encoder; 7. Drive board; 8. Robot external skin; 810. Heat dissipation fins; 811. Fin slot; 812. Steel ring; 9. Joint connection device. Detailed Implementation

[0063] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0064] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0065] Reference Figures 1 to 10 This invention discloses an integrated intelligent temperature control module for high-torque robot joints without a power source, comprising:

[0066] The housing assembly contains a power mechanism, a transmission mechanism, and a heat dissipation mechanism.

[0067] The power mechanism and the transmission mechanism are connected in a transmission configuration;

[0068] Heat exchange arrangement between the heat dissipation mechanism and the power mechanism, and the housing components;

[0069] The heat dissipation mechanism includes an intelligent liquid storage container 3 and a heat pipe heat dissipation part connected to the intelligent liquid storage container 3. One end of the heat pipe heat dissipation part is configured to exchange heat with the intelligent liquid storage container 3 and the power mechanism, and the other end of the heat pipe heat dissipation part is configured to exchange heat with the outer shell assembly.

[0070] The intelligent liquid storage container 3 includes:

[0071] A liquid storage container 313 is used to store refrigerant, and the liquid storage container 313 is coaxially fixed inside the housing assembly;

[0072] The liquid storage container 313 is connected to the heat pipe heat dissipation section via an adaptive regulating valve 310;

[0073] The adaptive regulating valve 310 consists of a shape memory alloy and a valve core. The shape memory alloy is fixed to the valve core, and the valve core is movably disposed inside the liquid storage container 313. The valve core is used to block the communication hole between the liquid storage container 313 and the heat pipe heat dissipation part.

[0074] The shape memory alloy is heat exchanged with the power mechanism. When heated, the shape memory alloy deforms, causing the valve core to separate from the connecting hole.

[0075] Furthermore, the liquid storage container 313 is equipped with a high-precision temperature sensor 311 and a high-precision pressure sensor 312.

[0076] When the robot's high-torque joints begin operation, the power mechanism, acting as the core heat source, generates a large amount of heat. This heat is rapidly transferred via heat conduction to a heat dissipation mechanism that exchanges heat with the power mechanism. This heat dissipation mechanism includes a smart liquid storage container 3 and a heat pipe cooling section connected to it. One end of the heat pipe cooling section is tightly connected to the power mechanism for heat exchange, while the other end is efficiently connected to the outer shell assembly for heat exchange. The liquid storage container 313 within the smart liquid storage container 3 stores refrigerant and is connected to the heat pipe cooling section via an adaptive regulating valve 310. The adaptive regulating valve 310 is composed of a shape memory alloy and a valve core. The shape memory alloy is connected to the power mechanism for heat exchange. When the power mechanism... When the temperature rises, the shape memory alloy undergoes a phase change deformation due to heat, driving the valve core fixed to it to move. This causes the valve core to separate from the communication hole between the liquid storage container 313 and the heat pipe heat dissipation section, thereby opening the passage and allowing the refrigerant to flow from the liquid storage container 313 into the heat pipe heat dissipation section. After absorbing heat in the heat pipe heat dissipation section, the refrigerant evaporates and vaporizes, forming a vapor flow. This vapor flow is then transported along the heat pipe heat dissipation section to the part that exchanges heat with the outer shell assembly. Under the heat exchange action between the outer shell assembly and the external environment, the vaporized refrigerant releases latent heat and condenses into a liquid state. Subsequently, it flows back to the intelligent liquid storage container 3 by gravity or capillary action, completing a completely autonomous phase change cycle process without an external power source. The adaptive regulating valve 310, based on the temperature-sensitive properties of shape memory alloy, achieves intelligent regulation of heat dissipation flow. This ensures increased refrigerant flow under high loads to enhance heat dissipation and reduced flow under low loads to improve energy efficiency, thereby dynamically matching the heat load and avoiding overheating or energy waste problems associated with traditional heat dissipation solutions. The efficient heat exchange setup between the heat pipe cooling section and the outer shell assembly, combined with the liquid storage and regulation functions of the intelligent liquid storage container 3, eliminates the need for external power sources such as fans and pumps, significantly reducing energy consumption, noise, and system complexity. Simultaneously, the integrated design deeply integrates the power mechanism, transmission mechanism, and heat dissipation mechanism within the outer shell assembly, greatly improving space utilization efficiency and structural compactness, perfectly meeting the stringent requirements of robot joints for lightweight and high reliability. Finally, through passive phase change cycling and intelligent adaptive mechanisms, this module ensures the temperature stability and service life of the joint under high torque conditions, providing a highly efficient, reliable, and low-maintenance intelligent temperature control solution for high-torque robot joints.

[0077] Meanwhile, the integration of high-precision temperature sensor 311 and high-precision pressure sensor 312 provides a data foundation for system status monitoring and life prediction, enhancing the maintainability and intelligence level of the module.

[0078] As an optional implementation, the heat pipe heat dissipation part includes an integrated motor housing 450, and a plurality of heat pipe grooves 451 are formed inside the integrated motor housing 450. One end of an interconnected heat pipe is embedded in the heat pipe groove 451. The heat pipe includes an evaporation section 420, an insulation section 430 and a condensation section 440. The evaporation section 420 is configured to exchange heat with the power mechanism, and the condensation section 440 is configured to exchange heat with the housing assembly.

[0079] The liquid storage container 313 is located on the side of the heat pipe away from the condenser section 440;

[0080] The liquid storage container 313 contains refrigerant. After evaporating and absorbing heat from the power mechanism in the evaporation section 420, the refrigerant evaporates and vaporizes. The vaporized refrigerant moves along the insulation section 430 to the condensation section 440, where it is condensed into a liquid state by heat exchange with the outside through the outer shell assembly and flows back to the liquid storage container 313.

[0081] When the power mechanism operates at high torque output, it generates a large amount of heat as a heat source. This heat is transferred to the heat dissipation mechanism, which is closely connected to the power mechanism for heat exchange, via thermal conduction. Specifically, the heat is transferred to the heat pipe evaporation section 420, which is embedded in the heat pipe groove 451 of the integrated motor housing 450. At this time, the liquid refrigerant from the intelligent liquid storage container 3 flows through the evaporation section 420 and absorbs heat, rapidly evaporating and vaporizing. The vaporized refrigerant then flows through the heat pipe's adiabatic section 430 to the condensation section 440, which is connected to the housing assembly for heat exchange. Under the effective heat exchange between the housing assembly and the external environment, the vaporized refrigerant releases its latent heat and condenses back into a liquid. The condensate then flows back to the intelligent liquid storage container 3, located on the side of the heat pipe away from the condensation section, thus completing a completely autonomous phase change heat transfer cycle that requires no external power input.

[0082] As an alternative implementation, the heat pipe is arranged around the outside of the power mechanism.

[0083] When the power unit operates, the heat generated is evenly conducted to the heat pipe evaporation section 420 surrounding it, allowing the refrigerant to vaporize efficiently on a larger contact surface. The vaporized refrigerant is then transported through the insulation section 430 to the condensation section 440 for condensation and recirculation. This structure significantly increases the heat exchange area through its surrounding layout, enhances heat capture efficiency, makes the surface temperature distribution of the power unit more uniform, avoids local overheating, and further improves the heat dissipation stability and reliability of the integrated module.

[0084] As an alternative implementation, the power mechanism includes components fixed within the housing assembly:

[0085] A high-power-density motor 5 is configured to exchange heat with the evaporation section 420 and the adaptive regulating valve 310.

[0086] The control unit is electrically connected to the high-power-density motor 5.

[0087] The high-power-density motor 5 generates heat during operation, which is simultaneously transferred to the evaporation section 420 and the adaptive regulating valve 310, triggering the circulation of the working fluid and flow regulation. Meanwhile, the control unit monitors and precisely drives the high-power-density motor 5 in real time. This structure, through deep coupling between the thermal management unit and the power unit, achieves simultaneous and intelligent control of heat generation and dissipation, ensuring the motor's thermal stability and control accuracy under high torque output.

[0088] As an optional implementation, the control unit includes a high-precision encoder 6 and a drive board 7 that are electrically connected to the high-power-density motor 5.

[0089] The drive board 7 outputs control signals according to motion commands to drive the high power density motor 5 to run; at the same time, the high-precision encoder 6 detects the position and speed of the motor rotor in real time and feeds them back to the drive board 7 to form a closed-loop control and realize precise control of the joint output.

[0090] The high-response closed-loop control system composed of the high-precision encoder 6 and the drive board 7 not only ensures the high precision and stability of the joint power output, but also provides the intelligent temperature control system with predictive adjustment based on the real-time operating data such as speed and current, realizing the synergistic optimization of power control and thermal management, thereby significantly enhancing the reliability and performance of the integrated module under dynamic working conditions.

[0091] As an optional implementation, the high power density motor 5 includes a motor housing, which is fixedly connected to the inner wall of the outer casing assembly, and also includes:

[0092] The stator is fixed inside the motor housing;

[0093] The rotor is rotatably mounted inside the motor housing;

[0094] The stator and rotor are connected in a transmission configuration.

[0095] The stator section is fitted onto the outside of the rotor section;

[0096] The stator section includes:

[0097] The stator core 510 is fixed inside the housing assembly;

[0098] The stator winding 520 is fixedly connected to the stator core 510;

[0099] The rotor section includes:

[0100] The rotor core 560 is coaxially and rotatably disposed inside the stator core 510;

[0101] Shaft 550 is coaxially fixed inside rotor core 560, and shaft 550 is rotatably engaged with motor housing;

[0102] Several rotor ventilation openings 570 are provided on the rotor core 560;

[0103] Shaft 550 is connected to the input end of the transmission mechanism;

[0104] The rotor core 560 has several permanent magnets embedded at equal intervals around its circumference. The several permanent magnets form the rotor winding 530, and the permanent magnets are connected to the stator winding 520 for transmission.

[0105] An end ring 540 is fixed on the rotor core 560, and the end ring 540 is used to constrain the axial displacement of the rotor core 560.

[0106] During operation, the high-power-density motor 5 generates a rotating magnetic field when the stator winding 520 is energized. This magnetic field interacts electromagnetically with the rotor winding 530, composed of circumferentially spaced permanent magnets, driving the rotor core 560 to rotate at high speed relative to the stator core 510. The rotor core 560 drives the coaxially fixed shaft 550 to rotate. This rotational motion is precisely output through the transmission connection between the shaft 550 and the input end of the transmission mechanism. During this process, several rotor ventilation openings 570 on the rotor core 560 promote airflow inside the motor, aiding in heat dissipation. Simultaneously, the end ring 540 fixed to the rotor core 560 effectively constrains the axial displacement of the rotor core 560, ensuring the dynamic stability of the rotor at high speeds. The entire motor is securely connected within the housing assembly via the motor housing, forming a compact power unit.

[0107] By employing a permanent magnet synchronous motor structure with the stator mounted outside the rotor, combined with the heat dissipation design of the rotor vent 570, efficient energy conversion and preliminary thermal management under high power density are achieved. The axial constraint of the end ring 540 on the rotor core 560 significantly enhances the structural rigidity of the motor rotor, improving the mechanical reliability of the motor under frequent start-stop and load variation conditions. The efficient connection between the high-power-density motor 5 and the transmission mechanism ensures smooth and precise power transmission from the motor to the joint output. Its compact integrated structure lays a solid foundation for the entire power-free intelligent temperature control integrated module to achieve high torque output within the limited space of the robot joint.

[0108] As an optional implementation, the transmission mechanism includes an output device 1 and a harmonic reducer 2. The fixed ends of the output device 1 and the harmonic reducer 2 are fixedly connected to the housing assembly, the input end of the harmonic reducer 2 is connected to the shaft 550, and the output end of the harmonic reducer 2 is connected to the input end of the output device 1.

[0109] When the transmission mechanism is working, the shaft 550 of the high-power-density motor 5 transmits high-speed rotational power to the input wave generator of the harmonic reducer 2. After being reduced in speed and increased in torque by the internal transmission structure of the harmonic reducer 2, the low-speed, high-torque output is sent to the output device 1 by the flexible wheel at its output end. Finally, the output device 1 drives the robot joints to produce precise movements. In this process, the fixed ends of the harmonic reducer 2 and the output device 1 are rigidly connected to the housing assembly, providing a stable support foundation for the entire transmission chain.

[0110] With its high reduction ratio, the harmonic reducer 2 efficiently converts the high speed and low torque of the motor shaft 550 into the low speed and high torque of the output device 1, perfectly meeting the power requirements of the robot joint. Its compact structure and integrated design with the output device 1 greatly improve the module's space utilization efficiency and torque transmission density. At the same time, the rigid connection installation method ensures high precision and low backlash during the transmission process, significantly enhancing the accuracy and reliability of joint motion control.

[0111] As an optional implementation, the harmonic reducer 2 includes a wave generator 211, a rigid wheel 212, and a flexible wheel 213; the rigid wheel 212 is fixedly connected to the housing assembly; the flexible wheel 213 is rotatably disposed inside the rigid wheel 212, and the external teeth of the flexible wheel 213 mesh with the internal teeth of the rigid wheel 212; the wave generator 211 is coaxially disposed inside the flexible wheel 213, and the wave generator 211 is fixedly connected to the shaft 550. The wave generator 211 is used to drive the flexible wheel 213 to generate elastic deformation to achieve interlocking meshing transmission with the rigid wheel 212.

[0112] The high-power-density motor 5's shaft 550 drives the wave generator 211 to rotate. The elliptical profile of the wave generator 211 forces the flexible wheel 213 to undergo elastic deformation, causing the external teeth of the flexible wheel 213 to engage with the internal teeth of the fixed rigid wheel 212 in a periodic meshing motion. Through the staggered meshing transmission, the input high-speed rotation is converted into low-speed high torque, which is finally output by the flexible wheel 213 to the output device 1.

[0113] The elastic drive of the flexible wheel 213 by the wave generator 211 achieves high-precision and high-rigidity power transmission with small transmission backlash and high torque density. The fixed connection between the rigid wheel 212 and the housing assembly provides a stable transmission reference, ensuring motion accuracy under high torque conditions. The entire reducer has a compact structure, perfectly meeting the core requirements of robot joints for high power density and precise control.

[0114] As an optional implementation, the housing assembly includes:

[0115] Robot external skin 8 and joint connection device 9 coaxially fixed inside robot external skin 8;

[0116] A passive heat dissipation unit is provided at one end of the robot's external skin 8;

[0117] The passive heat dissipation section and the condensation section 440 are heat exchanged.

[0118] The intelligent liquid storage container 3, the non-powered ring heat dissipation module 4, the high power density motor 5, the high precision encoder 6, the drive board 7, the fixed end of the harmonic reducer 2, and the fixed end of the output device 1 are all fixedly connected to the robot's external skin 8.

[0119] As an optional implementation, the passive heat dissipation unit includes:

[0120] Several fin slots 811 are arranged around the robot's outer skin 8. The fin slots 811 are opened at one end of the robot's outer skin 8. Heat dissipation fins 810 are fixedly connected to the fin slots 811. Several heat dissipation fins 810 are fixed to the robot's outer skin 8 by steel rings 812.

[0121] The heat exchange configuration includes heat dissipation fins 810 and condensation section 440.

[0122] Heat is efficiently transferred from the condensation section 440 of the heat pipe to the robot's external skin 8, where it exchanges heat. Subsequently, the heat is rapidly conducted within the robot's external skin 8 to the other end, where several surrounding fin slots 811 are located, and diffuses to the heat dissipation fins 810 fixed thereon. Finally, the heat is efficiently dissipated into the surrounding environment through the large surface area of ​​the heat dissipation fins 810 via natural convection and thermal radiation. During this process, steel rings 812 firmly bind the heat dissipation fins 810 to the robot's external skin 8, ensuring the structural stability of the heat dissipation interface and the continuity of heat transfer.

[0123] The combination of the robot's external skin 8 and the heat dissipation fins 810 creates an extremely efficient passive heat dissipation interface, significantly increasing the contact area with air, greatly enhancing the natural heat dissipation effect, and ensuring the rapid release of heat from the condensation section 440.

[0124] In this embodiment, the output device 1 is connected to the harmonic reducer 2, which is connected to the high power density motor 5 via a rotating shaft. The right side has a high-precision encoder 6 and a drive board 7.

[0125] The intelligent temperature control module implemented in this invention passively and passively achieves efficient heat extraction and intelligent regulation, which is the core technology of this solution. It includes: intelligent liquid storage container 3, adaptive regulating valve 310, non-powered annular heat dissipation module 4, evaporation section 420, insulation section 430, condensation section 440, integrated motor housing 450, robot external skin 8, and heat dissipation fins 810.

[0126] The evaporation section 420 of the non-powered annular heat dissipation module 4 is located inside the integrated motor housing 450, the heat insulation section 430 is located in the area between the robot joints, the condensation section 440 is located inside the robot's outer skin 8, and a large number of heat dissipation fins 810 are provided.

[0127] The evaporation section 420 of the non-powered annular heat dissipation module 4 is tightly fitted with the built-in groove of the integrated motor housing 450, which efficiently captures the heat generated by the high power density motor 5; the insulation section 430 is covered with heat insulation material to achieve lossless heat transfer in the internal space of the joint; the condensation section 440 is combined with the robot's external skin 8 to finally release the heat into the environment.

[0128] The workflow of this solution is a closely collaborative closed-loop process involving heat generation and capture: when the joint performs high-torque actions, the high-power-density motor 5 and the driver generate a large amount of heat. This heat is rapidly captured by the evaporation section 420 of the non-powered annular heat dissipation module 4 through thermal conduction.

[0129] During heat transfer, the liquid working fluid in the evaporation section 420 absorbs heat and vaporizes, forming vapor bubbles, leading to a local pressure increase. The pressure difference drives a two-phase flow of vapor and liquid plugs, flowing at high speed through the adiabatic section 430 and reaching the condensation section 440. In the condensation section 440, the vapor releases latent heat to the cooler outer skin 8 of the robot, condensing back into a liquid. Under the influence of gravity and capillary force, the condensed liquid automatically flows back to the evaporation section 420, completing an autonomous, unpowered cycle.

[0130] When heat is dissipated, the heat transferred to the robot's external skin 8 is eventually dissipated into the surrounding environment through natural convection and thermal radiation.

[0131] The non-powered annular heat dissipation module 4 features a ring design. Its working principle utilizes the phase change circulation of the internal working fluid: liquid absorbs heat and evaporates → steam flows → steam releases heat and condenses → liquid recirculates, achieving efficient heat transfer. This process requires no external power and has an extremely high equivalent thermal conductivity. The pipe diameter must meet certain requirements so that the influence of the working fluid's surface tension is comparable to or even exceeds the influence of gravity. At this time, a stable state of alternating gas plug and liquid distribution can be formed inside the tube. Substituting into the above equation, the critical diameter of the pulsating heat pipe can be obtained as:

[0132]

[0133] In the formula, The surface tension of the liquid is N / m, and g is the acceleration due to gravity in m / s². 2 , This refers to the density of the working fluid in its gaseous or liquid state.

[0134] Because the flow resistance of a pipe increases sharply as the pipe diameter decreases, the pipe diameter range for pulsating heat pipes in actual research is generally as follows:

[0135]

[0136] Calculate the thermal resistance of a non-powered heat pipe based on the temperature difference between the evaporation and condensation sections:

[0137]

[0138] In the formula These are the temperatures of the evaporation section and the condensation section, respectively, and Q is the external heat absorbed by the pulsating heat pipe.

[0139] The above calculations yield the following structural parameters for the heat pipe: a pipe diameter of 3mm, a bend diameter of 10mm, and 24 pulsating tubes. These parameters ensure that the pulsating heat pipe has good start-up performance and continuous working capability, while also meeting the thermal management requirements of the joint module.

[0140] The non-powered annular heat dissipation module 4 requires custom-manufactured annular pulsating heat pipes, making their processing particularly important. The pipes are made of TP2-grade seamless copper tubing with high thermal conductivity and high ductility, with a purity ≥99.9%, ensuring excellent thermal conductivity and processing capabilities. The pipes are filled with 3M Novec 7200 electronic fluorinated liquid, which has a moderate boiling point, chemical inertness, non-flammability, and excellent dielectric properties, making it ideal for enclosed heat dissipation scenarios.

[0141] The heat pipe manufacturing process mainly includes the following steps:

[0142] Pipe forming and bending: CNC pipe bending machine is used for precise bending to ensure that the pipe diameter of 3mm and the bending diameter of 10mm do not collapse or wrinkle during the bending process; in order to ensure the consistency of 24 parallel pulsating pipe units, customized pipe bending molds are used to achieve one clamping and multi-circuit synchronous forming.

[0143] Cleaning and decontamination: The formed copper tubes need to undergo a strict cleaning process: ultrasonic cleaning combined with organic solvents is used to remove oil stains and metal debris from the inner wall, and then high-purity nitrogen is used to blow dry to ensure that the inner wall is clean and to avoid impurities affecting the phase change and flow of the working fluid.

[0144] Assembly and Welding: The cleaned annular pipeline is assembled with the intelligent liquid storage container interface and the vacuum filling valve using high-vacuum brazing technology under an argon protective atmosphere. The welding process ensures airtightness, smooth and defect-free welds, and the ability to withstand internal pressure fluctuations and long-term thermal stress.

[0145] Vacuuming and working fluid charging: This step is the most critical. A high-vacuum unit is connected via a self-sealing vacuum filling valve integrated into the system to evacuate the entire loop to a high vacuum, completely eliminating non-condensable gases. Under vacuum, Novec 7200 fluorinated liquid, filling 50% of the total cavity volume, is injected using a precision liquid metering pump. This ratio has been calculated and experimentally verified to create a stable alternating vapor-liquid plug flow under the combined effects of gravity and capillary force, achieving optimal pulsating heat transfer.

[0146] Sealing and performance testing: After filling, the self-sealing valve automatically closes and locks to ensure a permanent system seal. Finally, airtightness and performance testing are performed: the evaporation section is heated on a constant-temperature hot plate, and the condensation section is forcibly cooled. The start-up characteristics and steady-state heat transfer power are verified using a thermal resistance tester to ensure they meet the design specifications.

[0147] As an optional implementation method, the heat pipe processing flow mainly includes the following steps:

[0148] Pipe forming and bending;

[0149] Pipeline cleaning and decontamination;

[0150] Piping installation;

[0151] The pipeline installation is evacuated and filled with working fluid.

[0152] Precise bending is performed using a CNC pipe bending machine to ensure that pipes with a diameter of 3mm and a bending diameter of 10mm do not collapse or wrinkle during the bending process; to ensure the consistency of the 24 parallel pulsating pipe units, a customized pipe bending mold is used to achieve simultaneous forming of multiple circuits in one clamping.

[0153] After forming, the copper tubes need to undergo a strict cleaning process: ultrasonic cleaning combined with organic solvents is used to remove oil stains and metal debris from the inner wall, and then high-purity nitrogen is used to blow them dry to ensure that the inner wall is clean and to avoid impurities affecting the phase change and flow of the working fluid.

[0154] The cleaned annular pipeline was assembled with the intelligent liquid storage container interface and the vacuum filling valve using high-vacuum brazing technology under an argon protective atmosphere. The welding process ensured airtightness, smooth and defect-free welds, and the ability to withstand internal pressure fluctuations and long-term thermal stress.

[0155] A self-sealing vacuum filling valve integrated into the system is connected to a high-vacuum unit, evacuating the entire loop to a high vacuum to completely eliminate non-condensable gases. Under vacuum, a precision liquid metering pump fills the system with Novec 7200 fluorinated liquid, filling 50% of the total cavity volume. This ratio, verified through calculation and experimentation, ensures a stable alternating vapor-liquid plug flow under the combined effects of gravity and capillary force, achieving optimal pulsating heat transfer.

[0156] Sealing and performance testing;

[0157] After filling, the self-sealing valve automatically closes and locks to ensure a permanent system seal. Finally, an airtightness test and performance test are conducted: the evaporation section is heated on a constant-temperature hot plate, and the condensation section is forcibly cooled. The start-up characteristics and steady-state heat transfer power are verified using a thermal resistance tester to ensure they meet the design specifications.

[0158] As an additional implementation method, the insulating section in the middle of the heat pipe is provided with a corrugated structure.

[0159] The heat pipe features a flexible design, with the insulation pipe incorporating a corrugated structure to allow for flexible deformation. The insulation section in the middle of the heat pipe is made into a continuous corrugated shape. The corrugated structure itself has the characteristics of low axial stiffness and high radial stiffness, allowing the heat pipe to be easily compressed, stretched, or bent at small angles in the axial direction. Meanwhile, the radial stiffness of the pipe wall is sufficient to maintain the integrity of its internal structure, preventing collapse due to deformation, while also allowing for a more flexible design.

[0160] The intelligent liquid storage container 3, serving as the system's "control center," not only stores the working fluid but also integrates a high-precision temperature sensor 311, a high-precision pressure sensor 312, and an adaptive regulating valve 310. Based on direct temperature signals and indirect motor operating parameters such as current and speed, it dynamically adjusts the working fluid circulation flow rate, achieving intelligent temperature control that moves from "passive response" to "active prediction." Intelligent control feedback signals: The system monitors the motor casing temperature in real time and can optionally combine encoder speed signals and drive board current signals to predict heating trends earlier. Decision-making and execution: The intelligent control algorithm processes these signals and outputs commands to the adaptive regulating valve. Normal operating conditions: When the temperature is within the safe threshold, the valve maintains a basic opening to ensure basic heat dissipation. High load conditions: When the temperature rises or is predicted to rise, the valve opening increases, increasing the working fluid circulation and improving heat dissipation. Overheat protection: If the temperature exceeds the danger threshold, in addition to maximizing heat dissipation, commands can be sent to the joint power module to trigger protection strategies such as current limiting, load reduction, or alarms.

[0161] This adaptive control valve, based on shape memory alloy (SMA), utilizes the temperature-sensitive properties of SMA to achieve passive actuation. It comprises a valve core, a shape memory alloy spring, a compression spring, a valve cover, and a sealing assembly. The SMA spring is made of nickel-titanium alloy and undergoes a two-stage memory training process, including a 30-minute constrained holding at 450°C followed by water quenching. This ensures its phase transformation temperature matches the temperature control threshold. At low temperatures (T < 50°C), the shape memory spring is weak, and under the action of the compression spring, the valve core is pushed towards the valve seat, maintaining the basic circulation. As the motor temperature rises, the shape memory spring temperature increases through heat conduction, exceeding its austenitic phase transformation initiation temperature. The spring then begins to recover its memory shape, overcoming the compression spring's force and pushing the valve core away from the valve seat. Once the shape memory spring has fully transformed into the austenitic phase, it generates maximum thrust, bringing the valve to a fully open state. When the motor temperature drops, the shape memory spring cools, its force weakens, and the compression spring gradually pushes the valve core to close, restoring the system to a low flow state. Based on the valve core stroke and required force, the wire diameter, number of coils, and length of the shape memory spring are calculated. Through thermomechanical training, its phase change temperature is precisely set near 60°C and 80°C to match the control threshold. Good thermal coupling is achieved between the valve body, the motor housing, and the evaporation section piping. High thermal conductivity silicone grease is used to fill the gaps, or the valve body is directly embedded in the groove of the motor housing to ensure that the shape memory spring can respond quickly and accurately to changes in motor temperature.

[0162] The robot's external skin 8 serves as the system's "ultimate heat sink," and its outer side is typically designed with heat dissipation fins 810. One side of these fins is located within the fin slot 811 and is connected and fixed by a steel ring 812 to maximize the area for convection and radiation heat dissipation with ambient air.

[0163] The high-power-density motor 5, as the core component, is a permanent magnet synchronous motor that pursues extremely high torque and power density, and is the core heat source of the system. The harmonic reducer 2 converts the high-speed, low-torque of the high-power-density motor 5 into the low-speed, high-torque required by the joint, generating heat in the process. The harmonic reducer 2 achieves high-precision differential gear transmission by driving the flexible wheel 213 to deform through the wave generator 211. The outer rigid wheel 212 has a larger number of gears, characterized by small backlash, high transmission accuracy, long lifespan, and strong stability. The high-precision encoder 6 and the integrated drive board 7 are connected to the high-power-density motor 5 via cables, enabling precise closed-loop control of the high-power-density motor 5 and providing predictive data for intelligent temperature control.

[0164] This module features a compact cylindrical structure, seamlessly integrated between two joints of a robot limb, such as the shoulder or hip joint. This implementation offers highly efficient passive cooling: utilizing the extremely high heat transfer efficiency of the pulsating heat pipe, it achieves efficient heat dissipation without the need for external power sources like fans or pumps, significantly reducing system complexity and energy consumption. Deep integration and compactness: The temperature control element is highly integrated with the joint structure, occupying no additional space and perfectly meeting the design requirements of lightweight and compact robot joints. In terms of intelligence and forward-looking design: through multi-source information fusion control, passive cooling is transformed into active thermal management, resulting in more timely response and more precise control, greatly improving the system's stability and lifespan under dynamic operating conditions. Regarding high reliability and safety: the annular pulsating heat pipe has no moving parts, ensuring silent and reliable operation; the intelligent system has overheat protection, providing double protection for this expensive joint module.

[0165] The working process of this module includes the following steps:

[0166] S100. When the robot joint is running with high torque output, the high power density motor 5 serves as the main heat source, and its outer shell temperature rises rapidly.

[0167] S200: Heat is transferred through copper pipes to the evaporation section 420 of the unpowered annular heat dissipation module 4, causing the liquid fluoride liquid in the section to absorb heat and evaporate, forming high-pressure steam bubbles.

[0168] S300, the vapor bubble and liquid plug, driven by the pressure difference and surface tension inside the tube, flow at high speed through the adiabatic section 430 to the condensation section 440;

[0169] S400, In the condensation section 440, the steam releases latent heat to the robot's cooler external skin 8 and condenses into a liquid;

[0170] S500, the liquid working fluid flows back to the evaporation section 420 under the assistance of gravity and the microstructure of the pipe wall;

[0171] The S600 and intelligent liquid storage container 3 replenish the working fluid and regulate its flow, completing an autonomous, efficient, and externally power-free phase change heat transfer cycle.

[0172] As demonstrated above, the embodiments of the present invention significantly improve joint heat dissipation efficiency, proving the effectiveness of the solution. This technical solution provides a clear and feasible technical path for the joint design of next-generation high-performance, high-reliability humanoid robots and various advanced robots.

[0173] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0174] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A robot large torque joint sourceless intelligent temperature control integrated module, characterized in that, The utility model relates to a high-power density motor cooling device, including: The shell assembly is equipped with power mechanism, transmission mechanism and heat dissipation mechanism in the shell assembly; The power mechanism and the transmission mechanism drive cooperation; The heat dissipation mechanism and the power mechanism, the shell assembly heat exchange arrangement; The heat dissipation mechanism includes intelligent liquid storage container (3) and the heat pipe heat dissipation part of intelligent liquid storage container (3) intercommunication, one end of heat pipe heat dissipation part and intelligent liquid storage container (3) with power mechanism heat exchange arrangement, the other end of heat pipe heat dissipation part and the shell assembly heat exchange arrangement; The intelligent liquid storage container (3) includes: Liquid storage container (313) is used for storing refrigerant, and the liquid storage container (313) is coaxially fixed in the shell assembly; The liquid storage container (313) is communicated with the heat pipe heat dissipation part through the self-adapting regulating valve (310); The self-adapting regulating valve (310) is a memory alloy and a valve core, the memory alloy is fixed with the valve core, the valve core is movably arranged in the liquid storage container (313), and the valve core is used for blocking the communication hole of the liquid storage container (313) and the heat pipe heat dissipation part; The memory alloy and the power mechanism heat exchange arrangement, the memory alloy is deformed after being heated to make the valve core separate from the communication hole.

2. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 1, characterized in that, The heat pipe heat dissipation part includes integrated motor housing (450), a plurality of heat pipe grooves (451) are formed in the integrated motor housing (450), one end of the heat pipe embedded in the heat pipe grooves (451) is communicated, the heat pipe includes evaporation section (420), heat insulation section (430) and condensation section (440), the evaporation section (420) and the power mechanism heat exchange arrangement, the condensation section (440) and the shell assembly heat exchange arrangement; The liquid storage container (313) is located on the side, away from the condensation section (440) of the heat pipe; The liquid storage container (313) is provided with refrigerant, the refrigerant is evaporated and vaporized after absorbing the heat of the power mechanism through the evaporation section (420), the vaporized refrigerant moves along the heat insulation section (430) to the condensation section (440), and the refrigerant is condensed into liquid state by the shell assembly and the outside heat exchange and returns to the liquid storage container (313).

3. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 2, characterized in that: The heat pipe is arranged on the outside of the power mechanism.

4. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 2, characterized in that, The power mechanism includes the high-power density motor (5) and the self-adapting regulating valve (310) heat exchange arrangement fixed in the shell assembly; The control part is electrically connected with the high-power density motor (5). The control part includes high-precision encoder (6) and drive board (7) electrically connected with the high-power density motor (5).

5. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 4, characterized in that: The high-power density motor (5) includes a motor housing, the motor housing is fixedly connected with the inner wall of the shell assembly, and further includes a stator portion fixed in the motor housing and a rotor portion rotatably arranged in the motor housing.

6. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 4, characterized in that, The stator portion and the rotor portion drive cooperation; The stator portion is arranged on the outside of the rotor portion; The stator portion includes: ​ ​ ​ A stator core (510) is fixed in the housing assembly; A stator winding (520) is fixed with the stator core (510); The rotor part comprises: A rotor core (560) is coaxially and rotatably arranged inside the stator core (510); An axle (550) is coaxially fixed in the rotor core (560), and the axle (550) is rotatably connected with the motor housing; A plurality of rotor ventilation openings (570) are arranged on the rotor core (560); The axle (550) is drivingly connected with the input end of the transmission mechanism; A plurality of permanent magnets are fixed on the rotor core (560) at equal intervals in the circumferential direction, and the permanent magnets form a rotor winding (530), which is drivingly connected with the stator winding (520); An end ring (540) is fixed on the rotor core (560), and the end ring (540) is used to restrict the axial displacement of the rotor core (560).

7. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 6, characterized in that, The transmission mechanism comprises an output device (1) and a harmonic reducer (2), the fixed ends of the output device (1) and the harmonic reducer (2) are fixed with the housing assembly, the input end of the harmonic reducer (2) is connected with the axle (550), and the output end of the harmonic reducer (2) is connected with the input end of the output device (1). 8.The robot large torque joint source-free intelligent temperature control integrated module according to claim 7, characterized in that: The harmonic reducer (2) comprises a wave generator (211), a rigid gear (212) and a flexible gear (213), the rigid gear (212) is fixedly connected with the housing assembly, the flexible gear (213) is rotatably arranged inside the rigid gear (212), the external teeth of the flexible gear (213) are engaged with the internal teeth of the rigid gear (212), and the wave generator (211) is coaxially arranged in the flexible gear (213), the wave generator (211) is fixedly connected with the axle (550), and the wave generator (211) is used to drive the flexible gear (213) to produce elastic deformation to realize the tooth-mismatched engagement transmission with the rigid gear (212).

9. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 2, characterized in that, The housing assembly comprises: A robot external skin (8) and a joint connecting device (9) coaxially fixed in the robot external skin (8); One end of the robot external skin (8) is provided with a passive heat dissipation part; The passive heat dissipation part is in heat exchange with the condensation section (440).

10. The robot large torque joint unpowered source intelligent temperature control integrated module according to claim 9, characterized in that, The passive heat dissipation part comprises: A plurality of fin clamping grooves (811) are arranged around, the fin clamping grooves (811) are arranged at one end of the robot external skin (8), heat dissipation fins (810) are fixed on the fin clamping grooves (811), and a plurality of heat dissipation fins (810) are fixed on the robot external skin (8) through a steel ring (812); The heat dissipation fins (810) are in heat exchange with the condensation section (440).

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