Speed reducer module

Abstract

The invention relates to the field of speed reducers, in particular to a speed reducer module which comprises an outer rigid gear, an inner rigid gear, a flexible gear, a wave generator, a torque sensor and a motor module, the torque sensor is fixedly connected with the outer rigid gear, the flexible gear is connected with the torque sensor through a fixing flange of the flexible gear, and the output end of the motor module is connected with the wave generator. The flexible gear is driven by the wave generator to periodically and elastically deform, so that outer teeth of the flexible gear are meshed with inner teeth of the inner rigid gear. The sensor outer ring is fixedly connected with the outer rigid gear, the flexible gear is connected with the sensor inner ring through the fixing flange of the flexible gear, the torsional force of the output end is sensed through the strain gauges in the sensor, and mechanical signals are converted into electric signals for real-time monitoring. The motor module dynamically adjusts output parameters according to torque data fed back by the sensor, a closed-loop control system is formed, and accurate transmission and overload protection are achieved. And the torque change of the output end is monitored in real time, so that structural damage caused by overload can be avoided.

Description

Technical Field

[0001] This invention relates to the field of speed reducers, and more particularly to a speed reducer module. Background Technology

[0002] As a core component in the field of precision transmission, the performance of the reducer module directly affects the operational reliability and control accuracy of equipment such as robots and CNC machine tools. Existing technologies suffer from two prominent problems in practical applications: Traditional reducer modules generally lack effective overload protection mechanisms. Due to the absence of integrated real-time torque monitoring, the equipment can only trigger passive protection through accumulated mechanical deformation or temperature rise, resulting in a significant response delay (typically exceeding 0.5 seconds). Under overload conditions, the flexible and rigid gears are prone to irreversible deformation due to instantaneous overload, leading to decreased transmission accuracy or even structural failure. For example, when a robot handles an object exceeding its rated load, the delayed protection in a traditional reducer may cause a significant increase in tooth surface wear.

[0003] Furthermore, existing technologies have shortcomings in terms of dynamic load adaptability. Most traditional reducer modules adopt an open-loop control mode, and the motor output parameters (speed, torque) cannot be adjusted in real time according to actual load changes. In scenarios with frequent load switching (such as robots grasping objects of different weights), the system is prone to operational instability due to the rigid fixed torque output, manifesting as objects slipping or robotic arm shaking, affecting operational accuracy. Summary of the Invention

[0004] To address the aforementioned issues, this invention provides a speed reducer module that significantly improves overload protection response speed and adaptability to multiple load scenarios through real-time torque monitoring and dynamic parameter adjustment.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a reducer module, comprising an outer rigid wheel, an inner rigid wheel, a flexible wheel, a wave generator, a torque sensor, and a motor module, wherein the torque sensor is fixedly connected to the outer rigid wheel, the flexible wheel is connected to the torque sensor through its own fixed flange, and the output end of the motor module is connected to the wave generator. The wave generator drives the flexible wheel to periodically elastically deform, causing the outer teeth of the flexible wheel to mesh with the inner teeth of the inner rigid wheel, and the inner rigid wheel to rotate and serve as the output end of the reducer.

[0006] Furthermore, the torque sensor includes an outer sensor ring and an inner sensor ring, which are connected by a strain beam. The surface of the strain beam is provided with strain gauges, and the flexible wheel is connected to the inner sensor ring through a fixed flange.

[0007] Furthermore, it also includes a fixed inner ring, which is connected to the fixed flange of the flexible wheel, and the fixed inner ring is movably fitted inside the outer rigid wheel.

[0008] Furthermore, the inner wall of the outer rigid wheel is provided with a first ball groove, and the outer wall of the fixed inner ring is provided with a second ball groove. A number of balls are fitted between the first ball groove and the second ball groove, so that the fixed inner ring is movably fitted inside the outer rigid wheel.

[0009] Furthermore, the inner ring of the sensor has multiple first mounting holes distributed along its circumference, and the fixed flange is provided with several second mounting holes. The fixed flange on the flexible wheel is mounted on the inner ring of the sensor by bolts passing through the second mounting holes and the first mounting holes.

[0010] Furthermore, the fixed inner ring and the fixed flange are an integral structure.

[0011] Furthermore, a third ball groove is provided on the inner wall of the outer rigid wheel, and a fourth ball groove is provided on the outer wall of the inner rigid wheel. Several balls are fitted between the third ball groove and the fourth ball groove, so that the inner rigid wheel is movably fitted inside the outer rigid wheel.

[0012] Furthermore, the inner rigid wheel is connected to an output flange, and the output flange is also connected to an output sleeve, wherein the end of the output sleeve is provided with a first code disk, and the corresponding motor module is provided with an encoder control disk that cooperates with the first code disk.

[0013] Furthermore, the motor module is also equipped with a second code disk, which works in conjunction with the encoder control disk.

[0014] Furthermore, the motor module includes a motor housing, a rotor, a stator, and an output shaft. The rotor and stator are built inside the motor housing. The rotor rotates relative to the stator. At the same time, the rotor is connected to an output shaft that extends to the outside of the electronic housing. This output shaft is connected to a wave generator. The sensor outer ring, outer rigid wheel, and motor housing are fixed by bolts.

[0015] The beneficial effects of this invention are as follows: The outer ring of the sensor is fixedly connected to the outer rigid wheel, while the flexible wheel is connected to the inner ring of the sensor via its own fixing flange. The sensor's internal strain gauges sense the torsional force at the output end, converting the mechanical signal into an electrical signal for real-time monitoring. The motor module dynamically adjusts its output parameters based on the torque data fed back from the sensor, forming a closed-loop control system that achieves precise transmission and overload protection. Furthermore, real-time monitoring of output torque changes prevents structural damage caused by overload. The system dynamically adjusts the motor output based on torque data, optimizing motion planning under different loads, improving the stability of gripping and handling operations, and solving the problems of lag in overload protection and insufficient control precision in traditional reducers. Attached Figure Description

[0016] Figure 1 This is a cross-sectional structural diagram of the reducer module.

[0017] Figure 2This is an exploded view of the torque sensor, flexible wheel, and fixed inner ring assembly.

[0018] Figure 3 This is a cross-sectional structural diagram of a fixed flange and a fixed inner ring that are integrated into one unit.

[0019] Figure 4 This is a cross-sectional structural diagram of the reducer module after omitting the motor module.

[0020] Reference numerals: 1. Motor module; 11. Motor housing; 12. Stator; 13. Rotor; 14. Output shaft; 15. Second code disk; 16. Encoder control disk; 20. Wave generator; 21. Outer rigid wheel; 211. First ball groove; 212. Third ball groove; 22. Inner rigid wheel; 221. Fourth ball groove; 222. Ball; 23. Torque sensor; 231. Sensor outer ring; 232. Sensor inner ring; 2321. First mounting hole; 261. Second mounting hole; 233. Strain beam; 24. Flexible wheel; 25. Fixed inner ring; 251. Second ball groove; 26. Fixed flange; 27. Output flange; 28. Output sleeve; 29. ​​First code disk. Detailed Implementation

[0021] Please see Figure 1-4 As shown, this invention relates to a reducer module, including an outer rigid wheel 21, an inner rigid wheel 22, a flexible wheel 24, a wave generator 20, a torque sensor 23, and a motor module 1. The torque sensor 23 is fixedly connected to the outer rigid wheel 21, and the flexible wheel 24 is connected to the torque sensor 23 through its own fixing flange 26. The output end of the motor module 1 is connected to the wave generator 20. The wave generator 20 drives the thin-walled flexible wheel 24 to periodically elastically deform, causing the outer teeth of the flexible wheel 24 to mesh with the inner teeth of the inner rigid wheel 22 (meshing at the major axis of the ellipse and disengaging at the minor axis, using the difference in the number of teeth to achieve speed reduction transmission); the inner rigid wheel 22 rotates and serves as the output end of the reducer.

[0022] The output of motor module 1 is directly connected to wave generator 20. Wave generator 20 drives thin-walled flexible wheel 24 to generate periodic elastic deformation. The external teeth of flexible wheel 24 mesh with the internal teeth of inner rigid wheel 22 at the major axis of the ellipse and disengage at the minor axis, achieving speed reduction transmission through the difference in the number of teeth. Inner rigid wheel 22 rotates and serves as the output to transmit power. The outer ring of torque sensor 23 is fixedly connected to outer rigid wheel 21, and flexible wheel 24 is connected to the inner ring 232 of sensor through its own fixing flange 26. The torque sensor 23 senses the torsional force at the output end through strain gauges, converting the mechanical signal into an electrical signal for real-time monitoring. Motor module 1 dynamically adjusts output parameters based on the torque data fed back by torque sensor 23, forming a closed-loop control system to achieve precise transmission and overload protection.

[0023] For example, in practical applications: when the robot attempts to move an object exceeding its rated load (e.g., 10kg), the torque sensor 23 integrated between the flexible wheel 24 and the outer rigid wheel 21 immediately detects that the torque value exceeds the safety threshold. The system triggers overload protection within 0.1 seconds, cutting off the motor power output and issuing an alarm to prevent the flexible wheel 24 from breaking due to excessive torsion. Compared to traditional reducers (which typically require more than 0.5 seconds to respond), safety is greatly improved. Furthermore, when the robot is moving a 5kg object, the closed-loop control system identifies load changes through torque data (e.g., 3N·m) and automatically adjusts the motor speed to 1200rpm and the torque output to 4N·m to ensure smooth handling. If the load suddenly increases to 7kg, the system increases the torque to 6N·m and reduces the speed to 800rpm within 2ms to prevent the object from slipping.

[0024] Please see Figure 2 As shown, in this specific embodiment, the torque sensor 23 includes an outer sensor ring 231 and an inner sensor ring 232. The outer sensor ring 231 and the inner sensor ring 232 are connected by a strain beam 233, and strain gauges are provided on the surface of the strain beam 233. The flexible wheel 24 is connected to the inner sensor ring 232 through a fixed flange 26.

[0025] The torque sensor 23 of this invention consists of an outer ring, an inner ring, and a strain beam 233, with strain gauges disposed on the surface of the strain beam 233. When the flexure 24 is subjected to force and undergoes torsion, the torque is transmitted to the inner ring 232 of the sensor through the fixed flange 26, causing the strain beam 233 to undergo slight deformation. After sensing this deformation, the strain gauge converts the mechanical signal into an electrical signal output, realizing real-time torque monitoring. The motor module 1 dynamically adjusts the output parameters according to the electrical signal fed back by the sensor, forming a closed-loop control system to ensure transmission accuracy and overload protection. For example, in this embodiment, a BX120-3AA high-precision resistance strain gauge is specifically used.

[0026] Please see Figure 1-4 As shown, in another embodiment, a fixed inner ring 25 is further included. The fixed inner ring 25 is fixedly connected to the fixed flange 26 of the flexible wheel 24. Simultaneously, the fixed inner ring 25 is movably fitted inside the outer rigid wheel 21, allowing the fixed flange 26 to twist, but restricting its deformation along its own axial direction. Furthermore, in another embodiment, the inner wall of the outer rigid wheel 21 is provided with a first ball groove 211, and the outer wall of the fixed inner ring 25 is provided with a second ball groove 251. A plurality of balls 222 are fitted between the first ball groove 211 and the second ball groove 251, allowing the fixed inner ring 25 to be movably fitted inside the outer rigid wheel 21.

[0027] Because the fixed flange 26 receives radial torsional force and axial push-pull force when the flexible wheel 24 is under normal operation, the sensor will receive unwanted deformation signal (axial push-pull force) when the flexible wheel 24 is under torsion. In order to solve this problem, in this embodiment, the fixed inner ring 25 is fixedly connected to the fixed flange 26 of the flexible wheel 24, and the fixed inner ring 25 is movably fitted inside the outer rigid wheel 21. Specifically, the outer rigid wheel 21 and the fixed inner ring 25 are fitted with balls 222 through the first ball groove 211 and the second ball groove 251 to limit the axial deformation of the fixed inner ring 25 and only allow it to twist.

[0028] When the flexible wheel 24 is subjected to force, the torsional force is transmitted to the fixed inner ring 25 through the fixed flange 26, allowing it to rotate slightly (to allow the generation of radial torsional force). Simultaneously, the balls 222 convert sliding friction into rolling friction, reducing energy loss. The torque sensor 23 senses the torsional deformation of the fixed inner ring 25 through strain gauges, converting the mechanical signal into an electrical signal output, achieving precise monitoring of only the torsional force.

[0029] Furthermore, in another embodiment, the fixed inner ring 25 and the fixed flange 26 are an integral structure (see [reference]). Figure 3 Integrated design reduces the number of parts and assembly steps, thereby improving assembly efficiency.

[0030] Furthermore, the inner wall of the outer rigid wheel 21 is provided with a third ball groove 212, and the outer wall of the inner rigid wheel 22 is provided with a fourth ball groove 221. A number of balls 222 are fitted between the third ball groove 212 and the fourth ball groove 221, so that the inner rigid wheel 22 is movably fitted inside the outer rigid wheel 21.

[0031] A rolling ball 22 is fitted between the third ball groove 212 on the inner wall of the outer rigid wheel 21 and the fourth ball groove 221 on the outer wall of the inner rigid wheel 22, forming a rolling support structure. The balls 222 roll within the grooves, converting sliding friction into rolling friction, significantly reducing energy loss. Simultaneously, the balls 222 evenly bear the radial and axial loads during the rotation of the inner rigid wheel 22, avoiding localized overload, and maintain the relative position of the inner rigid wheel 22 and the outer rigid wheel 21 through precise guidance, thereby achieving efficient and smooth transmission. In another embodiment, the balls 22 fitted between the third ball groove 212 on the inner wall of the outer rigid wheel 21 and the fourth ball groove 221 on the outer wall of the inner rigid wheel 22 are specifically cylindrical rollers.

[0032] Furthermore, the inner rigid wheel 22 is connected to an output flange 27, and the output flange 27 is also connected to an output sleeve 28. The end of the output sleeve 28 is provided with a first code disk 29, and the corresponding motor module 1 is provided with an encoder control disk 16 that cooperates with the first code disk 29. Furthermore, a second code disk 15 is also provided inside the motor module, and the second code disk 15 cooperates with the encoder control disk 16.

[0033] The inner rigid wheel 22 transmits its rotational motion to the output sleeve 28 via the output flange 27. The first code disk 29 at the end of the sleeve rotates synchronously with the inner rigid wheel 22. The first code disk 29 cooperates with the encoder control disk 16 in a non-contact manner (such as photoelectric or magnetoelectric) to provide real-time feedback on the position and speed information of the inner rigid wheel 22. At the same time, the second code disk 15 inside the motor module 1 cooperates with the encoder control disk 16 to monitor the position and speed of the motor rotor 13, forming a closed-loop control at the motor level. Through the dual feedback of the two code disks, the control system can simultaneously monitor the status of the reducer output and the motor input, achieving high-precision position and speed control and dynamically adjusting to adapt to load changes.

[0034] Furthermore, in another embodiment, the inner ring 232 of the sensor has a plurality of first mounting holes 2321 distributed along its circumference, and the fixed flange 26 is provided with a plurality of second mounting holes 261. The fixed flange 26 on the flexible wheel 24 is mounted on the inner ring 232 of the sensor by bolts passing through the second mounting holes 261 and the first mounting holes 2321.

[0035] The sensor inner ring 232 has multiple first mounting holes 2321 distributed circumferentially, and the fixing flange 26 has corresponding second mounting holes 261. A rigid connection is achieved by bolts passing through both. This design ensures that the fixing flange 26 of the flex wheel 24 is tightly fixed to the sensor inner ring 232, transmitting torque and motion. The circumferential mounting holes distribute the connection force evenly around the circumference, avoiding localized stress concentration and improving fatigue resistance. Simultaneously, when the flex wheel 24 undergoes periodic elastic deformation during transmission, the circumferential mounting hole design ensures that it rotates synchronously with the sensor inner ring 232, avoiding transmission errors caused by loose connections. The bolted connection also allows insertion from different angles, simplifying the assembly process, and is particularly suitable for scenarios with limited space or requiring rapid assembly and disassembly.

[0036] Furthermore, the motor module 1 includes a motor housing 11, a rotor 13, a stator 12, and an output shaft 14. The rotor 13 and the stator 12 are built inside the motor housing 11. The rotor 13 rotates relative to the stator 12. At the same time, the rotor 13 is connected to the output shaft 14 extending outside the electronic housing. The output shaft 14 is connected to the wave generator 20.

[0037] Furthermore, the sensor outer ring 231, outer rigid wheel 21, and motor housing 11 are fixed with bolts. This bolted fixing of the sensor outer ring 231, outer rigid wheel 21, and motor housing 11 forms a stable, rigid structure. The bolts pass through through holes or threaded holes on each component, and preload ensures a tight connection, preventing relative movement or separation. This design effectively transmits torque and axial force, maintains the relative positional accuracy of each component, reduces deformation caused by external loads, enhances the overall structural bending and torsional stiffness, and adapts to dynamic load changes.

[0038] The above embodiments are merely descriptions of 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 speed reducer module, characterized in that, It includes an outer rigid wheel, an inner rigid wheel, a flexible wheel, a wave generator, a torque sensor, and a motor module. The torque sensor is fixedly connected to the outer rigid wheel, and the flexible wheel is connected to the torque sensor through its own fixed flange. The output end of the motor module is connected to the wave generator, which drives the flexible wheel to periodically deform elastically, causing the outer teeth of the flexible wheel to mesh with the inner teeth of the inner rigid wheel. The torque sensor detects the torsional force of the fixed flange and converts it into an electrical signal for real-time monitoring.

2. The reducer module according to claim 1, characterized in that: The torque sensor includes an outer sensor ring and an inner sensor ring, which are connected by a strain beam. The surface of the strain beam is provided with strain gauges, and the flexible wheel is connected to the inner sensor ring through a fixed flange.

3. A reducer module according to claim 2, characterized in that: It also includes a fixed inner ring, which is connected to the fixed flange of the flexible wheel, and the fixed inner ring is movably fitted inside the outer rigid wheel.

4. A reducer module according to claim 3, characterized in that: The inner wall of the outer rigid wheel is provided with a first ball groove, and the outer wall of the fixed inner ring is provided with a second ball groove. A number of balls are fitted between the first ball groove and the second ball groove, so that the fixed inner ring is movably fitted inside the outer rigid wheel.

5. A reducer module according to claim 3, characterized in that: The sensor inner ring has multiple first mounting holes distributed along its circumference, and the fixed flange has several second mounting holes. The fixed flange on the flexible wheel is mounted on the sensor inner ring by bolts passing through the second mounting holes and the first mounting holes.

6. A reducer module according to claim 3, characterized in that: The fixed inner ring and the fixed flange are an integral structure.

7. A reducer module according to claim 3, characterized in that: The inner wall of the outer rigid wheel is also provided with a third ball groove, and the outer wall of the inner rigid wheel is provided with a fourth ball groove. Several balls are fitted between the third ball groove and the fourth ball groove, so that the inner rigid wheel is movably fitted inside the outer rigid wheel.

8. A reducer module according to claim 3, characterized in that: The inner rigid wheel is connected to an output flange, and the output flange is also connected to an output sleeve. The end of the output sleeve is provided with a first code disk, and the corresponding motor module is provided with an encoder control disk that cooperates with the first code disk.

9. A reducer module according to claim 7, characterized in that: The motor module also has a second code disk inside, which works in conjunction with the encoder control disk.

10. A reducer module according to claim 9, characterized in that: The motor module includes a motor housing, a rotor, a stator, and an output shaft. The rotor and stator are built inside the motor housing. The rotor rotates relative to the stator. At the same time, the rotor is connected to an output shaft that extends to the outside of the electronic housing. This output shaft is connected to a wave generator. The sensor outer ring, outer rigid wheel, and motor housing are fixed by bolts.

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