Ultra-light servo steering engine and integrated control system thereof

Abstract

The invention discloses an ultralight servo steering engine and an integrated control system thereof, the ultralight servo steering engine comprises a steering engine execution unit and an integrated control unit, the steering engine execution unit comprises a motor, a speed reducing mechanism connected with an output shaft of the motor, and a position sensor for feeding back the actual position angle of the output shaft of the steering engine; the position sensor is calibrated through the sensing calibration system; the integrated control unit and the steering engine execution unit are integrated in the same shell, the integrated control unit comprises a controller, a driving circuit and a communication interface, the communication interface is connected with the controller and used for achieving data interaction with external equipment, and the controller is used for receiving an external control instruction and generating a motor control signal; the driving circuit is electrically connected between the controller and the motor and used for driving the motor to rotate according to the motor control signal, and the controller is further used for receiving a position feedback signal of the position sensor, conducting closed-loop control operation according to an external control instruction and the position feedback signal and adjusting the running state of the motor through the driving circuit.

Description

Technical Field

[0001] This application relates to the field of micro-electro-mechanical systems (MEMS) technology, and more specifically, to an ultra-lightweight servo motor and its integrated control system. Background Technology

[0002] Miniature servos are small, precision motion control systems driven by electricity, used to precisely control the angle or position of their output shafts. They play a crucial role in micro unmanned aerial vehicles (UAVs), small guided weapon systems, tactical communication and detection antennas, and their performance directly affects the control accuracy of the devices. Traditional servos mostly employ low-integration analog servo control schemes, which have limitations such as slow response speed and weak anti-interference capabilities. With the development of high-performance digital processors and advanced sensing technologies, integrated and high-precision digital servo systems have become a current research hotspot. However, the weight of servos reported in existing literature is mostly in the tens of grams range, and systematic design and performance verification of ultra-miniature servos ≤0.7g are still rarely addressed. The design of such servos requires the collaborative solution of interdisciplinary challenges such as lightweight structure, micro-device fabrication, and nonlinear closed-loop control. The research results will not only meet the urgent needs of micro UAVs, small guided weapons, and military robots, but will also play an important role in promoting the advancement of nonlinear control theory and micro / nano manufacturing technology. Summary of the Invention

[0003] This application provides an ultra-lightweight servo motor and its integrated control system, which solves the technical problems of low weight, slow response speed and poor control accuracy of existing servo motors. It can be widely used in small mechanical and electronic equipment to achieve precise position control.

[0004] The specific technical solution is as follows: This application provides an ultra-lightweight servo motor and its integrated control system, including: The servo actuator includes a motor, a reduction gear connected to the output shaft of the motor, and a position sensor that provides feedback on the actual position angle of the servo output shaft; wherein the position sensor is calibrated and adjusted using a sensor calibration system. An integrated control unit is integrated with the servo actuator unit within the same housing. The integrated control unit includes a controller, a drive circuit, and a communication interface. The communication interface is connected to the controller for data interaction with external devices. The controller receives external control commands and generates motor control signals. The drive circuit is electrically connected between the controller and the motor and drives the motor to rotate according to the motor control signals. The controller also receives position feedback signals from the position sensor and performs closed-loop control calculations based on the external control commands and the position feedback signals, adjusting the motor's operating state through the drive circuit.

[0005] In some embodiments of this application, the motor is a miniature hollow cup DC motor.

[0006] In some embodiments of this application, the reduction mechanism is a two-stage hybrid reduction mechanism that combines a worm gear transmission mechanism and a gear transmission mechanism.

[0007] In some embodiments of this application, the reduction mechanism includes the worm, worm wheel, intermediate shaft, pinion, hollow sector gear, and reduction output shaft; The worm and the worm wheel are disposed in the first plane of the circuit board, and the pinion and the hollow sector gear are disposed in the second plane of the circuit board; The central axis of the worm is parallel to the first plane of the circuit board. The output shaft of the motor is connected to the worm and drives the worm to rotate. The worm meshes with the worm wheel. The intermediate shaft passes through the circuit board, and the worm wheel and the pinion are fixedly connected through the intermediate shaft to achieve synchronous rotation. The pinion meshes with the hollow sector gear to convert the rotational motion into oscillating motion. The hollow sector gear is fixedly connected to the reduction output shaft, and the reduction output shaft passes from the second plane of the circuit board to the first plane to output the oscillating motion to an external mechanism.

[0008] In some embodiments of this application, the hollow sector gear is an aluminum alloy CNC gear.

[0009] In some embodiments of this application, the worm gear transmission mechanism serves as a first-stage reduction mechanism, and the gear transmission mechanism serves as a second-stage reduction mechanism.

[0010] In some embodiments of this application, the reduction ratio of the worm gear transmission mechanism is 20 to 50, and the reduction ratio of the gear transmission mechanism is 2 to 7.5.

[0011] In some embodiments of this application, the position sensor is an off-axis 3D Hall sensor, and a cylindrical annular permanent magnet is fixedly installed at the end of the deceleration output shaft of the deceleration mechanism. The actual position angle of the servo motor output shaft is obtained by measuring the magnetic field angle of the cylindrical annular permanent magnet through the off-axis 3D Hall sensor. The sensing calibration system is an off-axis calibration system based on a three-axis linear Hall chip, and the position sensor is calibrated and adjusted by combining a magnetic field surface fitting algorithm. The internal integrated angle calculation circuit of the three-axis linear Hall chip is configured to directly output the arctangent angle value based on the X-axis and Y-axis magnetic field measurement values.

[0012] In some embodiments of this application, the driving circuit is a 3.3V single-voltage digital driving control circuit.

[0013] In some embodiments of this application, the controller is configured to perform friction compensation control based on Lyapunov stability theory to suppress microscale static friction disturbances in the deceleration mechanism.

[0014] The beneficial effects of the embodiments of this application are as follows: This ultra-lightweight servo motor and its integrated control system achieve ultra-lightweight and high torque density design through the collaborative design of a micro coreless DC motor, a two-stage hybrid reduction mechanism combining a worm gear drive and a gear drive, a calibrated and standardized off-axis 3D Hall sensor, and a 3.3V single-voltage digital drive control circuit. This meets the core requirements of micro unmanned aerial vehicles (UAVs) and miniaturized missiles for ultra-lightweight payloads. Furthermore, the system's off-axis calibration system based on a three-axis linear Hall chip, combined with a magnetic field surface fitting algorithm, significantly reduces detection errors caused by mechanical misalignment, thus significantly improving the strike accuracy of tactical equipment. Simultaneously, Lyapunov friction compensation control effectively suppresses microscale static friction disturbances, achieving a peak drive capability of 70 mA at a low voltage of 3.3V, ensuring reliability in extreme environment missions. In addition, the system combines rapid dynamic performance with the corrosion-resistant properties of aluminum alloy CNC gears, which can extend the endurance of micro UAVs and improve the hit rate of miniaturized missiles. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 A schematic block diagram of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 2 A first-view structural schematic diagram of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 3 A second-view structural diagram of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 4 This application provides a schematic diagram of the structure of a reduction gear mechanism in an ultra-lightweight servo motor and its integrated control system. Figure 5 Waveforms of the command angle and actual angle during a small-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 6 A waveform diagram showing the difference between the command angle and the actual angle during a small-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 7 A waveform diagram of voltage output during a small-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 8 Waveforms of commanded and actual angles during a large-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 9 A waveform diagram showing the difference between the command angle and the actual angle during a large-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 10 A waveform diagram of voltage output during a large-angle step test of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 11 Waveforms of commanded angle and actual angle during multiple free tests of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 12 Waveform diagram of the difference between command angle and actual angle during multiple free tests of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment; Figure 13 The waveform of voltage output during multiple free tests of an ultra-lightweight servo motor and its integrated control system provided in this application embodiment. Detailed Implementation

[0017] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The terms "comprising" and "having," and any variations thereof, in the embodiments and drawings of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0019] Existing ultra-miniature servo motors suffer from drawbacks such as ultra-lightweight limitations, off-axis errors, insufficient control precision, and lack of thermal management. Traditional structures cannot meet the ≤0.7g requirement. Furthermore, mechanical assembly misalignment easily leads to angle detection failure with errors >5%, and classic PID control cannot suppress microscale static friction disturbances, resulting in steady-state errors >2°. Additionally, the lack of a protection mechanism leads to motor temperature rise exceeding 120°C under stall current. To address these technical problems, this application discloses an ultra-lightweight servo motor and its integrated control system. Through synergistic optimization of electromagnetics, mechanics, sensing, and control, it achieves high torque density, high response speed, and high-precision positioning under ultra-lightweight conditions. These are described in detail below.

[0020] Figure 1 An ultra-lightweight servo motor and its integrated control system according to an embodiment of this application are illustrated. Figure 1 As shown, the ultra-lightweight servo motor and its integrated control system include: a servo actuator unit and an integrated control unit integrated with the servo actuator unit in the same housing. The servo actuator unit serves as the power output of the system, converting electrical energy into precise mechanical motion (torque and angle) and providing feedback on the current position. The integrated control unit serves as the command center of the system, receiving external commands, interpreting the command target, comparing the current state, and calculating how to drive the motor to accurately reach the target position.

[0021] Specifically, the servo actuator unit includes a motor 1, a reduction mechanism 2, and a position sensor 3. The motor 1 provides the initial power, and the reduction mechanism 2 is connected to the output shaft of the motor 1. The reduction mechanism 2 converts the high speed and low torque of the motor 1 into low speed and high torque. Simultaneously, the position sensor 3 provides feedback on the actual position angle of the servo output shaft, enabling real-time monitoring of the actual position angle of the servo output shaft and feeding this information back to the integrated control unit. In this embodiment, the position sensor 3 is calibrated and standardized using a sensor calibration system, effectively eliminating errors, improving sensor accuracy and precision, ensuring a unified standard, guaranteeing consistency and interchangeability, facilitating replacement, enhancing reliability and safety, and achieving high-quality closed-loop control.

[0022] The integrated control unit includes a controller 4, a drive circuit, and a communication interface. The communication interface is connected to the controller 4 to enable data interaction with external devices. The controller 4 receives external control commands and generates control signals for the motor 1. The drive circuit is electrically connected between the controller 4 and the motor 1 and drives the motor 1 to rotate according to the control signals. In this embodiment, the controller 4 also receives position feedback signals from the position sensor 3 and performs closed-loop control calculations based on the external control commands and position feedback signals. The drive circuit adjusts the operating state of the motor 1, effectively addressing system uncertainties, improving dynamic response performance, and exhibiting strong automatic anti-interference capabilities.

[0023] In some embodiments, motor 1 is a miniature hollow cup DC motor. The hollow cup rotor completely eliminates the iron core, thus eliminating iron loss. It has extremely high energy conversion efficiency, and the rotor is extremely lightweight with very small moment of inertia. It has high dynamic response characteristics, runs smoothly, has no cogging effect, high energy density, small size, light weight, good control characteristics, and a wide speed range. At the same time, the commutator spark is small, and the generated electromagnetic interference is relatively low.

[0024] In other embodiments, the reduction mechanism 2 is a two-stage hybrid reduction mechanism combining a worm gear drive mechanism and a gear drive mechanism, with the worm gear drive mechanism serving as the first-stage reduction mechanism 2 and the gear drive mechanism serving as the second-stage reduction mechanism 2. The initial torque generated by the motor 1 is amplified by this two-stage hybrid reduction mechanism 2, which effectively increases the output torque and suppresses inertial reversal and external disturbances due to the self-locking characteristic of the worm gear drive mechanism. In specific implementations, the motor 1, reduction mechanism 2, position sensor 3, controller 4, and drive circuit are all mounted on the same circuit board 5, such as... Figure 2 – Figure 4As shown, the reduction mechanism 2 includes a worm 21, a worm wheel 22, an intermediate shaft 23, a pinion 24, a hollow sector gear 25, and a reduction output shaft 26. Specifically, the two-stage reduction mechanism is located in two different planes. The worm 21 and worm wheel 22 are located in the first plane of the circuit board 5, while the pinion 24 and hollow sector gear 25 are located in the second plane of the circuit board 5. The central axis of the worm 21 is parallel to the first plane of the circuit board 5. The output shaft of the motor 1 is connected to the worm 21, driving the worm 21 to rotate. The worm 21 acts as the driving element in the first-stage reduction, and the worm wheel 22 meshes with the worm 21, acting as the driven element in the first-stage reduction. The intermediate shaft 23 is a key component connecting the two-stage transmission. It passes through the circuit board 5, with one end fixedly connected to the worm gear 22 and the other end fixedly connected to the pinion 24. The worm gear 22 and the pinion 24 are fixedly connected through the intermediate shaft 23 to achieve synchronous rotation. The pinion 24 serves as the driving gear of the second-stage transmission. The pinion 24 meshes with the hollow sector gear 25 to convert the rotational motion into oscillating motion. The hollow sector gear 25 is fixedly connected to the reduction output shaft 26, which passes through the second plane of the circuit board 5 to the first plane to output the oscillating motion to the external mechanism.

[0025] When motor 1 is working, the high-speed input rotational motion of motor 1 is transmitted to worm 21. Worm 21 drives worm wheel 22 to rotate through meshing with worm wheel 22. After the first stage of deceleration, intermediate shaft 23 rotates at a lower speed and drives pinion 24 on it to rotate synchronously. Pinion 24 meshes with hollow sector gear 25. Since hollow sector gear 25 is not a complete circle, it cannot rotate continuously. Thus, the continuous rotational motion of pinion is converted into the reciprocating oscillating motion of hollow sector gear 25, completing two stages of deceleration and converting the input high-speed low-torque rotation into the output low-speed high-torque oscillation.

[0026] In this embodiment, the deceleration mechanism 2 employs a hollowed-out sector gear, which reduces weight, lowers the inertia of moving parts, and enables faster start-stop and response. It also reduces the load on the supporting bearings, avoids interference, and provides clearance for other components. Furthermore, material is removed from areas where structural strength is not required, saving material and reducing costs. Further, the hollowed-out sector gear 25 is made of aluminum alloy CNC gear, achieving extreme lightweighting. The low-density aluminum alloy material combined with the CNC-machined hollowed-out design allows for the removal of material from all non-critical parts, achieving maximum weight reduction. It also exhibits excellent shock absorption and damping characteristics, as well as good surface properties and corrosion resistance.

[0027] Furthermore, in this embodiment, the worm gear transmission mechanism has a reduction ratio of 20 to 50, and the gear transmission mechanism has a reduction ratio of 2 to 7.5, so that the mixed reduction ratio of the reduction mechanism 2 is ≥200:1, achieving a very significant speed reduction and torque increase effect of the system, outputting huge torque, and realizing precise and smooth motion control.

[0028] In other embodiments, the position sensor 3 is an off-axis 3D Hall sensor 31, and a cylindrical annular permanent magnet 32 ​​is fixedly installed at the end of the deceleration output shaft 26 of the deceleration mechanism 2. The installation position of the off-axis 3D Hall sensor 31 corresponds to the installation position of the cylindrical annular permanent magnet 32. The actual position angle of the servo motor output shaft is obtained by measuring the magnetic field angle of the cylindrical annular permanent magnet 32 ​​through the off-axis 3D Hall sensor 31. The sensing calibration system is an off-axis calibration system based on a three-axis linear Hall chip, and the position sensor 3 is calibrated and calibrated by combining a magnetic field surface fitting algorithm. The internal integrated angle calculation circuit of the three-axis linear Hall chip is configured to directly output the arctangent angle value based on the X-axis and Y-axis magnetic field measurement values. Through compensation by the surface fitting algorithm, the final output position signal is made to have a near-perfect linear relationship with the actual physical position of the magnet, with an accuracy down to the micrometer level. It has extremely high measurement accuracy and linearity, significantly enhancing the robustness and reliability of the system. Thus, through the deep integration of hardware (off-axis 3D Hall sensor and triaxial linear Hall chip) and software (magnetic field surface fitting algorithm), a certified, reliable, and high-precision physical quantity measurement value can be provided, providing a solid and reliable feedback foundation for the entire control system. The off-axis Hall calibration error is ≤1%.

[0029] In this embodiment, the drive circuit is a 3.3V single-voltage digital drive control circuit with a peak current ≥70mA. It features extremely low dynamic and static power consumption, significantly extending battery life, reducing heat generation, and seamlessly integrating with the controller 4, position sensor 3, etc., demonstrating high integration. Furthermore, the controller 4 is configured for friction compensation control based on Lyapunov stability theory to suppress microscale static friction disturbances in the deceleration mechanism 2.

[0030] The above describes the various components of the ultra-lightweight servo motor and its integrated control system provided in this embodiment, as well as their interconnections. The following section will discuss these components in conjunction with... Figure 1 – Figure 13 This paper details the working principle of ultra-lightweight servo motors and their integrated control systems.

[0031] This system integrates four modules: a high-performance miniature hollow cup DC motor, a two-stage hybrid reduction mechanism combining worm gear transmission and gear transmission, a calibrated and adjusted off-axis 3D Hall sensor, and a 3.3V single-voltage digital drive control circuit. Through the synergistic optimization of electromagnetic, mechanical, sensing, and control, it constructs a lightweight and high-efficiency closed-loop servo control system, achieving high torque density, high response speed, and high-precision positioning with a weight of ≤0.7g.

[0032] like Figure 1 As shown, after the host computer issues an angle command, the controller 4 reads the real-time sensor signal from the position sensor 3 and quickly calculates the drive command using a built-in closed-loop algorithm. Then, the 3.3V single-voltage digital drive control circuit directly drives the miniature hollow cup DC motor to generate initial torque. This initial torque is amplified by a two-stage hybrid reduction mechanism consisting of a worm gear transmission mechanism with a reduction ratio of 20 to 50 and a gear transmission mechanism with a reduction ratio of 2 to 7.5, effectively improving the output torque, with a torque density ≥ 2.0 N·m / kg.

[0033] During operation, the off-axis 3D Hall sensor continuously collects magnetic field components. Relying on the surface fitting compensation algorithm inside the high-speed MCU (Microcontroller Unit), it corrects mechanical eccentricities caused by manufacturing and assembly in real time, thereby ensuring that the angle detection error is always ≤1%. In addition, while meeting the requirements of closed-loop accuracy and response speed, the overall weight of the entire system can be controlled below 0.7g by reasonably allocating the mass indicators of each part. The consistency and reliability of the design are verified through prototype testing.

[0034] To verify the control effect of the ultra-lightweight servo motor and its integrated control system in the embodiments of this application, experimental tests were conducted. A 10° and 60° step angle command was sent to the micro servo motor via a host computer, and multiple free-running tests were performed. The angle commands were recorded using host computer software. From a practical perspective Error between angle command and actual angle ( The controller output u is then used to import the data into MATLAB software for plotting.

[0035] (1) Small-angle step test A small-angle step test was performed on the micro servo motor. The waveform when the angle command increased from 0° to 10° is as follows: Figure 5 – Figure 7 As shown, the actual angle reaches the vicinity of the command value in about 70ms, with a peak-to-peak fluctuation of about 2.5° and a steady-state error of about 0.8° near the target value.

[0036] (2) Large-angle step test A large-angle step test was performed on the micro servo motor. The waveform when the angle command increased from 0° to 60° is as follows: Figure 8 – Figure 10 As shown, the actual angle reached near the command value in about 76ms, with an overshoot of about 2.8° (4.6%) and a steady-state error of about 0.1°.

[0037] (3) Multiple free tests Multiple free tests were performed on the micro servo motor, and the waveforms were as follows: Figure 11 – Figure 13 As shown, the actual angle can effectively follow the angle command value, and the micro servo is working normally.

[0038] In summary, this application discloses an ultra-lightweight servo motor and its integrated control system. Its core applications focus on micro unmanned aerial vehicles (wing or gimbal control), small guided weapon systems (adjusting missile heading, pitch, and roll angles), tactical communication and detection antennas (precise pointing of communication antennas / sensors), and military robot joints. Through the collaborative design of a micro hollow-cup DC motor, a two-stage hybrid reduction mechanism (worm gear transmission with a reduction ratio of 20 to 50 + gear transmission with a reduction ratio of 2 to 7.5), and a 3.3V single-voltage digital drive control circuit (eliminating the need for a DC / DC module), the system achieves a total servo motor weight ≤0.7 g and a torque density of 2.46 N·m / kg, meeting the core requirements of micro unmanned aerial vehicles and miniaturized missiles for ultra-light loads. Regarding high-precision off-axis detection, an off-axis calibration system based on a three-axis linear Hall chip, combined with a magnetic field surface fitting algorithm, compresses the detection error caused by mechanical misalignment to below 0.8°, significantly improving the strike accuracy of tactical equipment. Simultaneously, Lyapunov friction compensation control effectively suppresses microscale static friction disturbances, achieving a peak drive capability of 70 mA at a low voltage of 3.3 V, ensuring reliability for missions in extreme environments. Furthermore, the rapid dynamic performance with a 149° rotation stroke and a 76 ms response time, combined with the corrosion-resistant properties of the aluminum alloy CNC gears (wide operating temperature range of -40℃ to 85℃), can extend the endurance of micro unmanned aerial vehicles and improve the hit rate of miniaturized missiles.

[0039] It will be understood by those skilled in the art that the accompanying drawings are merely schematic diagrams of one embodiment, and the components or modules shown in the drawings are not necessarily essential for implementing the present invention. It should also be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0040] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, in the description of the embodiments of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In addition, the modules in the system of the embodiments can be distributed in the system of the embodiments as described in the embodiments, or they can be located in one or more systems different from this embodiment with corresponding changes. The modules of the above embodiments can be combined into one module, or they can be further divided into multiple sub-modules.

[0041] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of protection described in the claims.

Claims

1. An ultra-lightweight servo motor and its integrated control system, characterized in that, include: The servo actuator includes a motor, a reduction gear connected to the output shaft of the motor, and a position sensor that provides feedback on the actual position angle of the servo output shaft; wherein the position sensor is calibrated and adjusted using a sensor calibration system. An integrated control unit is integrated with the servo actuator unit within the same housing. The integrated control unit includes a controller, a drive circuit, and a communication interface. The communication interface is connected to the controller for data interaction with external devices. The controller receives external control commands and generates motor control signals. The drive circuit is electrically connected between the controller and the motor and drives the motor to rotate according to the motor control signals. The controller also receives position feedback signals from the position sensor and performs closed-loop control calculations based on the external control commands and the position feedback signals, adjusting the motor's operating state through the drive circuit.

2. The ultra-lightweight servo motor and its integrated control system according to claim 1, characterized in that, The motor is a miniature hollow cup DC motor.

3. The ultra-lightweight servo motor and its integrated control system according to claim 2, characterized in that, The reduction mechanism is a two-stage hybrid reduction mechanism that combines a worm gear transmission mechanism and a gear transmission mechanism.

4. The ultra-lightweight servo motor and its integrated control system according to claim 3, characterized in that, The reduction mechanism includes the worm, worm wheel, intermediate shaft, pinion, hollow sector gear, and reduction output shaft; The worm and the worm wheel are disposed in the first plane of the circuit board, and the pinion and the hollow sector gear are disposed in the second plane of the circuit board; The central axis of the worm is parallel to the first plane of the circuit board. The output shaft of the motor is connected to the worm and drives the worm to rotate. The worm meshes with the worm wheel. The intermediate shaft passes through the circuit board, and the worm wheel and the pinion are fixedly connected through the intermediate shaft to achieve synchronous rotation. The pinion meshes with the hollow sector gear to convert the rotational motion into oscillating motion. The hollow sector gear is fixedly connected to the reduction output shaft, and the reduction output shaft passes from the second plane of the circuit board to the first plane to output the oscillating motion to an external mechanism.

5. The ultra-lightweight servo motor and its integrated control system according to claim 4, characterized in that, The hollowed-out sector gear is made of aluminum alloy CNC gear.

6. The ultra-lightweight servo motor and its integrated control system according to claim 3, characterized in that, The worm gear transmission mechanism serves as the first-stage reduction mechanism, and the gear transmission mechanism serves as the second-stage reduction mechanism.

7. The ultra-lightweight servo motor and its integrated control system according to claim 6, characterized in that, The worm gear transmission mechanism has a reduction ratio of 20 to 50, and the gear transmission mechanism has a reduction ratio of 2 to 7.

5.

8. The ultra-lightweight servo motor and its integrated control system according to claim 1, characterized in that, The position sensor is an off-axis 3D Hall sensor. A cylindrical annular permanent magnet is fixedly installed at the end of the deceleration output shaft of the deceleration mechanism. The actual position angle of the servo motor output shaft is obtained by measuring the magnetic field angle of the cylindrical annular permanent magnet through the off-axis 3D Hall sensor. The sensing calibration system is an off-axis calibration system based on a three-axis linear Hall chip, and the position sensor is calibrated and adjusted by combining a magnetic field surface fitting algorithm. The internal angle calculation circuit of the three-axis linear Hall chip is configured to directly output the arctangent angle value based on the X-axis and Y-axis magnetic field measurement values.

9. The ultra-lightweight servo motor and its integrated control system according to claim 1, characterized in that, The driving circuit is a 3.3V single-voltage digital driving control circuit.

10. The ultra-lightweight servo motor and its integrated control system according to claim 1, characterized in that, The controller is configured to perform friction compensation control based on Lyapunov stability theory to suppress microscale static friction disturbances in the deceleration mechanism.

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