Modularized hyper-redundant continuum robot for deep cavity operation and control method

Abstract

The invention discloses a modularized hyper-redundant continuum robot for deep cavity operation and a control method, and belongs to the technical field of specialized robots. The robot comprises a modular continuum robot mechanical body, a hyper-redundant continuum robot module, a driving transmission module, a power conversion module, a power supply, a control system module and a mobile chassis. The modular continuum robot mechanical body is located on the movable chassis. The hyper-redundant continuum robot module realizes mechanical positioning or signal interconnection through a composite interface at the front end of the modularized continuum robot mechanical body; the driving transmission modules are arranged in the modular continuum robot mechanical body in groups in the axial direction. According to the robot, on-demand combination and in-place replacement of operation units are achieved through structural control decoupling, redundancy and fault-tolerant design, the long, thin, smooth and high-degree-of-freedom characteristics are considered, and therefore the accessibility and stability in the deep cavity environment are improved, and the maintenance difficulty and the shutdown cost are remarkably reduced.

Description

Technical Field

[0001] This invention belongs to the field of special robot technology, specifically relating to a modular, super-redundant continuum robot and its control method for deep cavity operations. Background Technology

[0002] In numerous fields such as industrial automation and special environment operations, increasingly stringent requirements are being placed on the environmental adaptability and operational flexibility of robots. Continuum robots, with their unique compliant characteristics and excellent environmental adaptability, have demonstrated extremely broad application prospects in congested and unstructured environments. They can flexibly navigate inside engines and gas turbines to complete meticulous maintenance work; they can penetrate deep into nuclear containers for safety inspections, ensuring the safe operation of nuclear facilities; and they can operate freely in confined spaces such as pipelines and deep wells, effectively solving problems that are difficult for traditional robots to access.

[0003] To further enhance the accessibility and obstacle-avoidance capabilities of continuum robots and better adapt to complex and ever-changing working environments, multi-axis layouts are commonly adopted in engineering. This design significantly increases the system's controllable degrees of freedom by increasing the number of axes, enabling the robot to perform more complex and precise movements. However, this improvement is not without its costs. Multi-axis layouts lead to a dramatic increase in the number of motors and transmission channels, which in turn causes a series of challenging engineering problems. Wiring harnesses and conduits become densely intertwined, not only occupying a large amount of space but also increasing the difficulty and complexity of wiring; assembly processes become increasingly cumbersome, requiring precise operation at every step, and even slight errors can affect the performance of the entire system; tension calibration is also extremely difficult, making it hard to ensure that every part reaches the ideal tension state.

[0004] Currently, existing integrated robot solutions attempt to address some issues by tightly coupling and customizing the drive, transmission, and body. This approach facilitates prototype integration and centralized optimization to some extent, allowing for comprehensive performance consideration during the design phase. However, it reveals significant limitations in practical applications. Particularly in confined work environments, installation becomes extremely difficult, often requiring substantial time and effort for debugging. Furthermore, when equipment malfunctions and requires repair, complete disassembly is typically necessary. This not only results in prolonged downtime and increased lifecycle costs but also severely limits the robot's reconfigurability, hindering rapid configuration adjustments to meet diverse operational needs.

[0005] Furthermore, with the continuous increase in degrees of freedom, continuum robots also face numerous technical challenges. The increased number of motors increases the size and weight of the drive and transmission systems, and the denser interfaces and wiring further complicate the installation and assembly process; failure of any drive or transmission unit may lead to the disassembly of the entire machine, resulting in insufficient maintenance granularity and a significant increase in mean time to repair; the simultaneous increase in the number and tension of tendons leads to concentrated root loads, making the proximal end of traditional continuous skeletons prone to buckling instability, which brings great difficulties to initial pose calibration and tension calibration. Summary of the Invention

[0006] To address the problems of existing continuum robots, such as the need for complete disassembly during later maintenance, high downtime and lifecycle costs, and poor reconfigurability, this application provides a modular, ultra-redundant continuum robot for deep cavity operations. Through structural control decoupling, redundancy, and fault-tolerant design, it enables on-demand combination and in-situ replacement of working units, balancing slender flexibility with high degrees of freedom. This improves accessibility and stability in deep cavity environments, significantly reducing maintenance difficulty and downtime costs.

[0007] To achieve the above objectives, the present invention provides the following technical solution.

[0008] In a first aspect, the present invention provides a modular, super-redundant continuum robot for deep cavity operations, comprising a modular continuum robot body, super-redundant continuum robot modules, a drive transmission module, a power conversion module, a power supply, a control system module, and a mobile chassis; the modular continuum robot body is located on the mobile chassis; the super-redundant continuum robot modules achieve mechanical positioning or signal interconnection through a composite interface at the front end of the modular continuum robot body; the drive transmission modules are arranged in groups along the axial direction inside the modular continuum robot body, the modular continuum robot body includes a transmission module fixing upper top plate, a transmission module fixing lower top plate, and a drive module fixing plate, used to support or replace the drive transmission modules; the output channel of the drive transmission module corresponds to the force transmission channel of the super-redundant continuum robot module; the power conversion module is located on the power supply side inside the modular continuum robot body, used to supply power to the super-redundant continuum robot module, drive transmission module, control system module, and mobile chassis; the power conversion module is connected to the power supply; the control system module is located in the upper region inside the modular continuum robot body, communicating with the drive transmission module, the super-redundant continuum robot module, and the mobile chassis, the super-redundant continuum robot module has repeating units inside, and several repeating units are connected in series.

[0009] As a further improvement of the present invention, the drive transmission module includes drive branches; several drive branches are arranged in parallel; the drive branches include a servo drive motor, a planetary reducer, a coupling and a lead screw and nut transmission module; the servo drive motor is connected to the planetary reducer; the output shaft of the planetary reducer is coaxially connected to the lead screw of the lead screw and nut transmission module via the coupling.

[0010] As a further improvement of the present invention, the modular continuous robot mechanical body includes a transmission module fixed upper top plate, a transmission module fixed lower top plate, and a drive module fixed plate; the lead screw and nut transmission module is disposed between the transmission module fixed upper top plate and the transmission module fixed lower top plate; the transmission module fixed lower top plate is disposed between the coupling and the lead screw and nut transmission module; and the drive module fixed plate is disposed between the planetary reducer and the coupling.

[0011] As a further improvement of the present invention, the transmission module fixing upper plate includes a first upper plate module, a second upper plate module, and a third upper plate module; a plurality of second upper plate modules are disposed between the first upper plate module and the third upper plate module; the first upper plate module is provided with a first structural fixing hole, a first sensor mounting hole, a first lead screw distal end fixing hole, a first distal guide rail fixing hole, a first sensor inlet hole, and a first tendon through hole; the second upper plate module is provided with a second lead screw distal end fixing hole, a second sensor mounting hole, a second sensor inlet hole, and a second distal guide rail fixing hole; the third upper plate module is provided with a third structural fixing hole, a third sensor inlet hole, a third tendon through hole, and a third proximal guide rail fixing hole.

[0012] As a further improvement of the present invention, the transmission module fixing lower top plate includes a first lower top plate module, a second lower top plate module, and a third lower top plate module; a plurality of second lower top plate modules are disposed between the first lower top plate module and the third lower top plate module; the first lower top plate module is provided with a first lower top plate structure fixing hole, a first lower top plate lead screw proximal end fixing hole, a first lower top plate sensor mounting hole, a first lower top plate proximal end lead screw guide rail fixing hole, a first upper top plate proximity sensor inlet hole, and a first lower top plate proximity sensor inlet hole; the first The second lower top plate module is provided with a second lower top plate near-end lead screw fixing hole, a second lower top plate sensor mounting hole, a second upper top plate proximity sensor inlet hole, a second lower top plate proximity sensor inlet hole, and a second lower top plate near-end lead screw guide rail fixing hole; the third lower top plate module is provided with a third lower top plate structure fixing hole, a third lower top plate proximity sensor inlet hole, a third upper top plate proximity sensor inlet hole, a third lower top plate near-end lead screw fixing hole, a third lower top plate proximity sensor mounting hole, and a third lower top plate near-end lead screw guide rail fixing hole.

[0013] As a further improvement of the present invention, the drive module fixing plate has a number of fourth structure fixing holes around its perimeter and corners; and the drive module fixing plate has a number of fourth fixing grooves arranged in a matrix on its surface.

[0014] As a further improvement of the present invention, a tendon transition component is provided on the output side of the drive transmission module; the tendon transition component includes a tendon transition module top plate and a tendon transition expansion and contraction plate; the tendon transition module top plate is disposed between the mechanical body of the modular continuous robot and the fixed end of the continuous robot; the tendon transition expansion and contraction plate is provided with a number of guide holes at equal angles along the circumference.

[0015] As a further improvement of the present invention, the super-redundant continuum robot module also includes a base fixed end and an end connecting flange module; a number of repeating units are arranged between the base fixed end and the end connecting flange module; the repeating unit includes a proximal hinge module and a distal hinge module; the proximal hinge module and the distal hinge module are arranged alternately.

[0016] As a further improvement of the present invention, the control system module includes a processor, a memory, and a communication interface. After power-on, the control system module checks the super-redundant continuum robot module and the mobile chassis, and reads the electrical data of the power conversion module to confirm electrical safety. During task execution, the control system module sends the target quantity of the channel to the drive transmission module according to the trajectory planning. The target quantity is at least one of displacement, velocity, or tension, causing the super-redundant continuum robot module to generate attitude changes and sending speed and attitude commands to the mobile chassis to achieve coordinated motion. During operation, the control system module implements closed-loop compensation and redundant channel scheduling based on feedback signals. When a fault is detected or the power is lower than the threshold, the control system module performs power limiting and orderly power-off, and implements emergency power-off.

[0017] Secondly, the present invention provides a control method for a modular, super-redundant continuum robot for deep cavity operations, comprising: S1: Connect the power supply and supply power to the power conversion module, drive transmission module, control system module and mobile chassis; S2: The control system module sequentially performs self-tests, zero-position calibrations, and parameter loading on the super-redundant continuum robot module and the mobile chassis, and reads the insulation, overcurrent, and temperature status of the power conversion module to confirm electrical safety; when electrical safety is confirmed, the control system module issues a task execution signal. S3: During task execution, the control system module moves the drive transmission module according to the trajectory planning, causing the super-redundant continuum robot module to deform; at the same time, it sends speed and attitude commands to the mobile chassis to achieve coordinated motion; the control system module implements closed-loop compensation and redundant channel scheduling based on the displacement and tension feedback from the super-redundant continuum robot module; during the task, when a fault is detected or the power is lower than the preset threshold, the control system module performs power limiting and orderly power-down; when the emergency shutdown conditions are met, the control system module controls the power cut-off.

[0018] Compared with the prior art, the present invention has the following beneficial effects: In this invention, the drive transmission module adopts a matrix-style standard mounting position and evenly distributed fastening holes, combined with a three-section modular design of the upper and lower top plates and a specific assembly sequence. This not only ensures the centering of the drive unit's force path and high-rigidity connection, supporting rapid replacement and large-scale deployment, but also enables high-density, maintainable installation of dozens of transmission units. When a working unit malfunctions, it can be replaced in place without disassembling the entire machine, greatly shortening maintenance time, reducing downtime costs, and minimizing potential damage to the robot's overall structure caused by frequent disassembly, effectively extending the robot's service life. (Transmission section) The modular architecture uses a framed carrier to support multiple motors and reducers, unifying mechanical and electrical interfaces. Combined with tendon transition components and coaxial quick-connect interfaces, it achieves streamlined channels, simplified assembly, and rapid maintenance. The control system module uniformly issues commands, collects information in a closed loop, and coordinates with the motion control of the mobile chassis. It features main circuit power-off, rapid branch power-off, and multiple electrical protection functions. Upon power-up, it automatically completes self-testing, zero-position calibration, and parameter loading. During task execution, it performs redundant channel scheduling and real-time compensation. In case of faults or power threshold triggers, it implements power limiting, orderly power-off, or emergency power-off, improving operational and intrinsic safety. The ultra-redundant continuum robot module consists of multi-level module units connected in series, with adjacent unit hinge axes arranged orthogonally. Combined with multi-channel tendons, it achieves multi-degree-of-freedom control with near-continuous curvature. The standardized end-effector flange and universal interface adapt to various end effectors and sensors. The modular continuum robot's mechanical body is fixed to the mobile chassis and equipped with vibration damping and quick-assembly / disassembly mechanisms, working collaboratively with each module. It balances slender compliance with high degree-of-freedom characteristics, improving accessibility and stability in deep cavity environments. The modules in this application have clear division of labor and reasonable layout. The drive and transmission modules are arranged in groups along the axial direction and the output channels correspond to the force transmission channels of the super-redundant continuum robot modules, which ensures the high efficiency and precision of power transmission. Attached Figure Description

[0019] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way. In the drawings: Figure 1 This is an overall schematic diagram of a modular, super-redundant continuum robot for deep cavity operations according to the present invention. Figure 2 This is a schematic diagram of the drive and control structure of a modular, super-redundant continuum robot for deep cavity operations according to the present invention. Figure 3 This is a schematic diagram of the transmission module fixed to the top plate of a modular super-redundant continuum robot for deep cavity operations according to the present invention. Figure 4This is a schematic diagram of the first upper top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a reverse view of the first upper top plate module; b) is a front view of the first upper top plate module; Figure 5 This is a schematic diagram of the second upper top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a front view of the second upper top plate module; b) is a back view of the second upper top plate module; c) is an axonometric view of the second upper top plate module; Figure 6 This is a schematic diagram of the third upper top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a front view of the third upper top plate module; b) is a back view of the third upper top plate module; Figure 7 This is a schematic diagram of the transmission module of a modular super-redundant continuum robot for deep cavity operations according to the present invention, with the lower top plate fixed. Figure 8 This is a schematic diagram of the first lower top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a front view of the first lower top plate module; b) is a back view of the first lower top plate module; Figure 9 This is a schematic diagram of the second lower top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a reverse view of the second lower top plate module; b) is a front view of the second lower top plate module; Figure 10 This is a schematic diagram of the third lower top plate module of a modular super-redundant continuum robot for deep cavity operations according to the present invention; wherein, a) is a reverse view of the third lower top plate module; b) is a front view of the third lower top plate module; Figure 11 This is a schematic diagram of the drive module fixing plate of a modular, super-redundant continuum robot for deep cavity operations according to the present invention. Figure 12 This is a schematic diagram of a modular super-redundant continuum robot module for deep cavity operations according to the present invention. Figure 13 This is a schematic diagram of the proximal fixing module structure of a modular super-redundant continuum robot for deep cavity operations according to the present invention; Figure 14 This is a schematic diagram of the proximal connection module structure of a modular super-redundant continuum robot for deep cavity operations according to the present invention; Figure 15 This is a schematic diagram of the remote connection module structure of a modular super-redundant continuum robot for deep cavity operations according to the present invention. Figure 16This is a schematic diagram of the end-effector module structure of a modular, super-redundant continuum robot for deep cavity operations according to the present invention.

[0020] In the diagram, 10 is the modular continuum robot's mechanical body; 101 is the transmission module fixing upper plate; 1011 is the first upper plate module; 10110 is the first embedded boss; 10111 is the first structural fixing hole; 10112 is the first sensor mounting hole; 10113 is the first lead screw distal end fixing hole; 10114 is the first distal guide rail fixing hole; 10115 is the first sensor inlet hole; 10116 is the first tendon through hole; 1012 is the second upper plate module; 10120 is the second lead screw distal end fixing hole; 10121 is the second sensor mounting hole; 10122 is the second sensor inlet hole; 10123 is the second embedded groove; 10124 is the second distal guide rail fixing hole; and 10125 is the second embedded groove. 1013, Third upper top plate module; 10130, Third structural fixing hole; 10131, Third embedded groove; 10132, Third sensor inlet hole; 10133, Third tendon through hole; 10134, Third proximal guide rail fixing hole; 10135, Third sensor mounting hole; 102, Transmission module fixing lower top plate; 1021, First lower top plate module; 10210, First lower top plate structural fixing hole; 10211, First lower top plate embedded boss; 10212, First lower top plate lead screw proximal fixing hole; 10213, First lower top plate sensor mounting hole; 10214, First lower top plate proximal lead screw guide rail fixing hole; 10215, First upper top plate proximity sensor inlet hole; 10216. 1022. First lower top plate proximity sensor inlet hole; 1022. Second lower top plate module; 10220. Second lower top plate proximal lead screw fixing hole; 10221. Second lower top plate embedded boss; 10222. Second lower top plate embedded groove; 10223. Second lower top plate sensor mounting hole; 10224. Second upper top plate proximity sensor inlet hole; 10225. Second lower top plate proximity sensor inlet hole; 10226. Second lower top plate proximal lead screw guide rail fixing hole; 1023. Third lower top plate module; 10230. Third lower top plate structure fixing hole; 10231. Third lower top plate embedded groove; 10232. Third lower top plate proximity sensor inlet hole; 10233. Third upper top plate proximity sensor inlet hole; 102 34. Proximal fixing hole of the third lower top plate lead screw; 10235. Mounting hole of the third lower top plate proximity sensor; 10236. Fixing hole of the guide rail of the third lower top plate proximal lead screw; 103. Drive module fixing plate; 1031. Fourth structure fixing hole; 1032. Fourth fixing groove; 104. Tendon transition module top plate; 105. Tendon transition expansion and contraction plate; 106. Continuous robot fixed end; 20. Ultra-redundant continuous robot module; 201. Base fixed end; 2011. Fork arm pin hole; 2012. First tendon hole; 2013. First bearing; 202. Proximal hinge module; 2021. Proximal hinge fork narrow arm; 2022. Second bearing; 2023. Second tendon hole; 2024. Proximal hinge fork wide arm;203. Distal hinge module; 2031. Third distal hinge fork-shaped narrow arm; 2032. Third distal hinge fork-shaped narrow arm pin hole; 2033. Third tendon hole; 2034. Third bearing; 2035. Third distal hinge fork-shaped wide arm; 204. End connection flange module; 2041. Flange fork arm; 2042. Fourth tendon hole; 2043. Fourth through hole; 2044. Fourth bearing; 30. Drive transmission module; 301. Servo drive motor; 302. Planetary reducer; 303. Coupling; 304. Screw and nut transmission module; 40. Power conversion module; 50. Power supply; 60. Control system module; 70. Mobile chassis. Detailed Implementation

[0021] To address the problems of existing continuum robots, such as frequent disassembly for later maintenance, high downtime and lifecycle costs, and poor reconfigurability, this application provides a modular, ultra-redundant continuum robot for deep cavity operations, such as... Figure 1 As shown, it includes: a modular continuum robot mechanical body 10, a super-redundant continuum robot module 20, a drive transmission module 30, a power conversion module 40, a power supply 50, a control system module 60, and a mobile chassis 70.

[0022] The super-redundant continuum robot module 20 is connected to the modular continuum robot mechanical body 10.

[0023] The modular continuous robot mechanical body 10, drive transmission module 30, power conversion module 40, power supply 50 and control system module 60 are placed on the mobile chassis 70.

[0024] The modular continuous robot mechanical body 10 is connected to the super-redundant continuous robot module 20 on one side, and a drive transmission module 30 is provided on the other side of the modular continuous robot mechanical body 10. A power conversion module 40 is provided between the drive transmission module 30 and the power supply 50. The control system module 60 is located above the drive transmission module 30, and the control system module 60 communicates with the drive transmission module 30, the super-redundant continuous robot module 20 and the mobile chassis 70.

[0025] The modular continuous robot mechanical body 10 is pluggably connected to the front end of the super-redundant continuous robot module 20. The front end of the modular continuous robot mechanical body 10 is provided with a composite interface consisting of a mechanical positioning mating surface and an electrical connector, which is used to realize the mechanical positioning, power supply and signal connection of the super-redundant continuous robot module 20. The drive transmission module 30 is arranged along the axial direction of the modular continuous robot mechanical body 10, and its several output channels are respectively connected to several force transmission channels of the super-redundant continuous robot module 20.

[0026] The aforementioned unit modules are modularly integrated through pluggable electrical and mechanical interfaces to form a unified electromechanical control platform that meets the collaborative requirements of continuous drive and mobile operation.

[0027] The modular continuous robot body 10 is fixed to the support frame of the mobile chassis 70, with vibration damping and quick assembly / disassembly structures between them. The super-redundant continuous robot module 20 achieves mechanical positioning or signal interconnection through the composite interface at the front end of the modular continuous robot body 10. The drive transmission module 30 is arranged in groups along the axial direction inside the modular continuous robot body 10, and its output channel corresponds one-to-one with each force transmission channel of the super-redundant continuous robot module 20. The power conversion module 40 is located in the electrical compartment inside the modular continuous robot body 10, close to the power supply side, which facilitates heat dissipation and wiring. The control system module 60 is placed in a position above that is conducive to maintenance and heat dissipation, and communicates with the drive transmission module 30, the super-redundant continuous robot module 20, and the vehicle controller of the mobile chassis 70 through an industrial bus.

[0028] Power supply 50 serves as the unified energy unit for the entire machine, preferably using a high-voltage DC battery pack. It is connected to the DC bus via a main relay and fuse, simultaneously supplying power to power conversion module 40, drive transmission module 30, control system module 60, and mobile chassis 70. Power conversion module 40 performs step-up / step-down, isolation, and voltage regulation on the DC power from power supply 50, providing multiple controlled DC power to the sensing / actuator units of drive transmission module 30, control system module 60, and ultra-redundant continuum robot module 20. The traction inverter and steering / braking actuators of mobile chassis 70 are directly powered from the DC bus of power supply 50 or by the high-power branch of power conversion module 40. The low-voltage power for the chassis is supplied by the low-voltage branch of power conversion module 40. Control system module 60 uniformly issues motion and power commands and collects status data. In case of emergency shutdown, it disconnects power supply 50 through the main circuit to achieve safe power-off of the entire machine. Power conversion module 40 has overcurrent, overtemperature, and insulation monitoring capabilities and reports to control system module 60.

[0029] The power supply 50 is connected to the main relay and fuse to form a DC bus; the traction inverter, steering actuator and braking actuator of the mobile chassis 70 are connected to the DC bus; the power conversion module 40 is equipped with a high-power branch and a low-voltage branch that are electrically connected to the DC bus. The high-power branch is configured to boost or step down the DC bus voltage and supply power to the traction inverter. The low-voltage branch is an isolated DC-DC converter that provides multiple regulated DC outputs to the low-voltage power consumption of the mobile chassis 70 and the sensing and execution units of the drive transmission module 30, the control system module 60 and the super-redundant continuum robot module 20.

[0030] The main relay is closed to power on the power supply 50, which simultaneously supplies power to the power conversion module 40, drive transmission module 30, control system module 60, and mobile chassis 70. The control system module 60 performs self-testing, zero-position calibration, and parameter loading for the super-redundant continuum robot module 20 and the mobile chassis 70, and confirms the electrical safety status of the power conversion module 40. During task execution, the control system module 60 sends multi-channel target quantities to the drive transmission module 30 according to the trajectory planning to drive the super-redundant continuum robot module 20 to produce bending, extension, and torsional deformations. At the same time, it sends speed and attitude commands to the mobile chassis 70 to achieve carrier movement and end-effector coordination. During operation, the sensor information is closed in real time. When a fault occurs or the power threshold is triggered, the control system module 60 implements power limiting, orderly power-off, or emergency power-off to ensure the inherent safety and high reliability of the entire machine.

[0031] The control system module 60 includes a processor, a memory, and an interface for communication with the power conversion module 40, the drive transmission module 30, the super-redundant continuum robot module 20, and the mobile chassis 70. The control system module 60 is configured to: upon power-up, sequentially perform self-tests, zero-position calibrations, and parameter loading on the super-redundant continuum robot module 20 and the mobile chassis 70, and read the insulation, overcurrent, and temperature status of the power conversion module 40 to confirm electrical safety; during task execution, according to trajectory planning, send channel target quantities to each drive branch of the drive transmission module 30, where the target quantity is at least one of displacement, velocity, or tension, so that the super-redundant continuum robot module 20 produces attitude changes, and sends speed and attitude commands to the mobile chassis 70 to achieve coordinated motion; during operation, implement closed-loop compensation and redundant channel scheduling based on feedback signals; when a fault is detected or the power is below a threshold, execute power limiting and orderly power-off, and implement emergency power-off by disconnecting the main relay.

[0032] like Figure 2 As shown, the drive control structure of the present invention is based on a frame-based mounting component. The modular continuous robot mechanical body 10 includes a transmission module fixed upper top plate 101, a transmission module fixed lower top plate 102, a drive module fixed plate 103, a tendon transition module top plate 104, a tendon transition expansion and contraction plate 105, and a continuous robot fixed end 106.

[0033] The drive transmission module 30 includes several drive branches arranged in parallel. Each drive branch includes a servo drive motor 301, a planetary reducer 302, a coupling 303, and a lead screw and nut transmission module 304.

[0034] The output shaft of the planetary reducer 302 is coaxially connected to the lead screw of the lead screw and nut transmission module 304 via a coupling 303, so that the rotation of the lead screw in the lead screw and nut transmission module 304 drives the nut to perform axial linear motion. A tendon transition assembly is provided on the output side of the drive transmission module 30, including a fixed tendon transition module top plate 104 and a tendon transition expansion and contraction disk 105 coaxial with it. The tendon transition expansion and contraction disk 105 has a number of guide holes spaced at equal angles along its circumference. The nut output end of each drive branch passes through a tendon through the corresponding guide hole and is connected to the corresponding continuous robot fixed end 106 of the ultra-redundant continuous robot module 20, so as to achieve a one-to-one correspondence with each force transmission channel of the ultra-redundant continuous robot module 20. The above components constitute an integrated drive and control unit of drive execution—tendon transition—continuum interface.

[0035] One end of the servo drive motor 301 is connected to one end of the planetary reducer 302, and the other end of the servo drive motor 301 is connected to the power conversion module 40. The other end of the planetary reducer 302 is connected to one side of the lead screw and nut transmission module 304 via a coupling 303. The other side of the lead screw and nut transmission module 304 is connected to the transmission module fixed upper top plate 101. The transmission module fixed lower top plate 102 is located between the coupling 303 and the lead screw and nut transmission module 304. The drive module fixing plate 103 is located between the planetary reducer 302 and the coupling 303. One end of the tendon transition expansion and contraction plate 105 is provided with the continuous robot fixed end 106, and the other end of the tendon transition expansion and contraction plate 105 is provided with the tendon transition module top plate 104. The tendon transition module top plate 104 is installed with the transmission module fixed upper top plate 101.

[0036] Specifically, the upper and lower top plates 101 and 102 of the transmission module fixation form the transmission cabin support frame. The lead screw and nut transmission module 304 is positioned between the upper and lower top plates 101 and 102. The drive module fixing plate 103 fixes a parallel array of multiple servo drive motors 301 and planetary reducers 302 in a replaceable modular manner. The output end of the planetary reducer 302 is coaxially connected to the lead screw and nut transmission module 304 via a coupling 303, converting rotational motion into linear stroke to drive each tendon channel. A tendon transition module top plate 104 is set at the front end of the upper top plate 101 of the transmission module fixation, on which a tendon transition retraction disc 105 is installed. The tendon transition retraction disc 105 distributes and guides the multi-channel tendons at equal angles and is coaxially connected to the fixed end 106 of the continuum robot, realizing rapid docking and disassembly between the drive end and the continuum body.

[0037] The power supply 50 provides the entire machine's DC bus, directly powering the mobile chassis 70. The power conversion module 40 distributes multiple controlled voltages to the servo drive motors 301, the control system module 60, and the low-voltage sensing / actuation circuits. The control system module 60 uses an industrial bus to implement closed-loop control of each servo drive motor 301, collecting displacement and end-effector tension feedback from the lead screw and nut transmission module 304. According to channel mapping, the linear displacement generated by the lead screw and nut transmission module 304 is guided through the tendon transition expansion and contraction disk 105 to the fixed end 106 of the continuous robot, thereby forming a composite deformation of bending, extension, and torsion on the continuous side. The power conversion module 40 has overcurrent, overtemperature, and insulation monitoring capabilities and reports these to the control system module 60. In case of abnormalities, it disconnects the bus or branch circuits.

[0038] The transmission module fixing upper top plate 101 and the transmission module fixing lower top plate 102 are spaced apart and fixed by connecting components to form a bearing frame for accommodating the drive transmission module 30; the drive module fixing plate 103 is detachably installed outside the bearing frame and is used to install servo drive motors 301 and planetary reducers 302 with the same number of drive branches; the control system module 60 implements closed-loop control of each servo drive motor 301 and collects displacement sensor signals from the lead screw and nut transmission module 304 and tension sensor signals from the tendon end; the control system module 60 has a channel mapping relationship so that the linear displacement of each lead screw and nut transmission module 304 is guided through the tendon transition expansion and contraction plate 105 to the continuous robot fixing end 106 of the super redundant continuous robot module 20 and connected to the corresponding force transmission channel.

[0039] After power-on, the power supply 50 establishes a DC bus, simultaneously supplying power to the power conversion module 40, control system module 60, servo drive motor 301, and mobile chassis 70. The control system module 60 completes self-testing and zero-position calibration of each channel, and loads channel parameters and limit thresholds. During task execution, the control system module 60 issues position / speed / force commands. The servo drive motor 301 drives the lead screw nut transmission module 304 to generate precise linear stroke via planetary reducer 302 and coupling 303. The tendon force is transferred without interference to the fixed end 106 of the continuous robot via tendon transition expansion and contraction plate 105 and acts on the continuous body. Multiple channels work together to achieve the desired posture. During operation, the control system module 60 performs real-time compensation and redundant channel scheduling based on displacement and tension feedback. When an emergency stop is triggered, the main circuit cuts off the output of the power supply 50 and quickly powers down the power conversion module 40 and the branch of the servo drive motor 301, ensuring the inherent safety and maintainability of the entire machine.

[0040] like Figure 3 As shown, the transmission module fixed upper plate 101 includes a first upper plate module 1011, a second upper plate module 1012 and a third upper plate module 1013.

[0041] The second upper top plate module 1012 is positioned between the first upper top plate module 1011 and the third upper top plate module 1013. The first upper top plate module 1011, the second upper top plate module 1012, and the third upper top plate module 1013 are modular standard plates, achieving self-positioning through their respective embedded bosses and recesses. Each plate is secured by structural fixing holes, forming a unified mounting base for the multi-channel lead screw, guide rail, and tendon. Proximity limit sensors are distributed at the proximal and distal ends of each channel. The tendons converge into the common wiring harness channel through the wire-passing holes in the upper top plate. The three types of plates—the first upper top plate module 1011, the second upper top plate module 1012, and the third upper top plate module 1013—are arranged in a row along the channel direction.

[0042] The transmission module fixing top plate 101 is formed by the detachable assembly of a first top plate module 1011, a second top plate module 1012, and a third top plate module 1013. The mating edges of adjacent modules are respectively provided with embedded bosses and embedded grooves, which cooperate with each other to achieve assembly positioning. Each module is clamped and connected to form an integral load-bearing component through structural fixing holes distributed on both sides of the mating edges and threaded fasteners. The transmission module fixing top plate 101 is provided with mounting holes for installing proximity limit sensors and corresponding inlet holes. Linear guides corresponding to the lead screw and nut transmission module 304 are also included. The upper plate 101 is fixed to the transmission module via fixing holes located at the near and far ends, respectively, to form a two-end fixation for each guide rail; each lead screw support is fixed at the near and far end lead screw fixing holes of the upper plate 101 of the transmission module to provide support for both ends of each lead screw; wherein, "near end" is based on the side where the super-redundant continuum robot module 20 is located, and "far end" is the opposite side; each drive channel is provided with a proximity limit sensor at the near and far ends of its guide rail, and the sensor is connected to the wiring harness channel in the upper plate via the inlet hole and electrically connected to the control system module 60.

[0043] like Figure 4 As shown, the first upper top plate module 1011 is disposed at one end of the transmission module fixing upper top plate 101. The first upper top plate module 1011 is provided with a first embedded boss 10110, a first structural fixing hole 10111, a first sensor mounting hole 10112, a first lead screw distal end fixing hole 10113, a first distal end guide rail fixing hole 10114, a first sensor inlet hole 10115, and a first tendon through hole 10116.

[0044] The first embedded boss 10110 is disposed on the inner side of the first upper top plate module 1011. Two first structural fixing holes 10111 are respectively disposed at both ends of the first upper top plate module 1011. Several first sensor mounting holes 10112 are located on the same horizontal axis of the first upper top plate module 1011, located to the side of the first lead screw distal end fixing hole 10113, close to the inner side of the first upper top plate module 1011. Several first lead screw distal end fixing holes 10113 are located on the central axis of the first upper top plate module 1011. Several first distal end guide rail fixing holes 10114 are disposed in the inner area of ​​the front of the first upper top plate module 1011. The first sensor inlet hole 10115 is located below the first lead screw distal end fixing hole 10113. The first tendon through hole 10116 is located to the side of the first lead screw distal end fixing hole 10113, close to the outer side of the first upper top plate module 1011.

[0045] The first embedded boss 10110 is used to mate with the embedded groove of the adjacent plate to complete lateral and height positioning. The first structural fixing hole 10111 is used to fasten to the main frame. The first sensor mounting hole 10112 is used to install a proximity limit sensor and correspond to the remote stroke detection. The first lead screw remote fixing hole 10113 is used to install the remote lead screw support assembly. The first remote guide rail fixing hole 10114 is used to lock the remote end of the guide rail. The first upper top plate module 1011 is close to the first sensor inlet hole 10115 as a sensor wiring channel. The first tendon through hole 10116 is coaxial with the channel axis to reduce friction and ensure consistent guidance.

[0046] like Figure 5 As shown, the second upper top plate module 1012 is a reusable assembly unit. The second upper top plate module 1012 is located in the middle area of ​​the transmission module fixed upper top plate 101. The second upper top plate module 1012 is provided with a second lead screw distal end fixing hole 10120, a second sensor mounting hole 10121, a second sensor inlet hole 10122, a second embedded groove 10123, a second distal guide rail fixing hole 10124, and a second embedded boss 10125.

[0047] Several second lead screw distal end fixing holes 10120 are arranged on the centerline of the second upper top plate module 1012. The second sensor mounting hole 10121 is arranged in the area diagonally below the second lead screw distal end fixing hole 10120. The second distal guide rail fixing hole 10124 is arranged in the area directly below the second lead screw distal end fixing hole 10120. A second embedded groove 10123 is provided on one side of the second upper top plate module 1012. A second embedded boss 10125 is provided on the other side of the second upper top plate module 1012. The second sensor inlet hole 10122 is arranged in the area of ​​the second upper top plate module 1012 near the second embedded boss 10125.

[0048] The second lead screw distal end fixing hole 10120 is used for supporting the distal end of the lead screw in another channel. The second sensor mounting hole 10121 is used to arrange a proximity limit sensor. The second sensor inlet hole 10122 serves as the wire harness inlet. The second embedded groove 10123 mates with the adjacent plate boss to achieve self-positioning. The second distal guide rail fixing hole 10124 is used for locking the distal end of the guide rail. The second embedded boss 10125 engages with the adjacent groove to improve assembly repeatability and suppress joint warping.

[0049] like Figure 6 As shown, the third upper top plate module 1013 is disposed at the other end of the transmission module fixing upper top plate 101. The third upper top plate module 1013 is provided with a third structure fixing hole 10130, a third embedded groove 10131, a third sensor inlet hole 10132, a third tendon through hole 10133, a third proximal guide rail fixing hole 10134 and a third sensor mounting hole 10135.

[0050] Two third structure fixing holes 10130 are provided at both ends of the third upper top plate module 1013; a third embedded groove 10131 is provided on the inner side of the third upper top plate module 1013; a number of third tendon through holes 10133 are arranged in two rows on the third upper top plate module 1013; a third sensor inlet hole 10132 is provided below the third tendon through hole 10133 in the area near the outer side of the third upper top plate module 1013; a third proximal guide rail fixing hole 10134 is provided below the third tendon through hole 10133 in the area near the inner side of the third upper top plate module 1013; and a third sensor mounting hole 10135 is provided in the area between the two third tendon through holes 10133.

[0051] The third structural fixing hole 10130 is used for fastening with the supporting frame or adjacent plate reinforcement. The third embedded groove 10131 mates with the boss of the first upper top plate module 1011 or the second upper top plate module 1012 to achieve boundary positioning. The third sensor inlet hole 10132 is used to cross the plate and merge the near-end or redundant sensor wiring harness into the main cable channel. The third tendon through hole 10133 is coaxial with the channel axis. The third near-end guide rail fixing hole 10134 is used for near-end locking and fine adjustment of the guide rail. The third sensor mounting hole 10135 is used to arrange the near-end proximity limit sensor and form a two-end limit redundancy monitoring with the far-end sensor.

[0052] The first upper top plate module 1011, the second upper top plate module 1012, and the third upper top plate module 1013 are sequentially assembled to form the transmission module fixing the upper top plate 101. The first embedded boss 10110, the second embedded groove 10123, the second embedded boss 10125, and the third embedded groove 10131 complete rapid self-positioning, forming a boss and groove assembly. The first structural fixing hole 10111 and the third structural fixing hole 10130 achieve overall clamping. The guide rail is fixed at the distal end by the first distal guide rail fixing hole 10114 and the second distal guide rail fixing hole 10124. It is fixed at the proximal end by the third proximal guide rail fixing hole 10134, forming a double-end constraint on the guide rail. Support components are installed at both ends of the lead screw at the first lead screw distal fixing hole 10113 and the second lead screw distal fixing hole 10120, respectively, and correspond to the stroke detection position. The proximity limit sensor is installed in the first sensor mounting hole 10112, the second sensor mounting hole 10121, and the third sensor mounting hole 10135. Its tendon sequentially enters through the first sensor inlet hole 10115, the second sensor inlet hole 10122, and the third sensor inlet hole 10132, passes through the cross-board, and merges into a unified wiring harness connected to the control system. This enables end-point limit detection, rapid assembly, and maintainable wiring for multi-channel transmission.

[0053] like Figure 7 As shown, the transmission module fixing lower top plate 102 includes a first lower top plate module 1021, a second lower top plate module 1022 and a third lower top plate module 1023.

[0054] The second lower top plate module 1022 is disposed between the first lower top plate module 1021 and the third lower top plate module 1023.

[0055] The transmission module fixing lower top plate 102 adopts a structure in which the first lower top plate module 1021 and the third lower top plate module 1023 at the left and right ends are clamped together, and several repeatable second lower top plate modules 1022 are arranged in a parallel array in the middle. Each module is connected and fastened by the positioning embedded boss or embedded groove to achieve quick assembly and replacement. The holes are arranged at equal intervals according to the transmission link unit, corresponding to each lead screw-guide rail-proximity sensor unit.

[0056] The transmission module fixing lower top plate 102 is detachably assembled from the first lower top plate module 1021, the second lower top plate module 1022, and the third lower top plate module 1023. The second lower top plate module 1022 is a reusable intermediate unit, and its opposite mating edges are alternately provided with embedded bosses or embedded grooves, which cooperate with each other to achieve assembly positioning and form a coplanar splicing. The transmission module fixing lower top plate 102 is provided with screw fixing holes that match the proximal end of the corresponding screw nut transmission module 304 and guide rail fixing holes that match the proximal end of the corresponding linear guide rail along the transmission axis of each drive channel, so as to provide proximal end fixation for each screw and each guide rail. The transmission module fixing lower top plate 102 is provided with mounting holes for installing proximity limit sensors and corresponding layered wiring holes. The layered wiring holes correspond to the wire inlet holes of the transmission module fixing upper top plate 101 in the channel position, thereby forming a through wire harness channel and electrically connecting to the control system module 60. The "proximal end" is based on the side where the super-redundant continuum robot module 20 is located.

[0057] like Figure 8 As shown, the first lower top plate module 1021 is located at the left end of the lower top plate 102 fixed by the transmission module.

[0058] The side of the first lower top plate module 1021 is provided with a first lower top plate embedded boss 10211. The first lower top plate module 1021 is provided with a first lower top plate structure fixing hole 10210, a first lower top plate lead screw near end fixing hole 10212, a first lower top plate sensor mounting hole 10213, a first lower top plate near end lead screw guide rail fixing hole 10214, a first upper top plate proximity sensor inlet hole 10215, and a first lower top plate proximity sensor inlet hole 10216.

[0059] The first lower top plate structural fixing hole 10210 is used for connection with the frame or adjacent components; the first lower top plate embedded boss 10211 is used for fixing the transmission module, self-positioning between modules of the lower top plate 102, and improving edge rigidity; the first lower top plate lead screw proximal fixing hole 10212 is used for mounting the proximal bearing seat or connecting parts; the first lower top plate sensor mounting hole 10213 is used for mounting the proximity sensor; the first lower top plate proximal lead screw guide rail fixing hole 10214 is used for fixing the proximal lead screw guide rail; the first upper top plate proximity sensor inlet hole 10215 is used for introducing the upper proximity sensor wiring harness; the first lower top plate proximity sensor inlet hole 10216 is used for the proximity sensor wiring harness to pass through and be managed. The above holes are arranged in a row along the transmission axis to ensure the coaxiality and relative positional accuracy of the lead screw, guide rail, and sensor.

[0060] like Figure 9 As shown, the second lower top plate module 1022 is a repeatable splicing unit in the middle of the lower top plate 102 for fixing the transmission module, which is used to expand the number of transmission links.

[0061] A second lower top plate embedded boss 10221 is provided on one side of the second lower top plate module 1022, and a second lower top plate embedded groove 10222 is provided on the other side of the second lower top plate module 1022; the second lower top plate module 1022 is provided with a second lower top plate proximal lead screw fixing hole 10220, a second lower top plate sensor mounting hole 10223, a second upper top plate proximity sensor inlet hole 10224, a second lower top plate proximity sensor inlet hole 10225, and a second lower top plate proximal lead screw guide rail fixing hole 10226.

[0062] The second lower top plate near-end lead screw fixing hole 10220 is used to fix the near-end lead screw end support; the second lower top plate embedded boss 10221 is used to achieve self-positioning and load-bearing with adjacent modules, and the second lower top plate embedded groove 10222, which cooperates with it, are arranged alternately to ensure the flatness and bending stiffness after the multi-module splicing; the second lower top plate sensor mounting hole 10223 is used to install proximity sensors; the second upper top plate proximity sensor inlet hole 10224 is used to pass through upper layer sensors or adjacent layer wiring harnesses; the second lower top plate proximity sensor inlet hole 10225 is used for wiring harness management in this layer; the second lower top plate near-end lead screw guide rail fixing hole 10226 is used to fix the near-end guide rail reference. The hole system of the second lower top plate module 1022 is positioned relative to the reference edge, and the hole spacing between repeating units is consistent, so as to form a regular array and simplify processing and inspection.

[0063] like Figure 10 As shown, the third lower top plate module 1023 is located at the right end of the transmission module fixing lower top plate 102, and is functionally complementary to the first lower top plate module 1021.

[0064] The third lower top plate module 1023 has a third lower top plate embedded groove 10231 on its side. The third lower top plate module 1023 is provided with a third lower top plate structure fixing hole 10230, a third lower top plate proximity sensor inlet hole 10232, a third upper top plate proximity sensor inlet hole 10233, a third lower top plate lead screw near end fixing hole 10234, a third lower top plate proximity sensor mounting hole 10235, and a third lower top plate near end lead screw guide rail fixing hole 10236.

[0065] The third lower top plate structure fixing hole 10230 is used to connect with the outer frame or end cover plate; the third lower top plate embedded groove 10231 is used to achieve end engagement with the middle second lower top plate module 1022; the third lower top plate proximity sensor inlet hole 10232 is used for layered wiring of the wire harness from bottom to top; the third upper top plate proximity sensor inlet hole 10233 is used to communicate with the upper layer; the third lower top plate lead screw near end fixing hole 10234 is used for near end support installation; the third lower top plate proximity sensor mounting hole 10235 is used for installing the proximity sensor; the third lower top plate near end lead screw guide rail fixing hole 10236 is used for guide rail end locking. The end chamfer and edge transition of the third lower top plate module 1023 are used to avoid interference between the wire harness and the edge, and improve assembly accessibility.

[0066] The second lower top plate module 1022 is positioned side-by-side in the middle according to the required number of channels. Lateral and vertical positioning is achieved by using the embedded boss 10221 of the second lower top plate and the adjacent embedded groove 10222 of the second lower top plate. The first lower top plate module 1021 and the third lower top plate module 1023 are installed at both ends respectively, and secured to the frame through the structural fixing holes 10210 and 10230 of the first and third lower top plates. Subsequently, proximal supports or connectors for the lead screw are installed at the proximal fixing holes 10212, 10220, and 10234 of the first, second, and third lower top plates. Corresponding guide rails are fixed at the proximal fixing holes 10214, 10226, and 10236 of the first, second, and third lower top plates, ensuring that the lead screw and guide rail form a parallel reference. The proximity sensors are installed in the first lower top plate sensor mounting hole 10213, the second lower top plate sensor mounting hole 10223, and the third lower top plate proximity sensor mounting hole 10235. The sensor signal lines pass through the first lower top plate proximity sensor inlet hole 10216, the second lower top plate proximity sensor inlet hole 10225, and the third lower top plate proximity sensor inlet hole 10232, respectively, and then sequentially pass through the first upper top plate proximity sensor inlet hole 10215, the second upper top plate proximity sensor inlet hole 10224, and the third upper top plate proximity sensor inlet hole 10233 to converge at the upper layer to the wiring harness slot or electrical interface. The proximity sensors are used for non-contact detection of the zero / limit or target position of each lead screw near its end, and together with the control system, realize the origin reset and stroke protection of each channel.

[0067] like Figure 11As shown, the drive module mounting plate 103 serves as the mounting base for fixing the drive device. Several fourth structural fixing holes 1031 are provided around the perimeter and corners of the drive module mounting plate 103 for positioning and fastening with the main load-bearing frame or adjacent reinforcing members. Fourth fixing slots 1032 are arranged in a matrix on the plate surface, with evenly distributed screw holes pre-drilled around the slots to achieve standardized installation of the reducer and alignment of the force path. This layout ensures rapid assembly of multiple drive units, a unified reference, and high-rigidity connections.

[0068] The drive module fixing plate 103 has several fourth structural fixing holes 1031 around its periphery for detachable connection with the upper top plate 101 or the lower top plate 102 of the transmission module fixing plate. The drive module fixing plate 103 has fourth fixing slots 1032 for mounting several planetary reducers 302 at equal intervals along its upper edge. Each mounting position is an annular stepped slot and coaxially forms a positioning ring platform. The positioning ring platform has equally spaced threaded through holes around its periphery for connecting with the flange bolts of the planetary reducer 302. A positioning pin hole is provided between the positioning ring platform and the through hole to cooperate with the reducer, so as to achieve coaxial positioning of the output shaft of the planetary reducer 302 and the mounting position, thereby allowing multiple drive branches to be installed in parallel on the drive module fixing plate 103.

[0069] like Figure 12 As shown, the super-redundant continuum robot module 20 consists of multiple levels of units connected in series along the axial direction. Each level of unit includes, in sequence: a base fixed end 201, a proximal hinge module 202, a distal hinge module 203, and an end-effector connection flange module 204. Adjacent units are connected by a fork-shaped arm and a pin rotating within a bearing to form a single-degree-of-freedom hinge. The rotation axes of adjacent hinges along the axial direction are orthogonal to each other, thereby achieving spatial bending capability with approximately continuous curvature. Each module is provided with tendon holes for drive tendons to pass through and converge at the end or connect to an external end effector, thereby achieving omnidirectional bending and extension posture control.

[0070] The super-redundant continuum robot module 20 consists of multiple repeating units connected in series along the axial direction. These repeating units are positioned between the base fixed end 201 and the end connecting flange module 204. Each repeating unit includes a proximal hinge module 202 and a distal hinge module 203. Adjacent repeating units are connected by a single-degree-of-freedom revolute joint consisting of a fork-shaped arm and a pin, with the pin supported in a bearing located within the connected modules. The rotation axes of the proximal hinge module 202 and the distal hinge module 203 within each repeating unit are orthogonal to each other. Each module is equipped with... The number of drive channels corresponds to the number of tendon guide holes, which are axially continuous to allow drive tendons to pass through; the end connecting flange module 204 is coaxially provided with a central through hole for cables or tools to pass through; a connecting sleeve is provided at the base of the super-redundant continuum robot module 20, which is detachably connected to the fixed end 106 of the continuum robot and can be installed with at least one of a pre-tightening mechanism and a displacement sensing unit or a tension sensing unit; wherein, "proximal end" is based on the side closest to the fixed end 106 of the continuum robot, and "distal end" is the opposite side.

[0071] like Figure 13 As shown, the base fixed end 201 is used to rigidly connect the super-redundant continuum robot module 20 to the modular continuum robot mechanical body 10 or the external drive / support platform, and provides an entry and pre-tightening adjustment interface for the tendons. A fork-shaped arm pin hole 2011 is provided at the top of the base fixed end 201 for cooperating with the second bearing 2022 of the upstream proximal hinge module 202 to install a pin and form a rotating pair. Several first tendon holes 2012 are distributed on the base fixed end 201, penetrating the body to allow multiple tendons to enter the body; the first tendon holes 2012 may have rounded corners or countersunk holes on the entry side to reduce wear. A first bearing 2013 is built into or pressed into the first tendon hole 2012; the first bearing 2013 is preferably a deep groove ball bearing or an oil-impregnated bearing to reduce hinge friction and improve service life.

[0072] like Figure 14 As shown, the proximal articulation module 202 is located at the proximal end of each repeating unit, forming a first hinge with the base fixed end 201 or an adjacent unit. It is provided with a proximal articulation fork-shaped narrow arm 2021 and a proximal articulation fork-shaped wide arm 2024, which are axially offset to form a typical "narrow arm-wide arm" insertion relationship. A second bearing 2022 is press-fitted into the fork-shaped arm and rotatably connected to the corresponding fork-shaped arm hole of the adjacent component via a pin. Second tendon holes 2023 are distributed on the top and side edges of the module, through which the tendon passes and around the hinge center, ensuring that the tension arm is fully engaged and does not interfere with rotation. The wall thickness and fillet transition of the narrow / wide arms are designed according to strength and fatigue requirements, and can be integrally formed by metal additive manufacturing.

[0073] like Figure 15As shown, the distal hinge module 203 and the proximal hinge module 202 appear alternately, forming an orthogonal arrangement of adjacent hinge axes. The third distal hinge fork-shaped narrow arm 2031 and the third distal hinge fork-shaped wide arm 2035 on the distal hinge module 203 are inserted into each other corresponding to the wide / narrow arms of the proximal hinge module 202. The third distal hinge fork-shaped narrow arm 2031 is provided with a third distal hinge fork-shaped narrow arm pin hole 2032, which cooperates with the third bearing 2034 in the opposite third distal hinge fork-shaped wide arm 2035 to form a rotating pair. The panel of the distal hinge module 203 is provided with several third tendon holes 2033. The holes of the third tendon holes 2033 are staggered relative to the previous module to maintain a constant torque of the tendon relative to the hinge axis and reduce the relative sliding between the tendon and the structure during bending. By alternating between the proximal articulation module 202 and the distal articulation module 203, the super-redundant continuum robot module 20 obtains two mutually perpendicular rotational degrees of freedom in each unit, which are then connected in series to form the kinematic characteristics of a continuum.

[0074] like Figure 16 As shown, the end-connecting flange module 204 is used to connect to an end effector, sensor, or tool quick-change mount, and provides an interface for end tendon exit and tensioning. The end-connecting flange module 204 has a flange fork arm 2041, which is connected to the corresponding fork arm of the preceding distal hinge module 203 by a bearing-containing pin. A fourth bearing 2044 ensures smooth end-twist rotation. Several fourth tendon holes 2042 are provided on the surface of the end-connecting flange module 204 for tendon exit or fixation and pre-tensioning via clamps / clamps inside the flange. A fourth through hole 2043 is provided in the center of the flange, which can be used as a cable, air path, or fiber optic channel, or as a locating pin or sensor mounting position. The end-connecting flange module 204 can adopt a circular, staggered, or irregular shape according to the application, and can be equipped with a standardized thread array to adapt to various tools.

[0075] During assembly, the first bearing 2013, the second bearing 2022, the third bearing 2034, and the fourth bearing 2044 are first press-fitted into each fork-shaped arm. Then, the base fixed end 201, the proximal hinge module 202, the distal hinge module 203, and the end connecting flange module 204 are connected sequentially by pins to form a continuous robot. Multiple repeating units are axially connected in series to form a "spine" structure of the required length. Tendons are introduced through the first tendon hole 2012 of the base fixed end 201 and pass through the second tendon hole 2023, the third tendon hole 2033, and the fourth tendon hole 2042 of each module in sequence according to a predetermined path, and are fixed or wrapped around at the end. The pre-tightening mechanism at the base realizes the initial tension setting and stroke compensation of multiple tendons. During driving, the tendon in any direction is stretched and bends around the corresponding hinge axis. The alternating orthogonal axes enable the end to achieve a three-dimensional omnidirectional configuration. The multi-level series connection and tendon differential control constitute super-redundant degrees of freedom, which can realize high compliance and obstacle avoidance movement.

[0076] Each module can be a one-piece metal part or a high-strength polymer part. The bearings use standard parts and are positioned by interference fit or adhesive bonding. The pins can be a detachable structure with snap rings or internal threaded ends for easy maintenance and replacement. The tendons are preferably high-modulus fiber ropes or plastic-coated steel cables, and the edges of the tendon holes are chamfered to reduce wear.

[0077] Through the above modular design, the super-redundant continuum robot module 20 can be quickly tailored in terms of size, number of sections, and degrees of freedom; different end-effector tasks can be adapted by replacing the end-connecting flange module 204; and an engineering trade-off can be made between stiffness, accessibility, and load by changing the ratio of the number of modules of the proximal articulation module 202 or the distance between the articulation axes.

[0078] In summary, this invention provides a modular, ultra-redundant continuum robot for deep cavity operations. Addressing the technical pain points of existing continuum robots, such as frequent disassembly during maintenance, high downtime and lifecycle costs, and poor reconfigurability, this invention constructs a reconfigurable system composed of standardized functional modules and quick-plug interfaces. Through structure-control decoupling, redundancy, and fault-tolerant design, this system enables on-demand combination and in-situ replacement of working units, balancing slender flexibility with high degrees of freedom. This improves accessibility and stability in deep cavity environments, significantly reducing maintenance difficulty and downtime costs.

[0079] The various units of this invention are modularly integrated through pluggable mechanical and electrical interfaces to form a unified electromechanical control platform. The drive transmission module adopts a matrix-style standard mounting position and evenly distributed fastening holes to ensure the centering of the force path of the drive unit and high rigidity connection, supporting rapid replacement and large-scale deployment. The transmission part adopts a "modular transmission part" architecture. The drive transmission module uses a frame-like carrier to support multiple motor-reduction units, with unified mechanical and electrical interfaces. Each rotary actuator outputs multi-line linear displacement to drive tendons through a rotary-linear conversion mechanism; a tendon transition component is set at the front end to converge, distribute and guide multi-channel tendons, and quickly docks and disassembles with the continuous body through a coaxial quick-connect interface, realizing channel compactness, simplified assembly and rapid maintenance. To support the high-density, maintainable installation of dozens of transmission units, the upper and lower top plates of the drive transmission module adopt a three-section modular design and specify the assembly sequence. First, the middle upper / lower top plate with a double-row channel layout is installed to establish the main load and channel benchmark; then, the two side sections are installed in sequence to complete the channel expansion and closure. Each segment employs an inlay method to prevent errors and ensure repeated positioning. The transmission and lower support plate combine end modules with reusable middle modules, achieving a unified installation benchmark for the lead screw / guide and sensing units through a self-positioning structure and equidistant hole system. The number of channels can be linearly expanded according to the task. The wiring harness is introduced in layers and centrally collected for easy assembly and maintenance. The ultra-redundant continuum robot module is composed of multi-level module units connected in series. The hinge axes of adjacent units are arranged orthogonally along the axial direction, and with the through-through multi-channel tendons, it achieves bending, extension, and torsion control with approximately continuous curvature. The end effector uses a standardized flange and universal interface to adapt to various types of end effectors and sensors. The modular continuum robot's mechanical body is fixed to the load-bearing structure of the mobile chassis and equipped with vibration damping and quick assembly / disassembly mechanisms. The continuum modules achieve mechanical positioning, power supply, and signal interconnection with the body through a front-end composite interface. The drive transmission modules are arranged in groups along the axial direction inside the body, with their output channels corresponding one-to-one with the force transmission channels of the continuum modules. The power conversion module is located near the power supply side in the electrical compartment. The control system module communicates with the drive transmission module, the continuum module, and the on-board controller of the mobile chassis via an industrial bus. The power supply is a unified DC energy unit, establishing a DC bus through the main relay and protection devices. The power conversion module performs step-up / step-down, isolation, and voltage regulation on the bus voltage, providing multiple controlled DC currents to the drive, control, and sensing / actuation units. The control system module uniformly issues motion and power commands, collects displacement and tension information in a closed loop, and coordinates with the motion control of the mobile chassis. Therefore, the present invention has the functions of main circuit power-off for emergency shutdown, branch rapid power-off, and overcurrent, overtemperature and insulation monitoring and reporting; after power-on, it automatically completes self-test, zero-position calibration and parameter loading; during task execution, it performs redundant channel scheduling and real-time compensation; and when a fault or power threshold is triggered, it implements power limiting, orderly power-off or emergency power-off.

[0080] This application integrates the drive and transmission systems within a modular frame, with standardized interfaces and hole systems enabling rapid assembly, alignment, and replacement. The end-plus-middle splicing scheme controls tolerance superposition and enhances overall rigidity, allowing for expansion of the number of channels according to task requirements. Layered import and centralized aggregation reduce mutual interference and improve maintainability. High operational safety is ensured through limit detection, main circuit power failure, and multiple electrical protections, enhancing intrinsic safety. A unified DC bus and multiple controlled DC lines, combined with centralized control, enable collaborative operation between the continuous body and the mobile chassis. The continuous body module dimensions, number of sections, and degrees of freedom are customizable; standardized end flange interfaces support various tools; and materials and manufacturing methods are replaceable.

[0081] Secondly, the present invention provides a control method for a modular, super-redundant continuum robot for deep cavity operations, comprising the following steps: S1: Close the main relay to connect the power supply 50 to the DC bus via the fuse and supply power to the power conversion module 40, drive transmission module 30, control system module 60 and mobile chassis 70. S2: The control system module 60 sequentially performs self-test, zero-position calibration and parameter loading on the super-redundant continuum robot module 20 and the mobile chassis 70, and reads the insulation, overcurrent and temperature status of the power conversion module 40 to confirm electrical safety; when electrical safety is confirmed, the task is executed. S3: During task execution, the control system module 60 sends the target quantity of the channel to each drive branch of the drive transmission module 30 according to the trajectory planning. The target quantity is at least one of displacement, velocity or tension, so that the super-redundant continuum robot module 20 produces bending, stretching and torsional deformation; at the same time, it sends speed and attitude commands to the mobile chassis 70 to achieve coordinated motion. S4: During operation, closed-loop compensation and redundant channel scheduling are implemented based on displacement and tension feedback from the super-redundant continuum robot module 20. S5: When a fault is detected or the power level is lower than the preset threshold, power limiting and orderly power-down are executed; when the emergency shutdown conditions are met, the main relay is disconnected to isolate the power supply 50 from the DC bus.

[0082] This control method modularizes the drive and transmission units and the continuous robot, allowing maintenance to be decentralized from the whole-machine level to the unit level. This significantly shortens the mean time to repair (MTBL) and supports on-site maintenance in confined environments, reducing downtime and lifecycle costs. Through segmented skeleton and load path reconstruction, tension zoned closed-loop management, and redundant configuration, it distributes root loads and suppresses pressure bar instability, achieving repeatable tension calibration and higher control accuracy. At the system level, it further improves the reliability, maintainability, and feasibility of large-scale deployment of the continuous robot, becoming a key path to overcome the bottleneck of continuous robots' deployment in confined environments with narrow entrances and deep cavities. Addressing the technical pain points of existing continuous robots, such as the need for complete disassembly during later maintenance, high downtime and lifecycle costs, and poor reconfigurability, a reconfigurable system composed of standardized functional modules and quick-plug interfaces is constructed. This system, through structure-control decoupling, redundancy, and fault-tolerant design, enables on-demand combination and in-situ replacement of working units, balancing slender compliance with high degrees of freedom, thereby improving accessibility and stability in deep cavity environments and significantly reducing maintenance difficulty and downtime costs.

Claims

1. A modular, super-redundant continuum robot for deep cavity operations, characterized in that, It includes a modular continuum robot mechanical body (10), a super-redundant continuum robot module (20), a drive transmission module (30), a power conversion module (40), a power supply (50), a control system module (60), and a mobile chassis (70). The modular continuum robot mechanical body (10) is located on the mobile chassis (70); The super-redundant continuum robot module (20) achieves mechanical positioning or signal interconnection through the composite interface at the front end of the modular continuum robot mechanical body (10); The drive transmission module (30) is arranged in groups along the axial direction inside the modular continuous robot mechanical body (10). The modular continuous robot mechanical body (10) includes a transmission module fixing upper top plate (101), a transmission module fixing lower top plate (102) and a drive module fixing plate (103), which are used to support or replace the drive transmission module (30). The output channel of the drive transmission module (30) corresponds to the force transmission channel of the super-redundant continuum robot module (20); The power conversion module (40) is located inside the modular continuum robot mechanical body (10) and is used to power the super-redundant continuum robot module (20), drive transmission module (30), control system module (60) and mobile chassis (70); the power conversion module (40) is connected to the power supply (50); The control system module (60) is located in the upper region inside the modular continuum robot mechanical body (10) and communicates with the drive transmission module (30), the super-redundant continuum robot module (20) and the mobile chassis (70); The super-redundant continuum robot module (20) is equipped with repeating units, and several repeating units are connected in series.

2. The modular, super-redundant continuum robot for deep cavity operations according to claim 1, characterized in that, The drive transmission module (30) includes a drive branch; Several of the aforementioned drive branches are connected in parallel; The drive branch includes a servo drive motor (301), a planetary reducer (302), a coupling (303), and a lead screw and nut transmission module (304). The servo drive motor (301) is connected to the planetary reducer (302); The output shaft of the planetary reducer (302) is coaxially connected to the lead screw of the lead screw and nut transmission module (304) via the coupling (303).

3. A modular, super-redundant continuum robot for deep cavity operations according to claim 1, characterized in that, The lead screw and nut transmission module (304) is disposed between the upper top plate (101) of the transmission module fixing and the lower top plate (102) of the transmission module fixing; The transmission module fixed lower plate (102) is disposed between the coupling (303) and the lead screw nut transmission module (304); The drive module mounting plate (103) is disposed between the planetary reducer (302) and the coupling (303).

4. A modular, super-redundant continuum robot for deep cavity operations according to claim 3, characterized in that, The transmission module fixed upper plate (101) includes a first upper plate module (1011), a second upper plate module (1012) and a third upper plate module (1013). A plurality of second upper top plate modules (1012) are disposed between the first upper top plate module (1011) and the third upper top plate module (1013); The first upper top plate module (1011) is provided with a first structural fixing hole (10111), a first sensor mounting hole (10112), a first lead screw distal fixing hole (10113), a first distal guide rail fixing hole (10114), a first sensor inlet hole (10115) and a first tendon through hole (10116). The second upper top plate module (1012) is provided with a second lead screw remote end fixing hole (10120), a second sensor mounting hole (10121), a second sensor inlet hole (10122) and a second remote end guide rail fixing hole (10124). The third upper top plate module (1013) is provided with a third structural fixing hole (10130), a third sensor inlet hole (10132), a third tendon through hole (10133) and a third proximal guide rail fixing hole (10134).

5. A modular, super-redundant continuum robot for deep cavity operations according to claim 4, characterized in that, The transmission module fixing lower top plate (102) includes a first lower top plate module (1021), a second lower top plate module (1022) and a third lower top plate module (1023). A plurality of second lower top plate modules (1022) are disposed between the first lower top plate module (1021) and the third lower top plate module (1023); The first lower top plate module (1021) is provided with a first lower top plate structure fixing hole (10210), a first lower top plate lead screw near end fixing hole (10212), a first lower top plate sensor mounting hole (10213), a first lower top plate near end lead screw guide rail fixing hole (10214), a first upper top plate proximity sensor inlet hole (10215) and a first lower top plate proximity sensor inlet hole (10216). The second lower top plate module (1022) is provided with a second lower top plate near end lead screw fixing hole (10220), a second lower top plate sensor mounting hole (10223), a second upper top plate proximity sensor inlet hole (10224), a second lower top plate proximity sensor inlet hole (10225), and a second lower top plate near end lead screw guide rail fixing hole (10226). The third lower top plate module (1023) is provided with a third lower top plate structure fixing hole (10230), a third lower top plate proximity sensor inlet hole (10232), a third upper top plate proximity sensor inlet hole (10233), a third lower top plate lead screw near end fixing hole (10234), a third lower top plate proximity sensor mounting hole (10235), and a third lower top plate near end lead screw guide rail fixing hole (10236).

6. A modular, super-redundant continuum robot for deep cavity operations according to claim 4, characterized in that, The drive module fixing plate (103) has several fourth structure fixing holes (1031) around its perimeter and corners. The surface of the drive module fixing plate (103) has several fourth fixing slots (1032) arranged in a matrix.

7. A modular, super-redundant continuum robot for deep cavity operations according to claim 1, characterized in that, A tendon transition component is provided on the output side of the drive transmission module (30); The tendon transition assembly includes a tendon transition module top plate (104) and a tendon transition retraction plate (105). The tendon transition module top plate (104) is disposed between the modular continuum robot mechanical body (10) and the continuum robot fixed end (106); The tendon transition expansion disc (105) has several guide holes spaced at equal angles along its circumference.

8. A modular, super-redundant continuum robot for deep cavity operations according to claim 1, characterized in that, The super-redundant continuum robot module (20) also includes a base fixed end (201) and an end connection flange module (204). Several repeating units are disposed between the base fixed end (201) and the end connecting flange module (204); The repeating unit includes a proximal articulation module (202) and a distal articulation module (203). The proximal articulation module (202) and the distal articulation module (203) are alternately arranged.

9. A modular, super-redundant continuum robot for deep cavity operations according to claim 1, characterized in that, The control system module (60) includes a processor, a memory, and a communication interface; After power-on, the control system module (60) checks the super-redundant continuum robot module (20) and the mobile chassis (70), and reads the electrical data of the power conversion module (40) to confirm electrical safety; During task execution, the control system module (60) sends the target quantity of the channel to the drive transmission module (30) according to the trajectory planning. The target quantity is at least one of displacement, speed or tension, which causes the super-redundant continuum robot module (20) to generate a posture change and sends speed and posture commands to the mobile chassis (70) to achieve coordinated movement. During operation, the control system module (60) implements closed-loop compensation and redundant channel scheduling based on feedback signals. When a fault is detected or the power is lower than the threshold, the control system module (60) performs power limiting and orderly power-off and implements emergency power-off.

10. A control method for a modular, hyper-redundant continuum robot for deep cavity operations, based on any one of claims 1-9, characterized in that, include: S1: Connect the power supply (50) and supply power to the power conversion module (40), drive transmission module (30), control system module (60) and mobile chassis (70); S2: The control system module (60) sequentially performs self-test, zero-position calibration and parameter loading on the super-redundant continuum robot module (20) and the mobile chassis (70), and reads the insulation, overcurrent and temperature status of the power conversion module (40) to confirm electrical safety; when electrical safety is confirmed, the control system module (60) issues a task execution signal; S3: During task execution, the control system module (60) moves the drive transmission module (30) according to the trajectory planning, causing the super-redundant continuum robot module (20) to deform; at the same time, it sends speed and attitude commands to the mobile chassis (70) to achieve coordinated movement; the control system module (60) implements closed-loop compensation and redundant channel scheduling based on the displacement and tension feedback from the super-redundant continuum robot module (20); during the task, when a fault is detected or the power is lower than the preset threshold, the control system module (60) performs power limiting and orderly power-off; when the emergency shutdown conditions are met, the control system module (60) controls the power-off.

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