Field rheological actuation system, texture, intelligent mechanical arm system and related use method

Abstract

The invention discloses a field rheological actuating system, a texture, an intelligent mechanical arm system and a related use method, and relates to the technical field of intelligent mechanical electronics and precise motion control. Differentiated asymmetric geometric topology structure sections are arranged on the surfaces of relative movement components of the field rheological actuating system, space differentiated field intensity distribution and local saturation of an excitation field are induced, field intensity distribution is optimized through geometric topology structures, solidification of rheological media in a topology locking area is achieved, and a mechanical interlocking effect is established. Therefore, the structural static holding torque exceeding the yield limit of the medium is output without continuous power supply of the motor. A joint of the mechanical arm system is composed of the actuating system, and a local real-time solution and geometric constraint control strategy is adopted to achieve safety constraint of a far-end motion center. The problems that a traditional rheological joint is insufficient in static retentivity, a joint motor is overheated due to long-term stalling, and the remote operation safety is insufficient are effectively solved.

Description

Technical Field

[0001] This application generally relates to the fields of intelligent electromechanical and precision motion control technology. Specifically, it relates to a field-induced rheological actuation system with a field modulation interface, a hybrid drive energy-saving control method based on physical property phase feedback, a motion control method based on local real-time calculation and physical safety constraints, and an intelligent robotic arm system applying the above-mentioned actuation device and method. Background Technology

[0002] 1. Pain points of field-induced rheological actuation systems: Pain Point 1: Torque Bottleneck of Traditional Structures Field-induced rheology technology, due to its millisecond-level response speed and controllable rheological characteristics, is widely used in semi-active damping and flexible actuation. However, traditional field-induced rheological actuation systems (such as magnetorheological brakes or clutches) typically use smooth cylindrical surfaces or simple disc structures as the working interface. To increase output torque, existing technologies often increase device size or excitation current, but this results in bulky devices and a surge in energy consumption.

[0003] While some existing technologies attempt to increase shear area by fabricating simple rectangular grooves or sandblasting textures on the working surface, these symmetrical and regular geometries often ignore the topological distribution characteristics of physical fields (magnetic / electric fields) at the microscopic scale. Under high magnetic / electric flux density, conventional structures often experience local magnetic / electric saturation, resulting in uniform field line distribution but low utilization, making it impossible to break through the yield shear strength limit of the medium within a limited space. Furthermore, under high-load static holding conditions, simple surface grooves cannot provide sufficient structural anti-slip torque, making it difficult for the robotic arm to maintain a heavy-load posture in power-off or low-power modes (e.g., the "arm drop" phenomenon in robotic or medical robotic arm applications).

[0004] Pain Point 2: The contradiction between control precision and linearity Furthermore, existing field-induced rheodynamic joints often exhibit strong "switching characteristics" or nonlinear hysteresis in torque output. Due to the simplicity of the stator and rotor magnetic circuit design, it is difficult to achieve linear and fine adjustment of the output torque. Especially in the precise force control operation of robots, there is a lack of a mechanism that can spatially modulate the field strength distribution through purely mechanical means. This forces the system to rely on extremely complex external control algorithms to compensate for the nonlinearity of the material itself, increasing the computational burden.

[0005] Pain Point 3: Thermal Failure and Media Settlement Even more challenging is that field-induced rheological actuation (especially electrorheological fluids and magnetorheological fluids) is highly sensitive to temperature and particle dispersion. In the high-frequency, high-dynamic reciprocating motion of robots, shear friction and coil heating can cause a sharp increase in the temperature of the working gap.

[0006] For electrorheological systems, high temperatures can cause leakage current to rise exponentially, and may even lead to thermal breakdown of the dielectric. For magnetorheological systems, high temperatures lead to a decrease in zero-field viscosity, affecting control accuracy. Simultaneously, when the actuation system is stationary or operating at low speeds for extended periods, solid particles in the medium are prone to agglomeration and sedimentation due to gravity or centrifugal force, causing device performance degradation or even jamming. Existing external air-cooling or liquid-cooling solutions cannot directly reach the core working gap and cannot solve the physical problem of particle sedimentation.

[0007] Pain Point 4: Low Energy Efficiency Finally, in mobile robot and exoskeleton applications, energy efficiency ratio is a core indicator. Existing systems often require a continuous supply of large currents to maintain magnetic / electric field saturation in order to maintain high static torque. This not only results in huge energy waste but also exacerbates the aforementioned thermal failure problem.

[0008] Therefore, there is an urgent need in the industry for a new type of field-induced rheological actuation system that can solve the problems of high torque density, anti-settling heat dissipation, and static low power consumption through underlying physical topology optimization.

[0009] 2. Common challenges in precision operations and interactions: In modern precision surgery (such as neurosurgery, orthopedic implants, and minimally invasive procedures), the core contradiction lies in the "absolute stability and fixation" of surgical instruments versus the "flexible and compliant adjustment" during surgery. Surgical assistants or robotic arms need to maintain sub-millimeter precision of retractors, endoscopes, or guides for extended periods, while simultaneously responding to the surgeon's adjustment commands. However, existing solutions have significant drawbacks: human hands are limited by physiological tremors, fatigue, and unconscious positional movements; and the adjustment process of traditional robotic arms is extremely cumbersome, forcing the surgeon to perform multiple steps, disrupting the "fluidity" of the surgery, and failing to provide intuitive "one-click continuous damping adjustment." This instability in positioning or lag in adjustment often leads to loss of the surgical field and can even cause life-threatening complications.

[0010] Similar "rigid-flexible conflict" is also prevalent in the fields of intelligent manufacturing and human-computer interaction: In high-load scenarios (such as industrial robotic arms, robots, humanoid robots, and wearable exoskeletons), the system needs to exhibit low impedance during movement to ensure safety, while also possessing high stiffness under load to resist deformation. Traditional drive solutions struggle to efficiently balance these two opposing states across a wide load range and suffer from high energy consumption and heat generation during static holding. For precision interaction scenarios (such as VR force feedback and camera gimbals): the system needs to simulate a full dynamic range of tactile gradients, from "the softness of squeezing a sponge" to "the rigidity of gripping an iron rod." Traditional motor solutions, limited by cogging torque and control bandwidth, struggle to simultaneously achieve high-fidelity force reproduction and smooth, jitter-free motion; traditional field-induced rheological joint solutions, constrained by the physical limits of the yield stress of fluid materials, still exhibit slight slippage under high damping conditions, making it difficult to provide sufficient absolute rigidity in the collision feedback.

[0011] In remote surgery or teleoperation scenarios, motors controlled by pure software algorithms are inherently prone to constraint failure due to network latency or communication interruptions, lacking an ontology-based physical safety barrier that does not rely on upper-level control.

[0012] 3. Analysis of the limitations of existing technologies Existing technologies mainly employ the following types of solutions, but all of them have inherent defects that are difficult to overcome: 3.1 Purely mechanical locking system: Multi-joint locking mechanisms that rely on friction plates or gears have the following main drawbacks: they are cumbersome to operate (requiring both hands to unlock / lock each joint individually), and after long-term use, they suffer from wear and creep and uneven and continuous force, resulting in a decrease in positioning accuracy over time. Furthermore, they cannot achieve digital remote control.

[0013] 3.2 Hydraulic and Pneumatic Systems: While fluid actuation can provide significant holding force, the compressibility of fluids (especially pneumatics) and pipeline transmission delays result in significant system hysteresis, making it difficult to achieve high-frequency chatter suppression. Furthermore, hydraulic systems have bulky pump stations and pose a risk of leakage, which is unacceptable in sterile surgical environments or precision electronics manufacturing environments.

[0014] 3.3 Electromagnetic Servo and Braking System: Electromagnetic servo-based drive systems (widely used in robots, industrial robotic arms, exoskeletons, wearable devices, and precision gimbals) have the following core drawbacks while achieving precise motion control: (1) Static holding power consumption and heat generation issues: In working conditions that require maintaining a static posture or resisting continuous load (such as surgical traction or exoskeleton load), the motor must continuously output stall torque, resulting in the windings carrying a large current for a long time, causing a serious Joule heating effect. This not only brings the risk of overheating and reduces the reliability of electronic components, but also greatly limits the endurance of the equipment in scenarios without external power supply.

[0015] (2) Limitations of binary control characteristics: Traditional electromagnetic brakes only have two states, "loose / tight" and lack continuous damping in the intermediate state. This "either open or closed" characteristic results in a stiff feel when dragging in medical devices and a lack of finesse in VR force feedback. It cannot simulate delicate tactile gradients, which seriously restricts its application in human-computer interaction scenarios that require high-fidelity force feedback.

[0016] 3.4 Bottlenecks and limitations of existing field-induced rheodynamic joint technology: Although magnetorheological (MR) or electrorheological (ER) technologies are widely used in vibration reduction due to their fast response and controllable damping, existing technologies still face three major bottlenecks when used in high-load locking mechanisms (such as surgical robotic arms and exoskeleton joints): (1) Physical ceiling of shear stress and slip risk: Existing field-induced rheological joints generally employ smooth mating surfaces or those that have undergone only micro-roughening treatments (such as sandblasting) to increase the coefficient of friction. Their braking torque primarily depends on the shear yield stress after the fluid becomes magnetically saturated. However, due to limitations in material physics, the upper limit of the shear yield stress for existing commercial magnetorheological fluids is typically between 50-80 kPa. Under high-load conditions (such as the strong traction in orthopedic surgery), once the shear stress generated by the external torque exceeds this threshold, the joint not only fails to form a rigid "hard lock," but also experiences uncontrollable "viscous creep" or slight slippage, leading to a failure in positioning accuracy.

[0017] (2) Inherent defects of existing solutions for increasing output torque: To obtain a larger moment under finite shear yield stress, existing technologies typically employ the following approaches: A. Multi-disc stacked structure: Increases torque by increasing shear area. However, this results in bulky and heavy joints, and usually only allows for single-axis rotation, losing the advantages of compact and multi-degree-of-freedom ball joints.

[0018] B. Large radius structure: Simply increasing the joint's rotation radius leads to a sharp increase in joint volume and weight, compromising the system's lightweight and dynamic performance, and limiting its application in scenarios such as minimally invasive surgical robotic arms or humanoid robot joints.

[0019] C-Squeeze Mode: High resistance is generated through minute compression between the electrode gaps. However, this results in a very small range of motion for the joints (typically only on the micrometer to millimeter scale), which cannot meet the needs of large-amplitude movements of the robotic arm.

[0020] The fundamental flaw of the "barrier-type" power-boosting design: Some existing solutions enhance locking force by placing physical blocks along the motion path. However, this design has inherent flaws: a) Discontinuous motion: The blocks break smooth motion into discrete segments, resulting in a "step-like" stuttering sensation and compromising the compliance necessary for precise operation. b) Impact and wear: Rigid contact is formed in the locked state, and even minor disturbances can trigger impact vibrations, leading to fretting wear of the blocks over time and generating abrasive debris that contaminates the medium. c) Risk of single-point failure: The load torque is concentrated at a single point on the blocks, creating stress concentration, which can easily lead to plastic deformation or fatigue fracture, resulting in catastrophic sudden loss of lock.

[0021] (3) The energy efficiency problem remains unresolved: Similar to servo motors, existing rheodynamic joints still require a continuous application of a strong physical field (such as excitation current) to maintain a high damping state when locked. This makes existing rheodynamic technology still face significant energy consumption and heat generation challenges in applications where static holding is required for a long time.

[0022] 3.5 Safety issues related to motion constraints in remote operation In remote surgery and other teleoperation scenarios, existing technologies for implementing geometric constraints such as remote centers of motion (RCM) mainly suffer from two types of problems: (1) Reliability risks of software constraints: It relies on the active compensation control of servo motors and software algorithms. The performance of this "soft constraint" mechanism is highly dependent on the low latency of the communication link and the absolute correctness of the algorithm calculation. It lacks physical-level security guarantees that the constraints can still be enforced in the event of system anomalies (such as communication interruption or program error).

[0023] (2) Insufficient flexibility of mechanical constraints: RCM can be physically rigidly achieved by using specific linkage mechanisms (such as parallelogram mechanisms), but such mechanisms are usually complex in structure and large in size, which severely limits the dexterity of operation and the degree of system integration.

[0024] 4. The solution proposed in this invention In summary, existing technologies have failed to provide a comprehensive solution that can simultaneously resolve the contradictions between high rigidity and operational compliance, and between extremely high energy efficiency and intrinsic safety.

[0025] Therefore, this invention proposes a systematic solution based on the deep coupling of multiple physics fields: field-structure-fluid. (1) Structural Mechanism Level: Breaking through the mechanical bottleneck of traditional smooth interfaces, an asymmetric field impedance modulation interface and a rotor-embedded fluid circulation system are innovatively introduced. Through the differentiated distribution of the stator and rotor surface topology, local convergence and saturation overflow of the physical field (magnetic / electric) are induced at the microscale, forcing the field-induced rheological medium to form a high-strength "wedge-shaped solidified body" in a specific geometrically interlocked region. This field-induced mechanical interlocking effect overcomes the force transmission limit of traditional devices that rely solely on the average shear yield strength of the medium, while simultaneously solving the problems of medium sedimentation and thermal failure by utilizing the hydrodynamic effect of the embedded flow channel.

[0026] (2) Control Architecture Level: Construct an independent joint control architecture based on physical field impedance feedback. Utilize the nonlinear response characteristics of the joint's physical structure to the excitation field to endow each joint unit with "body awareness" capabilities. The system can calculate the joint's stress state in real time by monitoring changes in field impedance, achieving active chatter suppression, geometric constraint (RCM) physical locking based on local logic, and refined variable stiffness compliant control, thus endowing the robotic arm system with inherent safety attributes.

[0027] (3) Energy efficiency strategy level: Integrate energy-saving control strategies based on magnetic / electric saturation overflow mechanisms. Utilize the structurally enhanced holding torque generated by the aforementioned field impedance modulation interface under static conditions to completely replace the high-energy-consuming "stalled" mode of traditional motors. The system only needs an extremely weak field strength to generate a huge geometric self-locking force, thereby fundamentally solving the energy consumption and heat generation problems of precision motion systems during long-term static posture maintenance (such as surgical posture fixation and heavy-load grasping).

[0028] The synergistic effect of this series of underlying physical topologies and upper-level control logic aims to build a next-generation, high-performance, high-safety, and high-energy-efficiency field-sensing rheometry general-purpose technology platform. Its applications extend beyond the medical field, encompassing robotics, humanoid robots, wearable exoskeletons, industrial robotic arms, VR wearable devices, industrial flexible assembly (such as camera gimbals), and even aerospace—applications requiring precision motion control and high safety, reliability, and energy efficiency. Summary of the Invention 1. Technical problems to be solved Addressing the common technical bottlenecks in "high-load silent locking," "all-condition thermal stability," and "remote intrinsic safety" of high-end medical surgical robots, humanoid robots, precision human-machine collaboration, and exoskeleton systems, this invention aims to solve the following specific technical problems: (1) Breaking through the physical limits and energy efficiency of the yield strength of rheological media materials, most existing field-induced rheological actuation systems use smooth or simple textured working surfaces, and their maximum output torque is strictly limited by the average shear yield stress of the rheological medium (MRF / ERF) itself. In order to obtain high static holding force, traditional solutions are forced to continuously input saturated excitation current / voltage, resulting in a vicious cycle of "high holding force must be accompanied by high energy consumption and high heat generation", which cannot achieve safe static stability after the servo motor is powered off, and it is difficult to meet the energy-saving requirements of long-term static surgical posture fixation or exoskeletons and robot joints.

[0029] (2) Overcoming the challenges of thermal failure and media sedimentation under high dynamic operating conditions. During high-frequency reciprocating motion or heavy-load braking of the joint, the shear heat accumulation in the closed working gap can lead to the degradation of the viscosity-temperature properties of the medium (magnetorheological fluid) or induce leakage current thermal breakdown (electrorheological fluid). At the same time, the existing closed rotor structure lacks an active media circulation mechanism, which makes it easy for solid particles to undergo phase separation and sedimentation under the action of centrifugal force or gravity when the device is stationary or running at low speed, resulting in fluctuations in the joint output torque, jamming or even complete failure.

[0030] (3) Addressing the latency risks and "soft safety" failures in remote force control: Existing robotic arm safety strategies largely rely on visual feedback from the host computer or pure current loop algorithms (soft constraints). In remote medical or complex human-machine collaboration scenarios, once network latency, sensor noise, or computing power failure occurs, the system cannot make an immediate physical-level response at the joint body level. The lack of a localized intrinsic safety mechanism based on feedback from the underlying physical structure makes it difficult to guarantee the spatial constraints of the remote motion center (RCM) under extreme failures.

[0031] 2. Technical Solution This invention, based on the innovative concept of "low-level physical topology reconstruction," "multi-physics field coupling control," and "system-level energy efficiency synergy," provides a complete solution covering the actuation system, robotic arm system, and control strategy: 2.1 System Overall Architecture This invention constructs a field-induced rheological actuation system and an intelligent robotic arm that uses the system.

[0032] Core actuation layer: The system contains at least one field-induced rheological joint unit, which has an asymmetric field impedance modulation interface built inside. It is configured to generate spatially differentiated field strength gradients and local magnetic / electric saturation under the action of the excitation field.

[0033] Robotic arm body layer: The above-mentioned joint units and links are connected in alternating series to form a multi-degree-of-freedom kinematic chain, supporting applications in all scenarios from light-load precision surgery to heavy-load orthopedic traction.

[0034] Control Decision Layer: Equipped with an independent control unit, it is configured to independently adjust the excitation field intensity of each joint based on the nonlinear rheological response characteristics of the joint physical structure, so as to achieve a continuous and smooth transition between the three states of "low-damped compliant following", "high-damped dynamic servo" and "ultra-high holding force rigid locking".

[0035] 2.2 Key Structural Innovations: Deep Coupling Mechanism Between Field, Structure, and Fluid To overcome the mechanical and thermal limits of traditional smooth joints, this invention implements a dual physical reconstruction within the actuation system: (1) Field-induced mechanical interlocking mechanism based on asymmetric topology: Microstructures with different geometric topological parameters (such as asymmetric inverted trapezoidal grooves and asymmetric ridges) are provided on the mating surfaces of the stator and rotor. This structure no longer relies solely on fluid viscosity, but guides the flux to accumulate and overflow in the geometrically interlocked region, inducing the field-induced rheological medium to enter a local instantaneous saturated yield state, forming a high-strength "virtual rigid wedge". This mechanism changes the force transmission mode from a single "interfacial laminar shear" to a composite "mechanical interlocking of field-induced solidification core", thereby outputting a structural holding torque that exceeds the average yield limit of the medium by several times.

[0036] (2) Fluid dynamic circulation mechanism based on rotor embedded tunnel: A medium circulation tunnel and inner wall turbulence texture are integrated inside the moving part (rotor) matrix. Utilizing the centrifugal fluid dynamic effect generated by joint movement and the pressure difference on the working surface, the field-induced rheological medium is driven to form a heat-mass exchange circulation between the working gap and the internal tunnel. This mechanism not only solves the problem of heat accumulation under high-frequency operation, but also effectively suppresses the sedimentation and agglomeration of solid particles through active turbulent stirring, ensuring performance stability throughout the entire life cycle.

[0037] 2.3 One of the key control innovations: a low-energy-consumption maintenance strategy based on structural gain. Given the enormous structural holding torque generated by the aforementioned physical structure, this invention proposes a groundbreaking hybrid drive timing energy-saving strategy: Dynamic accompanying stage: The control unit outputs a weak excitation and uses the linear damping characteristics generated by the gradient texture to assist the servo motor in achieving high-precision compliant motion or gravity compensation.

[0038] Static locking phase: When the robotic arm reaches the target pose (such as surgical positioning or exoskeleton load-bearing), the control unit activates a high-intensity excitation field, triggering a "field-induced mechanical interlocking effect" to rigidly lock the joint. Since the locking torque exceeds the external preset load torque (safety factor > 1), the system then cuts off the active holding current of the servo motor. At this time, the heavy load is entirely borne by the "geometric self-locking" of the actuation system or the joint's physical structure, achieving "zero power consumption and zero heat generation" hovering.

[0039] 2.4 Second major control innovation: Intrinsically safe strategy based on field impedance feedback The control unit utilizes the specific response of the joint's physical structure to the excitation field to endow the system with underlying intelligence: Physical impedance sensing and vibration suppression: The system monitors the impedance changes of the asymmetric magnetic circuit / circuit in real time (inductive / capacitive feedback), using this as a highly sensitive "body sensor" to identify high-frequency micro-vibrations at the end and adjust the rheological damping in reverse for physical dissipation, without the need for additional expensive torque sensors.

[0040] Hard-constraint RCM locking: In remote medical operations, the local controller calculates the joint's extreme positions based on geometric constraint algorithms (such as remote motor center RCM). Once the safety boundary is approached, the system directly locks the physical damping of the specific joint through medium solidification and matching locking force on the motion interface, forming an insurmountable "mechanical wall." Even if there is network latency or software crashes on the host computer, this physical locking mechanism remains effective, providing the ultimate barrier for surgical safety.

[0041] 3. Beneficial effects In summary, this invention, through the deep integration of underlying actuation system physical reconstruction, system-level energy efficiency management, and physical feedback control, has the following significant advantages over existing technologies: 3.1 Structural torque gain that breaks through the dielectric limit This invention abandons the traditional design approach that relies solely on fluid shear yield strength. Through an asymmetric field impedance modulation interface and an inverted trapezoidal topology, it achieves synergistic focusing of field strength and stress at the microscale. The resulting field-induced mechanical interlocking effect constructs a high-strength virtual rigid wedge within the rheological medium. Under the same excitation conditions and with joints of equal volume, the static holding torque of the structure described in this invention is significantly increased compared to traditional smooth interface structures. In a specific preferred embodiment, this torque increase can reach 3-5 times (depending on the medium type), reducing the risk of micro-slippage under high load conditions and realizing a shift from "flexible damping" to "rigid solid lock."

[0042] 3.2 Dynamic thermal-mass balance and high reliability under all operating conditions To address the inherent challenges of thermal failure and sedimentation in field-induced rheological media, this invention innovatively integrates a media circulation tunnel embedded within the rotor. By utilizing the centrifugal hydrodynamic effect excited by joint motion and the turbulent texture of the inner wall, "adaptive heat-mass exchange" is achieved without the need for an external pump source.

[0043] Thermal stability: The shear heat of the working gap is dissipated to the rotor matrix, preventing high-temperature degradation or electrical breakdown of the medium; Anti-settling properties: The active turbulent stirring mechanism inhibits the agglomeration and sedimentation of solid particles, giving the system high consistency and reliability throughout its entire life cycle.

[0044] 3.3 Static interlocking mechanism for "zero power consumption of motor" Thanks to the aforementioned structural torque gain, this invention constructs a hybrid drive mode of "low-energy field maintenance + high-strength geometric self-locking". In static scenarios such as surgical posture fixation, orthopedic traction, or exoskeleton weight-bearing, the system relies on the self-locking force at the physical level of the field-induced joint to resist external loads, allowing the servo motor to be powered off. This not only significantly reduces static energy consumption (requiring only microwatt-level field maintenance power consumption), but also solves the risk of overheating and overload caused by the long-term stalling of motors in traditional joints, significantly extending the device's battery life.

[0045] 3.4 Intrinsic safety and tactile intelligence based on physical ontology This invention utilizes the unique response of the asymmetric joint structure to the physical field (nonlinear field impedance feedback) to endow the robotic arm with "body perception" capability.

[0046] Tactile intelligence: Enables highly sensitive tremor suppression and smooth dragging; Intrinsic safety: The RCM physical locking mechanism based on local computation constructs a "hardware firewall" independent of the host computer software and network, ensuring that even in extreme situations such as network latency and computing power failure, the movement boundaries of the robotic arm can still be limited by local computing power combined with the joint medium to solidify the locking force, thus ensuring the safety of human-machine collaboration.

[0047] 3.5 Platform versatility across media and scenarios The field-rheological actuation system architecture proposed in this invention possesses high material versatility. It can be adapted to magnetorheological fluids (MRF) to meet the strong locking requirements of orthopedic, robotic, and heavy-duty industrial applications, and also to electrorheological fluids (ERF) to meet the lightweight and non-magnetic interference requirements of minimally invasive ophthalmic procedures and microfluidic assembly. This constitutes a universal intelligent actuation technology platform, expanding the application potential of this technology in high-end medical robots, humanoid robots, aerospace precision mechanisms, and VR haptic interaction devices.

[0048] Furthermore, to achieve the above objectives, the technical solution adopted by the present invention is as follows: 1. This invention provides a field-induced rheological actuation system with a field modulation interface, comprising: A first moving component and a second moving component define a working gap for accommodating a field-induced rheological medium; characterized in that: the working surface of the first moving component has a first field modulation structure, and the working surface of the second moving component has a second field modulation structure; the first and second field modulation structures are differentially asymmetrically distributed in geometric topological parameters, constructing an asymmetrical field impedance interface, thereby generating a spatially differentiated field strength distribution under the action of an excitation field to adjust the rheological properties of the field-induced rheological medium.

[0049] Optionally, the geometric topological parameters include microstructural features formed on the surfaces of the first and second field modulation structures; the microstructural features include at least one of continuous or discontinuous height undulations, curvature variations, periodic or non-periodic structures; wherein, the microstructural features include texture structures, ridge structures, and stepped structures; when the microstructural features adopt ridge structures, their geometric topological parameters include at least one of cross-sectional morphology, ridge width, groove depth, sidewall slope, distribution period, and ridge duty cycle.

[0050] Optionally, the texture distribution constructed by the first field modulation has a first spatial period (P1); the texture distribution constructed by the second field modulation has a second spatial period (P2); and the ratio of the first spatial period (P1) to the second spatial period (P2) is a non-integer.

[0051] Optionally, the field-induced rheological medium is selected from magnetorheological fluid or magnetic powder, and the excitation field is a magnetic field, which is generated by at least one of a coil, a permanent magnet or an external magnetic field source.

[0052] Optionally, the field-induced rheological medium is selected from electrorheological fluid, and the excitation field is an electric field.

[0053] Optionally, the first moving component constitutes the stator, and the second moving component constitutes the rotor, and their structural configuration is at least one of the following mating structures: a ball-and-socket mating structure to form a three-degree-of-freedom ball joint; a cylindrical tube mating structure to form a single-degree-of-freedom rotary joint; or a stator disk mating structure to form a rotor disk mating structure to form a relatively rotating disk joint.

[0054] Optionally, the microstructure features of the first or second field modulation structure surface have at least one geometric topological parameter that is spatially gradient distributed along the relative motion trajectory direction of the first and second moving parts, wherein the gradient distribution can be linear, nonlinear, segmented, stepped, periodic or aperiodic; the spatial gradient distribution is configured to establish a gradient field strength gradient within the working gap.

[0055] Optionally, when the field-induced rheological medium is a magnetorheological medium, the second field modulation structure includes a plurality of discretely distributed magnetically guided boss topologies; the total magnetic flux saturation of the magnetically guided boss topologies is configured to be less than the magnetic flux transferred from the first field modulation structure to the second field modulation structure, so as to cause magnetic flux to overflow into the field-induced rheological medium within the working gap.

[0056] 2. The present invention provides a texture of the working surface of a field-induced rheological actuation system, wherein at least one of the first and second field modulation structures has a surface microstructure comprising a plurality of groove topologies extending in the depth direction; the maximum internal width of the groove topology in the cross-section is greater than the width of its slot opening.

[0057] Optionally, the ratio of the depth to the width of the groove topology is in the range of 0.5 to 5.0; the geometric profile of the groove topology includes: a curved transition structure at the bottom of the groove, the equivalent radius of curvature of which is less than 20% of the width of the groove, so as to disperse the stress at the bottom of the groove; and a high curvature geometric region formed at the top edge of the groove.

[0058] Optionally, the cross-section of the groove topology has an inverted trapezoidal geometry; the angle β between the sidewall of the groove and the normal direction of the working surface of the moving part is configured to be 2° < β < 35°.

[0059] Optionally, the microstructural features of the first and second field modulation construction surfaces include groove topology and the groove topology defining a plurality of spatially discrete boss topology on the working surface, the boss topology being arranged in an array to form a local field modulation region within the working gap.

[0060] Optionally, the boss topology is defined by interconnected groove structures, which form a continuous or quasi-continuous network of depressions in the topology.

[0061] Optionally, the asymmetric field impedance modulation interface includes a first field modulation structure and a second field modulation structure that cooperate with each other; The surfaces of the first field modulation structure and the second field modulation structure opposite each other have asymmetrical microstructures, forming a geometrically interlocked region between them. Under static holding conditions, the excitation field flux density in the geometrically interlocked region is higher than that in other regions, causing the field-induced rheological medium in this region to locally enter a saturated yield state and form a wedge-shaped solidified body with a shape adapted to the geometrically interlocked region. The wedge-shaped solidified body combines with the protruding or recessed physical sidewalls to produce a field-induced mechanical interlocking effect.

[0062] Furthermore, this invention provides a method for designing an excitation magnetic field loop for a field-induced rheodynamic actuation system. At least one magnetic isolation break is actively provided in the magnetically conductive stator that constitutes the magnetic flux path; the magnetic isolation break is configured such that when the excitation component is energized, the working magnetic flux is forced from one side of the magnetically conductive stator, through the working gap filled with field-induced rheological medium, into the rotor, and then through the working gap back to the other side of the magnetically conductive stator, thereby forming an excitation magnetic field loop that crosses the working gap twice.

[0063] 3. The present invention also provides a moving component for a field-induced rheological actuation system, comprising: A solid substrate has an outer surface that at least partially defines a working surface for mating with a stator component; the solid substrate integrates at least one medium circulation tunnel; the medium circulation tunnel has a fluid inlet and a fluid outlet; the fluid inlet and the fluid outlet are respectively located in regions with different hydrodynamic pressures on the working surface, such that when the moving component moves in the medium, the pressure difference between the inlet and the outlet can drive the medium to flow through the medium circulation tunnel.

[0064] Optionally, when the system is a magnetorheological actuation system, the physical substrate is made of ferromagnetic material at least in the magnetic circuit region; when the system is an electrorheological actuation system, the physical substrate is made of conductive material, or is composed of an insulating material substrate and an electrode structure at least disposed in the working surface region.

[0065] Optionally, the spatial trajectory of the medium circulation tunnel and the field path of the dominant physical field within the solid matrix are in a non-complementary spatial interlacing relationship, so as to achieve fluid penetration while maintaining the continuity of the field path.

[0066] Optionally, the equivalent hydraulic diameter of the medium circulation tunnel is greater than the radial width of the working gap, forming a bypass path through which the field-induced rheological medium preferentially flows under dynamic operating conditions.

[0067] Optionally, the inner wall of the medium circulation tunnel is provided with microstructures or surface morphology features for disturbing boundary layer flow. These features are configured to enhance the shear mixing effect of the medium within the tunnel to suppress the deposition or stratification of solid components in the field-induced rheological medium.

[0068] 4. This invention provides an integrated thermal management system for a field-induced rheological actuation system, comprising: A magnetic circuit assembly, the magnetic circuit assembly being a magnetic-thermal composite structure, comprising: a magnetically conductive substrate made of magnetic material; and at least one thermally conductive component made of non-magnetic material, the thermally conductive component being integrated within the magnetically conductive substrate.

[0069] Optionally, at least a portion of the thermally conductive member is exposed outside the magnetic substrate and forms a thermally conductive connection with a heat dissipation member and / or the housing of the device to form an outward thermal conduction path.

[0070] Optionally, the device further includes an inner support structure; at least a portion of the magnetic substrate and the heat-conducting member forms a thermally conductive connection with the inner support structure; wherein the connection area between the magnetic substrate and the inner support structure constitutes part of a closed magnetic flux loop.

[0071] Optionally, an electrical insulation structure is provided between the heat-conducting component and the magnetic substrate.

[0072] Optionally, the device further includes an excitation coil and an inner support structure located inside the coil; an electrically insulating thermal barrier structure is provided between the excitation coil and the inner support structure.

[0073] Optionally, the excitation coil forms a thermal conduction relationship with the heat-conducting component and / or the magnetic substrate through at least one thermal coupling structure, thereby constructing a heat flow path from the outside of the excitation coil guiding device and suppressing the transfer of heat to the inside of the inner support structure.

[0074] Optionally, the volume of the heat-conducting component accounts for 5% to 40% of the total volume of the magnetic circuit assembly.

[0075] Optionally, the ratio of the thermal conductivity of the non-magnetic material to the thermal conductivity of the magnetic material is greater than 5:1.

[0076] 5. The present invention also provides an intelligent robotic arm system, characterized in that it comprises: A robotic arm comprising multiple field-rheological joint units and links connected in series, wherein the links and field-rheological joint units are alternately distributed; a base unit is configured to connect the robotic arm to a support platform; Each field-induced rheological joint unit includes a field-induced rheological medium and a field generating device configured to apply a physical field to change the rheological state of the field-induced rheological medium, thereby adjusting the joint damping coefficient; and a control unit configured to independently adjust the physical field intensity of each field-induced rheological joint unit to achieve continuously variable damping from a low-damped movable state to a high-damped rigid locked state. The joint surfaces of the field-induced rheological joint unit are provided with an anti-slip structure, which is configured to generate a structural anti-slip torque exceeding the yield limit of the medium through mechanical interlocking with the solidified medium, so as to prevent micro-slippage when the power is off.

[0077] Optionally, the connecting rod is rotatably connected to the field-induced rheological joint unit in a sealed manner.

[0078] Optionally, the base unit includes a universal connector and multiple interchangeable mounting modules to adapt to different operating table structures.

[0079] Optionally, the field-induced rheological medium includes at least one of magnetorheological fluid, magnetic powder, and electrorheological fluid.

[0080] Optionally, the field generating device includes at least one of an electromagnetic coil, an electrode, an adjustable permanent magnet, or a composite field generating device.

[0081] Optionally, it also includes a pose sensing module configured to monitor the spatial attitude of the robotic arm in real time, wherein the pose sensing module includes at least one of an inertial measurement unit (IMU), an optical sensor, an electromagnetic tracker, or an encoder.

[0082] Optionally, a force feedback module may also be included to monitor the force applied at the end of the robotic arm in real time.

[0083] Optionally, a safety control unit is also included, configured to forcibly switch the system to or maintain a high-damping rigid locking state when the pose sensing module detects that the pose exceeds the preset safety boundary, or when the force feedback module detects that the force exceeds the preset threshold.

[0084] Optionally, the control unit is configured to receive information from the pose sensing module and the force feedback module to adjust the damping of the field-induced rheodynamic joint unit in real time.

[0085] Optionally, the control unit includes a tremor suppression algorithm. When executing the tremor suppression algorithm, the control unit dissipates tremor energy by identifying high-frequency tremor signals from the pose sensing module and adjusting the damping of one or more field-induced rheological joint units in reverse; and / or adjusting the joint damping based on a preset safety boundary to generate tactile feedback force, thereby constraining the range of motion of the device end effector.

[0086] Optionally, it may also include a communication module configured to communicate with at least one external medical device, including a surgical navigation system, a master-slave surgical robot system, or a remote surgical console.

[0087] Optionally, it also includes at least one drive component coupled to the robotic arm. During the movement of the robotic arm driven by the drive component, the control unit controls the field-induced rheodynamic joint unit to be in a low-damped movable state or a zero-field state. After the drive component stops driving and reaches the target pose, the control unit executes a locking sequence to power the field generating device, thereby controlling the field-induced rheodynamic joint unit to enter a high-damped rigid locking state and cutting off the power supply to the drive component.

[0088] Optionally, the drive assembly includes an actuation device that converts electrical energy, fluid energy, or thermal energy into mechanical energy, and at least one of an electromagnetic actuation system, a hydraulic actuation system, a pneumatic actuation system, a piezoelectric actuation system, or a shape memory alloy actuation system; wherein, in order to coordinate with the hybrid drive timing to solve the energy consumption and heat generation problems during static holding, the drive assembly is an electromagnetic drive assembly, and the electromagnetic drive assembly includes at least one of a servo motor, a brushless DC motor, a stepper motor, a torque motor, or a frameless motor; wherein, the drive assembly further includes a precision reduction mechanism coupled to the output end of the electromagnetic drive assembly, and the reduction mechanism includes a harmonic reducer, an RV reducer, or a planetary gear reducer.

[0089] Optionally, it also includes an interface for communicating with external medical devices; the control unit is configured to parse digital instructions from the external medical devices, generate trajectory plans, and coordinate the drive components and the field-induced rheological joint units to move the end effector of the robotic arm and lock it in the target pose specified by the external medical devices.

[0090] Optionally, the field-induced rheological joint unit is configured to provide a holding torque sufficient to resist a preset external load in a highly damped rigid locking state; wherein the holding force is not less than 20N, thereby being able to adapt to the rigid positioning requirements of high-load clinical scenarios, from delicate surgery to strong orthopedic traction.

[0091] Optionally, the robotic arm is equipped with a sterile barrier interface for fitting a sterile isolation hood; or the robotic arm is a disposable sterile component that is connected to a reusable host unit via a quick-detachable electrical and mechanical interface.

[0092] Optionally, the robotic arm is equipped with an end effector at its end, which integrates a human-machine interface for communicating with the control unit. The human-machine interface includes at least one of the following components: a physical switch component configured to trigger the control unit to execute the hybrid drive sequence in response to user operation, thereby switching between the low-damped movable state and the high-damped rigid locked state; a continuous adjustment component configured to generate a continuous damping adjustment signal, enabling the control unit to steplessly adjust the basic viscous resistance of the field-induced rheological joint unit to provide variable tactile operation feel; and a voice control module configured to recognize specific voice commands and control the rheological state of the field-induced rheological joint unit in a non-contact manner.

[0093] 6. This invention provides a method for positioning surgical instruments, comprising: S1: The control unit receives the pose adjustment command; controls the field generator to reduce the damping of at least one field-induced rheodynamic joint unit; and allows the pose of the robotic arm to be adjusted by external force in the low-damping state. S2: The control unit receives the pose locking command; it instantly activates the field generating device and switches all joint units to a high-damping rigid locking state through the physical interference of the phase change of the medium properties and the groove topology.

[0094] Optionally, the pose adjustment command is set to trigger a specified joint unit to change its damping state while maintaining the high-damping locked state of the remaining joint units.

[0095] Optionally, step S1 further includes: in response to a continuous adjustment command, adjusting the damping of the at least one field-induced rheodynamic joint unit to an intermediate viscous state between a zero-field state and a high-damped rigid-locked state, to provide an operating feel for filtering out vibrations.

[0096] 7. The present invention also provides a motion control method based on local real-time calculation and physical safety constraints, the method being applied to a serial robotic arm comprising multiple field-induced rheological joint units, comprising the following steps: S1: Receive motion target command: The local control unit acquires the motion target of the end effector; S2: Obtain spatial geometric constraints: Load preset spatial geometric constraints, which include at least one fixed-point constraint (such as RCM) or safety boundary constraint; S3: Local calculation and path prediction: Real-time kinematic calculation is performed through the local control unit, and the actual running trajectory of the end effector of the robotic arm is predicted in advance; S4: Conflict Joint Identification: Identify conflict joint groups in the field-induced rheological joint unit that would cause the end effector to violate the spatial geometric constraints if the current motion command is executed. S5: Physical and Energy Co-operation: Generates coordinated control signals and performs the following operations: Physical side: Activate the field generating device in the conflict joint group, and switch the joint to a high-damping rigid locking state through the phase change of the physical properties of the field-induced rheological medium and the mechanical interlocking effect between it and the surface groove topology. Power side: Synchronously suppress or shut down the power drive components corresponding to the conflicting joint groups to eliminate residual drive energy.

[0097] This forces the end effector's motion trajectory to conform to the spatial geometric constraints, while the remaining non-conflict joints maintain their degrees of freedom to preserve local flexibility.

[0098] 8. The present invention further provides a hybrid drive energy-saving control method based on property-dependent phase feedback, wherein the module includes a field-induced rheological joint unit and a power drive component coupled thereto, and the method includes: S1 Dynamic Motion Stage: Activate the power drive component to output rotational or linear power to drive the field-induced rheological joint unit to perform motion; synchronously regulate the field generator to keep the field-induced rheological medium in a low-damping state to minimize system internal friction; S2 Damping Braking and Switching Sequence: When the joint unit approaches the target position, the "dynamic-damping balance" switching logic is executed: 1) The activation field generating device causes the medium to undergo instantaneous phase change in physical properties, and generates static holding torque by utilizing the mechanical interlocking effect between the medium shear force and the medium solidification and the groove topology; 2) Monitor the load current or position feedback of the power drive component in real time. When it is confirmed that the static holding torque has effectively offset the external load, or when the preset switching threshold is reached, cut off the power supply to the power drive component. S3 Drive Component Zero-Power Static Holding Stage: The target position is maintained solely by the physical shear resistance of the field-induced rheological medium and the mechanical interlocking effect. During this time, the drive component is in a zero-power standby state, and the mechanical interlocking effect compensates for the thermal drift of the medium, ensuring that no physical slippage occurs under a preset overload.

[0099] After adopting the above technical solution, the beneficial effects of the present invention are as follows: Compared with the prior art, the technical solution provided by the present invention can produce the following beneficial effects: (1) High load locking capability: By combining the shear resistance of the field-induced rheological medium with the mechanical interlock formed by the anti-slip structure and the solidified medium, the structural shear resistance of the joint is significantly improved, and the non-slip rigidity is maintained under high load.

[0100] (2) Smooth operation: Through the continuous adjustment of joint damping, it can provide a smooth motion feel and variable tactile feedback.

[0101] (3) High energy efficiency: By using a hybrid drive control method, the power supply to the drive components is cut off during the static holding phase, and the posture is maintained by using composite mechanical interlocking force, thereby solving the energy consumption and heat generation problems during static holding.

[0102] (4) Intrinsic safety features: By transforming geometric constraints into a physically damped state of specific joints, a local passive safety mechanism that does not depend on continuous network communication and software instructions is provided.

[0103] (5) Wide applicability: The field-induced rheological joint unit and control method of the present invention are not only applicable to the medical field, but also solve the common needs of dynamic rigid-flexible switching and efficient load maintenance in precision operations in fields such as robots, humanoid robots, wearable exoskeletons, metaverse / VR force feedback interaction, professional shooting and photoelectric tracking gimbals, and aerospace. Attached Figure Description

[0104] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0105] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the intelligent robotic arm system of the present invention. A partial lead-out view shows the location and general structure of its key actuator, the field-rheological joint unit (field-rheological actuation system). Figure 2 This is an axial half-sectional view of an embodiment of the field-induced rheological actuation system of the present invention (taking a ball joint as an example). It shows the basic spatial layout of the joint housing (stator), joint ball head (rotor), working clearance, field generating device, magneto-thermal composite, thermal coupling structure, and seal, wherein the first and second field modulation structures are enlarged schematic diagrams; Figure 3 This is a planar unfolded schematic diagram of the asymmetric field impedance modulation interface in an embodiment of the present invention. It shows the differentiated asymmetric configuration of the first field modulation structure (stator side) and the second field modulation structure (rotor side) in terms of geometric topological parameters (such as distribution period P1 / P2, ridge width W1 / W2); Figure 4 This is a high-magnification schematic diagram of the field modulation structure in the embodiment. It shows the asymmetry in the geometric topological parameters (such as distribution period P1 / P2, ridge width W1 / W2) of the first and second field modulation structures, the gradient distribution of the stator groove depth (deep on both sides transitioning to shallow in the center), the gradient distribution of the stator boss width (narrow on both sides and wide in the center), the inverted trapezoidal feature of the groove, the total area of ​​the bosses on the surface of the first field modulation structure (stator) being greater than the total area of ​​the bosses on the surface of the second field modulation structure (rotor), and the field-induced mechanical interlock generated after the field-induced rheological medium solidifies in the groove to form a "virtual rigid wedge block"; Figure 5 This is a magnified schematic diagram of the groove structure in the embodiment. It shows the inverted trapezoidal shape of the groove, the maximum internal width of the cross-section being greater than the width of its opening, the curved transition structure at the bottom of the groove, the high curvature geometric region at the top edge of the groove, and the angle β between the groove sidewall and the normal direction of the working surface, resulting in mechanical interlocking of the medium-curving wedge. Figure 6 This is a schematic diagram of the surface geometry and topology of the stator joint socket in an embodiment of the present invention. It shows that the grooves on the surface geometry and topology of the stator joint socket decrease in density from the equator to the poles, and the topological structure of the bosses defined by the grooves decreases in width from narrow to wide in a stepped distribution. Figure 7 This is a schematic diagram of the magnetic isolation structure and magnetic circuit of an embodiment of the present invention. It shows that the magnetic isolation structure blocks the magnetic circuit of the magnetically conductive stator (joint socket), forcing the magnetic flux to jump into the working gap and enter the ball joint, then cross the working gap again and return to the other side of the magnetically conductive stator, crossing the working gap twice, and then returning to the N pole along the magneto-thermal composite structure. The total magnetic flux of the stator is greater than the total magnetic flux of the rotor, and some of the magnetic flux is forced to overflow into the magnetorheological medium of the working gap; Figure 8 This is a schematic diagram of the medium circulation tunnel of the present invention. It shows the tunnel openings at low and high latitudes, and the solid arrows indicate that the medium flows into the tunnel from the working gap and then flows out from the other end of the tunnel to form a circulation; Figure 9 This is a perspective view of the ball joint in an embodiment of the present invention, overlooking the medium circulation tunnel. It shows that the tunnel opening slopes from a low latitude towards a high latitude exit, minimizing magnetic flux area disruption. Figure 10 This is a schematic diagram of the microstructure (helical rifling) and eddies of the inner wall of the medium circulation tunnel of this invention. It shows that the eddies generated when the medium flows through the tunnel help prevent medium settling; Figure 11 This is a schematic diagram of the integrated thermal management system of a field-rheological actuation system. It shows the basic spatial relationships of the thermal barrier structure, excitation coil, thermal coupling structure, magneto-thermal composite structure, joint shell, and inner support structure constituting the joint socket. Figure 12 This is a schematic diagram of the magnetic-thermal composite structure of a spherical joint embodiment. It shows that the heat-conducting component is embedded in the magnetically conductive matrix, separated by an electrically insulating structure. The solid arrows indicate the direction of heat flow in the actuation system, and the dashed arrows indicate the direction of the magnetic field loop. Figure 13 This is a schematic diagram of the joint heat conduction path in an embodiment; Figure 14 This is a simplified schematic diagram of the robotic arm of the present invention. Figure 15 This is a comparison curve of the current-torque response of the spatial periodic distribution and gradient topology design of the asymmetric structure of this invention with that of the traditional symmetric structure. Figure 16 This embodiment features a magnetorheological joint with a ball joint diameter of 60 mm and a working area of ​​8498 mm². It assumes the field-induced medium is magnetically saturated, the operating temperature is within the optimal range, and the yield stress of the magnetorheological joint (MR) is 60 kPa. A comparison of the maximum static holding torque of this embodiment with that of a smooth ball joint is provided. Figure 17 This is a schematic diagram illustrating the tremor suppression effect of the present invention; Figure 18 This is a schematic diagram of the force feedback and virtual wall effect of the present invention; Figure 19The present invention also provides a schematic diagram of a hybrid drive energy-saving control method based on physical property phase feedback; Figure 20 This invention also provides a schematic diagram of a motion control method based on local real-time calculation and physical safety constraints; Figure 21 This is a schematic diagram of a surgical instrument positioning method provided by the present invention; Explanation of reference numerals in the attached drawings: 1. First moving component; 2. Second moving component; 3. Field-induced rheological medium; 4. Connector; 5. First field modulation structure; 6. Second field modulation structure; 7. Groove topology; 7. Meridional groove; 711. Latitudinal groove; 722. Latitudinal narrow groove; 733. Curved transition structure; 71. High curvature geometric region; 72. Sidewall angle β; 73. Boss topology; 8. Field generating device; 9. Magnetic shielding structure; 10. Thermal barrier structure; 11. Thermal coupling structure; 12. Magneto-thermal composite structure; 13. Magnetic conductive substrate; 131. Thermally conductive component; 132. Electrically insulating structure; 133. Joint shell; 14. Inner sealing element; 15. Middle sealing element; 16. 17. Outer sealing element; 18. Medium circulation tunnel; 19. Latitude 0 degrees; 10. Latitude 45 degrees; 11. Latitude 65 degrees; 12. Tunnel microstructure; 13. Eddy current; 14. Field-induced joint unit; 25. Control unit; 26. Base unit; 27. Connector; 28. Interchangeable mounting module; 29. ​​Pose sensing module; 20. Force feedback module; 21. Safety control unit; 22. Drive assembly (electromagnetic drive assembly); 23. Drive cable; 24. Communication module; 25. Sterile barrier interface; 26. End effector; 27. Human-machine interaction module; 28. Wire; 30. Charging port; 33. Power cord; 34. Interface; 35. Battery; 36. Detailed Implementation The following is in conjunction with the appendix Figure 1-21 The present invention will be described in further detail below.

[0106] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive element, but such modifications are protected by patent law as long as they fall within the scope of the claims of the present invention.

[0107] 1. This invention provides the structure and function of a field-induced rheological actuation system with a field modulation interface, such as... Figure 1-7 As shown, it includes: 1.1 Diverse Configurations of Field-Induced Rheological Medium and Response Field Source The actuation system described in this invention has high field source compatibility and can be configured with different rheological media and corresponding physical excitation fields according to the application requirements of the scenario (such as response speed, output torque or power consumption limitations). 1.1.1 Magnetostrictive Response Configuration: High Torque Density Scheme When the system seeks high static holding force and dynamic damping gain, the field-induced rheological medium is preferably a magnetorheological fluid (MRF) or magnetic powder (mainly composed of micron-sized carbonyl iron powder). The corresponding excitation field is a magnetic field, the field strength distribution of which is provided by coil assemblies, high remanence permanent magnets (such as neodymium iron boron), or a controlled external magnetic field source located inside the stator or rotor. By adjusting the coil current, the gradient of magnetic induction intensity within the gap can be precisely controlled, thereby changing the chaining degree of magnetic particles within microseconds and achieving linear torque adjustment.

[0108] 1.1.2 Electro-response configuration: Ultrafast response and low power consumption solution When the system is applied to micro-incremental motion with extremely high dynamic performance requirements (such as active suppression of high-frequency vibration), such as in light-load precision applications (such as ophthalmic microsurgery, microelectronic assembly, and haptic feedback), the field-induced rheological medium is selected from electrorheological fluids (ERF). In this case, the first and second field modulation interfaces act as positive and negative plates, respectively, and the excitation field is switched to an electric field generated by a high-voltage DC or pulsed power supply. The "Winslow effect" generated by the electrorheological medium under a strong electric field has a faster conversion rate than the magnetorheological effect, and its system structure does not require bulky magnetic circuit components, which is beneficial for achieving extreme lightweighting of the joint. Although the basic shear stress of the ERF is low, thanks to the geometric gain effect of the asymmetric topology and inverted trapezoidal groove structure described in this invention, as well as the local electric field distortion induced by the geometric tip effect to enhance the solid-like phase transition strength of the field-induced rheological medium, it is sufficient to provide static holding force exceeding that of conventional ERF devices under precision conditions.

[0109] 1.1.3 Composite Excitation Configuration: Nonlinear Enhancement Scheme To overcome the performance bottleneck of a single physical field, this invention also supports a collaborative working mode of composite fluid and composite excitation field. Multi-field coupling: The system can be simultaneously filled with a composite fluid possessing electromagnetic dual-sensitivity characteristics. By spatially superimposing electric and magnetic fields, the complementary physical properties of the two fields are utilized (e.g., using the magnetic field to provide basic heavy-load torque, and using the electric field for high-frequency fine-tuning). This composite configuration can effectively broaden the dynamic bandwidth of the actuation system and, under extreme temperature difference or nonlinear interference conditions, maintain the physical stability of the field modulation interface through dual-field compensation, achieving a higher level of motion transparency.

[0110] In another embodiment of the present invention, the field-induced rheological medium is a fluid comprising two or more dispersed phases with different physical forms, particle sizes, or material properties. Preferably, the composite fluid may be a nanocomposite fluid comprising micron-sized and nano-sized particles, or a multiphase composite fluid comprising core-shell structured particles.

[0111] The specific forms of the field generating device for the excitation field include, but are not limited to: electromagnetic coils (used to generate controllable magnetic fields, suitable for magnetorheological fluids); one or more pairs of electrodes (used to generate high-voltage electric fields, suitable for electrorheological fluids); permanent magnets (such as Halbach arrays, which, in conjunction with mechanical moving mechanisms, achieve magnetic field adjustment); composite field generating devices (such as electromagnetic-permanent magnet hybrid excitation units); and any other generating unit capable of generating the physical fields required to change the rheological properties of the medium (such as temperature field generators, light field generators, etc.).

[0112] 1.2 Physical architecture, meaning, and significance of asymmetric field impedance modulation interfaces 1.2.1 System Motion Interface Topology The system mainly consists of a first moving part and a second moving part, which are positioned opposite each other and define a working gap for accommodating the field-induced rheological medium. The actuation system of the present invention is characterized by constructing an asymmetric field impedance modulation interface by setting a first field modulation structure and a second field modulation structure with different geometric topological parameters on opposite working surfaces, thereby realizing non-uniform modulation of the physical field (magnetic field or electric field) crossing the gap.

[0113] The asymmetric field impedance interface of this invention can be adapted to various geometric configurations according to the dimensional requirements of the actual working trajectory: Spherical joint configuration (three degrees of freedom): The first and second moving parts are respectively represented as nested joint sockets and ball heads. In this configuration, the field modulation structure is distributed in a three-dimensional spherical array. The asymmetry of its geometric topological parameters is reflected in the structural differences between the ball sockets and ball heads. Cylindrical joint configuration (single degree of freedom): The first and second moving parts are represented as coaxially arranged sleeves and shafts. The field modulation structure is distributed along the cylindrical surface. The asymmetric distribution is mainly reflected in the structural differences between the sleeves and shafts. Disc joint configuration (relative rotation): The first and second moving parts are represented as axially opposite discs. The field modulation structure is distributed on the disc end faces. Differentiated geometric topological parameters (such as the depth and width of the grooves gradually changing from the center to the edge) are set on the opposite discs.

[0114] The geometric topological parameters of the first and second field modulation structures include microstructural features formed on the surfaces of the first and second field modulation structures; the microstructural features include at least one of continuous or discontinuous height undulations, curvature variations, periodic or non-periodic structures; wherein, the microstructural features include texture structures, ridge structures, and stepped structures; when the microstructural features adopt ridge structures, their geometric topological parameters include at least one of ridge width, groove depth, sidewall slope, distribution period, and ridge duty cycle.

[0115] In a preferred embodiment, the geometric topology of the field impedance interface is preferably an array of scattered bosses defined by inverted trapezoidal grooves. Taking a ball joint as an example, such as... Figure 2 , Figure 4 and Figure 6 As shown, (1) the inner spherical surface of the stator (joint socket) is provided with inverted trapezoidal grooves in the longitudinal and latitudinal directions. The grooves in the longitudinal and latitudinal directions intersect to form a quadrilateral boss array. The latitudinal distribution of the grooves is gradient. The groove density and depth gradually increase from the polar region of the stator sphere axis to the equatorial working region. Among them, the groove depth in the polar region is shallower and sparser, while the groove depth in the equatorial region is deeper and denser. The depth of the longitudinal grooves on the stator surface is less than that in the latitudinal direction. The groove depth in the polar region is shallower and sparser, while the groove depth in the equatorial region is deeper and denser. (2) The outer spherical surface of the rotor (ball head) is provided with uniformly distributed inverted trapezoidal grooves in the longitudinal and latitudinal directions. The grooves in the longitudinal and latitudinal directions intersect to form a quadrilateral boss array. The width of the ridge of the inverted trapezoidal groove of the rotor is smaller than that of the stator groove, and the distance between the groove ridges is smaller than that between the stator groove ridges. The rotor contains 3-5 independent and unconnected medium circulation tunnels, with a diameter between 1.5mm and 2mm. The inlet and outlet of each tunnel open into different pressure zones on the outer spherical surface of the rotor. For example, the inlet is at latitude 45° and the outlet is at latitude 65° on the opposite side, directly connected to the working gap. (3) Spatial period parameters are limited (e.g. Figure 3 As shown), the period ratio is defined by the groove ridge spacing. The first spatial period of the stator-side modulation structure is set to be 1.2-1.4 times the second spatial period of the rotor-side modulation structure.

[0116] 1.2.2 Physical Definition and Function of Asymmetric Field Impedance Modulation Interface The actuation system of this invention constructs an asymmetric field impedance modulation interface. This interface achieves dynamic reconstruction of the physical field flux within the working gap through the geometric heterogeneity of the surfaces of the first moving component (such as the stator) and the second moving component (such as the rotor).

[0117] (1) Physical meaning of field impedance: In this invention, the term "field impedance" refers to the combined magnetic / electrical resistance encountered by the physical field flux when passing through the stator-rotor interface and the working gap. Under magnetorheological (MR) conditions: field impedance is mainly manifested as magnetic reluctance. Due to the difference in permeability between the magnetic matrix and the field-induced rheological medium, the geometry of the interface determines the total magnetic reluctance distribution of the magnetic circuit. Under electrorheological (ER) conditions: field impedance is mainly manifested as capacitive reactance. The geometric topology of the electrode interface directly determines the density of electric field lines and the distribution of equivalent capacitance.

[0118] (2) Physical comparison between the symmetrical structure and the asymmetrical structure of the present invention (Figure 6 Analysis) Referring to Figure 6, the present invention reveals the significant technical effects of asymmetrical modulation through physical simulation comparison: In a preferred embodiment of the magnetorheological spherical joint of the present invention, the field modulation structure employs a spatially differentiated impedance gradient design to achieve a spatial distribution strategy and gradient synergy of field impedance, aiming to optimize the balance between the overall energy efficiency of the magnetic circuit and the local working gap field strength.

[0119] Low-impedance energy entry region (polar / main pathway region): such as Figure 4 and Figure 6 As shown, in the region near the magnetic source or the central axis of the magnetic circuit, the microstructure is configured with a smaller slot depth or a larger feature spacing. This design reduces local magnetic reluctance, allowing the total magnetic flux generated by the excitation field to be introduced into the joint unit with lower total magnetic reluctance, thereby reducing the overall magnetic reluctance and energy consumption of the system. High field strength torque generation region (equatorial / main working gap region): When the magnetic flux flows from the aforementioned low impedance region to the working load region, due to the asymmetrical distribution of the first and second field modulation structures in the geometric topology and the gradually deepening inverted trapezoidal structure, the magnetic circuit encounters a predetermined impedance step in this region.

[0120] Magnetic flux guidance and localized focusing: This gradient design, from "globally unobstructed" to "locally obstructed," creates a "flux converging effect." When magnetic field lines pass through asymmetric textured areas, they are forced to undergo severe spatial distortion and overflow due to the cross-sectional area limitation of the metal teeth. This overflow effect results in a significant local field strength within the working gap.

[0121] Technical advantages: This design aims to reduce the severe coil heating problem caused by high magnetoresistance across the entire domain, while ensuring the formation of a solidified core with high shear strength in the critical torque generation region (near the equator). This is a motion control scheme based on the synergistic design of "macro-level energy efficiency optimization" and "micro-level torque enhancement". 1.2.3 Density distribution control strategy for groove textures on different joint surfaces To balance structural strength, magnetic circuit efficiency, and torque output contribution rate, this invention adopts a differentiated groove texture spatial arrangement strategy for field-induced rheological joints with different configurations: (A) Spherical and Disc Joints: Spherical Joints: High-density meridional grooves are configured in latitudes from 0° to 45° (the main force-bearing zone at the equator), with a stepped arrangement and termination as latitude increases, to increase the support area of ​​the polar protrusions and prevent polar magnetic saturation. Disc Joints (End-face Driven): High-density textures are configured in the outer circumference region of the disc (large radius of rotation region). As the rotation center approaches, the torque contribution rate decreases due to the reduced radius of rotation, and the space gradually shrinks. This invention adopts a periodic reduction of grooves to avoid material processing interference and structural instability caused by excessively dense textures in the central region. Common Principle: The common feature of these joints is that the radius of rotation (R) varies with spatial position. This solution focuses functional grooves in the large R region (high torque contribution region), realizing the on-demand allocation of functional textures.

[0122] (B) Circular Shaft (Cylinder) Joint: Equally Spacing Linear Distribution: Unlike the two joints mentioned above, the field modulation interface of a circular shaft joint is a cylindrical surface of equal radius. The radius of gyration at each point along its circumference is equal, and there are no geometric convergence points. Arrangement Logic: Therefore, in this type of joint, the grooves are preferably arranged axially or helically with equal spacing. This homogeneous distribution ensures the consistency of the magnetic field gradient and interlocking force at all points on the cylindrical surface, thus providing the most stable constant torque output without increasing local stress concentration.

[0123] In summary, this invention addresses the "polar congestion effect" at the spherical poles and the center of the disk by employing differentiated arrangements for different geometric configurations, thus protecting the mechanical integrity of the micro-boss structure. Allocating limited groove space to the areas contributing the greatest torque significantly increases the specific torque density of the system within the same volume. The stepped distribution effectively reduces the risk of tool interference during the machining of complex three-dimensional curved surfaces, improving the manufacturability and surface quality of the parts.

[0124] 1.2.4 Mechanism for Eliminating Magnetic Drag Torque Fluctuations Based on Non-Integer Spatial Period The design of the ratio of the first spatial period (P1) to the second spatial period (P2) described in this invention is a non-integer design, such as... Figure 3 and Figure 4 As shown, its core physical intent is to eliminate abrupt changes in the energy balance state of the system along its trajectory, thereby improving the linearity and smoothness of the motion: eliminating position-dependent magnetic drag torque pulsations: if P1 / P2 is an integer ratio, the first and second field modulation structures will generate full-area geometric phase synchronization during relative motion. This synchronization will cause severe periodic troughs in the electromagnetic energy within the working gap, thus generating a static magnetic drag torque. This torque manifests as a strong "adsorption effect" or "step-like feeling," not only increasing the system's initial static friction but also introducing significant torque pulsations during low-speed operation.

[0125] Constructing a vernier modulation effect: By configuring a differentiated spatial topology with non-integer periods, this invention creates a physical vernier phase difference between interfaces. This ensures that the microstructures on the stator and rotor surfaces are in a "not perfectly aligned" state at any instant. This non-integer ratio design achieves smoothing of electromagnetic energy level changes with displacement. Experiments show that this construction significantly reduces the static ripple torque of the system, ensuring interactive transparency of the actuation system in zero-field or weak-field follower states. This provides physical-level accuracy assurance for robots or precision machining scenarios that require frequent micro-incremental motions.

[0126] Smooth Response and Feel: This invention utilizes a non-integer ratio configuration, ensuring that only a small number of modulation units overlap in any relative pose. This design achieves "energy compensation" at the physical level, guaranteeing a uniform average field impedance for the joints during movement. This design is not for ease of manufacturing, but rather to achieve high static holding force without sacrificing dynamic smoothness and feel. This is a key means of balancing the two contradictory aspects of a robot's "stability" and "agility."

[0127] 1.3 Microstructural Features and the "Field-Actuated Mechanical Interlocking" Mechanism In order to further break through the physical limit of the shear yield strength of rheological media and realize the "structural holding moment beyond the yield limit of the medium" as claimed in the claims, the present invention preferably adopts an inverted trapezoidal or dovetail-like cross-section design in the micro-texture of the above-mentioned field modulation structure.

[0128] 1.3.1 Geometric definition of inverted trapezoidal groove like Figure 5 As shown, the first and / or second field modulation structure includes a plurality of groove units extending in the depth direction. The term 'groove' as used in this invention should be interpreted broadly, encompassing, but not limited to, grooves with continuous extending trajectories, discontinuously distributed recessed textures, pit arrays, or any recessed geometric feature formed on the surface of a solid substrate. Unlike conventional rectangular or semi-circular grooves, the grooves of this invention have a significantly larger maximum internal width in cross-section than their opening width, thus geometrically forming an inverted shape that is wider inside and narrower outside.

[0129] 1.3.2 Force Analysis From "fluid shearing" to "normal self-locking," the core innovation of this embodiment lies in achieving a qualitative change in the force-bearing mode using an inverted trapezoidal structure. When the field generator is activated, the field-induced rheological medium filling the groove rapidly solidifies under the influence of a local high field strength, especially the overflow field strength at the groove edge, forming a solid wedge block that perfectly matches the shape of the groove. Force decomposition and transformation: When the joint is subjected to an external load and experiences a relative sliding tendency (shear force F), the solid wedge block is forced to compress the inclined sidewall of the inverted trapezoid. Due to the existence of the sidewall inclination angle, the horizontal shear force F is decomposed into a frictional component along the tangential direction of the sidewall and a normal pressure perpendicular to the sidewall. Self-locking effect: This normal pressure presses the solid wedge block more tightly into the bottom of the groove, producing a geometric self-locking effect that tightens as it is pulled. At this point, the joint's anti-slip capability no longer depends solely on the viscous friction coefficient between the medium and the wall surface, but rather on the compressive strength of the solidified wedge block itself and the structural strength of the sidewall.

[0130] 1.3.3 Optimization of the range of key parameters This invention, through extensive simulation and experimental verification, has determined that the optimal range for the angle β between the groove sidewall and the normal direction of the working surface is 2° < β < 35°. Figure 5 As shown. Lower critical value β>2°: If β<2°, the groove shape tends to be rectangular, and the medium is prone to slippage under shear force. Upper critical value β<35°: If β>35°, the cross-sectional area of ​​the solid boss root between two adjacent grooves will be too small, forming a "neck" structure. Under strong magnetic / electric fields and high mechanical stress, the boss root is prone to fatigue fracture. In addition, excessive chamfers will also lead to a significant increase in manufacturing difficulty (such as mold demolding or chip removal). Therefore, controlling the β angle within 35 degrees is a balance point that takes into account both mechanical performance and engineering life. This invention limits the ratio of groove depth (H) to width (W) to 0.5 to 5.0, aiming to achieve the best balance of magnetic-force coupling: Lower limit constraint (≥0.5): Ensures sufficient geometric constraint space, induces deep stacking of medium particles, and upgrades the interface from simple friction to mechanical interlocking of virtual rigid wedges, eliminating macroscopic slippage. Upper limit constraint (≤5.0): Prevents excessive groove depth from causing a surge in magnetic reluctance and magnetic unsaturation at the bottom, ensuring effective penetration of magnetic field lines to the bottom of the groove, eliminating excitation dead zones, and maintaining high torque density. Technical significance: By locking this golden interval, physical consistency between geometric interlocking depth and magnetic field distribution is achieved, improving static locking torque while ensuring linear sensitivity and dynamic stability of torque output.

[0131] 1.3.4 Mechanical Coupling Enhancement Mechanism between Groove Wedge Angle β and Deep Groove Topology In a preferred embodiment of the present invention (ball head diameter 60mm, configured with MRF-140CG medium), in order to overcome the torque bottleneck of traditional magnetorheological joints limited by the shear yield stress (60 kPa) of the medium, this system adopts a coupled topology design with a 6° wedge angle (84° wall inclination angle) and a 0.5mm groove depth. This design transforms the static locking mechanism of the joint from a single interlayer shear to a "shear-extrusion composite blockage", and its physical gain mechanism is as follows: (1) The "critical wedge effect" induced by the 84° sidewall is different from the shallow flat texture commonly found in the prior art. In this embodiment, the sidewall inclination angle of the inverted trapezoidal groove is set to 84° (i.e., the equivalent wedge angle 6° relative to the force normal). Mechanical amplification principle: According to the wedge mechanical model, when the "magnetic wedge" formed by the solidification of the medium is subjected to tangential shear force F, the groove inclined wall will generate a huge normal reaction force Fn, and its theoretical amplification factor is K = 1 / tan(6°) = 9.5 times. Quasi-self-locking state: When the excitation magnetic field is activated, the highly dense particle chain forms a rigid support similar to mechanical deadlock within the 6° wedge angle, eliminating micro-creep; when the excitation magnetic field is removed, the particle chain disintegrates, the self-locking effect disappears instantly, ensuring the flexibility of joint reset. (2) "Shear-resistant root reinforcement" constructed by 0.5mm deep groove In order to cooperate with the above-mentioned high-magnification force amplification effect, the groove depth is set to 0.5mm (approximately 0.83% of the ball diameter) in this embodiment. Bulk modulus support: The deeper groove accommodates a sufficiently thick solidified medium layer. This ensures that the root of the "magnetic wedge" has a sufficient cross-sectional area to withstand the huge compressive stress rebounded from the 84° inclined wall, preventing brittle fracture at the root of the magnetic wedge. Deep blockage: The 0.5mm depth combined with the 1.0mm tooth pitch forms a high-constraint cavity with a depth-to-width ratio of approximately 1:1. In this cavity, the medium particles cannot undergo laminar sliding, but are in a state of hydrostatic pressure under triaxial pressure. It is known that the compressive strength of magnetorheological fluid is much higher than its shear strength (usually >600kPa), and this transformation of stress state is the physical basis for the leap in torque. (3) Performance empirical deduction Based on the above coupling effect, under the 1.0T magnetic saturation condition, the equivalent shear resistance of this joint is increased from 60kPa of the material body to 300-400kPa of the structural equivalent. It is calculated that the joint unit with a diameter of 60mm can output a static holding torque of more than 70 Nm-80Nm, realizing the ultimate balance between small volume and large torque.

[0132] 1.3.5 Stress Dispersion and Lifespan Management To prevent structural failure under high load conditions, this invention specifically optimizes the detailed contour of the inverted trapezoidal groove: Stress relief at the groove bottom: As shown in a partial enlargement in Figure 5, a curved transition structure is provided at the bottom corner of the inverted trapezoidal groove. Its equivalent radius of curvature R is configured to be less than 20% of the groove width W. This rounded corner design effectively eliminates stress concentration caused by sharp geometric corners, preventing cracks from initiating and propagating from the groove bottom, and improving the fatigue life of the stator and rotor surfaces. Enhanced field strength at the groove opening: Conversely, at the groove edge at the top of the groove, this invention retains a high-curvature geometric region (such as a micro-acute angle or a very small radius rounded corner). For magnetorheological systems, this acute angle promotes the saturation overflow of magnetic flux; for electrorheological systems, this acute angle utilizes the principle of tip discharge effect to induce a local electric field at the groove opening that is much stronger than the average field strength, thereby obtaining the strongest solidified dielectric layer at the most critical interlocking interface.

[0133] 1.4 Spatial gradient distribution of microstructures and output linearization mechanism To address the common problems of "switching" and nonlinear hysteresis under low field strength in existing field-induced rheostat devices, this invention introduces a spatial gradient distribution design at the micro-texture level, aiming to reduce the algorithmic complexity of the control system through the physical linearization of the hardware topology.

[0134] 1.4.1 Geometry Construction of Gradient Textures like Figure 4 As shown, on the surfaces of the first field modulation structure (stator) and / or the second field modulation structure (rotor), the geometric parameters of their microstructural features exhibit a regular gradient change along the direction of relative motion trajectory (or the flux penetration direction of the magnetic circuit / circuit). Variable depth / width design: For example, within the range of a single magnetic pole, the depth H of the groove topology increases from shallow to deep from the edge towards the working area, or the ridge width decreases from wide to narrow. Variable period design: The spatial distribution density (period P) of the topological texture increases linearly or exponentially along the direction of motion.

[0135] 1.4.2 Physical Mechanism The gradual magnetic / electric saturation gradient structure alters the activation mode of the field-induced rheological medium within the working gap, transforming the traditional overall abrupt change into a gradual accumulation. Traditional mode (symmetric structure): Under a uniform magnetic / electric field, the medium on the entire working surface reaches the yield threshold almost simultaneously. This results in an extremely steep curve of output torque versus excitation current, exhibiting strong "step characteristics," making fine adjustment of minute torques difficult. In this invention (gradient structure): Due to the gradient distribution of the texture, the equivalent field impedance (magnetic resistance / capacitive reactance) at different locations within the working gap changes continuously. When the excitation supply is weak, only the flux density in low-impedance regions (such as shallower textures) reaches the medium activation threshold, producing weak damping; as the excitation increases, the activation region gradually expands towards higher-impedance regions (such as deeper textures). Conclusion: This regionalized, sequential activation mechanism macroscopically smooths the total output torque and eliminates the nonlinear inflection point in the magnetic / electric hysteresis loop.

[0136] 1.4.3 Verification of Technical Effectiveness Current-torque response characteristics such as Figure 15 As shown, this instruction manual provides [details omitted] to visually demonstrate this beneficial effect. Figure 15 (Current-Torque Response Comparison Curves): Horizontal axis: Represents the excitation intensity input to the field generator (e.g., coil current I or electrode voltage V). Vertical axis: Represents the shear torque τ output by the joint. Curve A (Prior Art - Dashed Line): Exhibits a typical S-shaped or stepped characteristic. There is almost no response in the low current region (dead zone). Once the threshold is exceeded, the torque rises sharply and then quickly saturates. This characteristic results in a jerky feeling. Curve B (Invention - Solid Line): Thanks to the modulation of the gradient distribution, the curve exhibits high linearity over an extremely wide dynamic range. Soft-start characteristics: In the low field strength region near zero current, the torque increases smoothly and linearly with the current, without obvious dead zones or jumps. Stepless tactile feedback: This physical linearization eliminates the need for complex nonlinear compensation algorithms (such as complex lookup tables or neural network compensation) in the control unit. Only simple proportional control P is required to achieve silky smooth tactile feedback, which is significant for the micro-manipulation feel of ophthalmic surgical robots or the immersive experience of VR exoskeletons.

[0137] 1.5 Magnetic Saturation Overflow Mechanism and Flux Redirection In order to achieve the "structural holding torque beyond the yield limit of the medium" as claimed in the claims within a limited joint volume, in the preferred embodiment of the magnetorheological fluid actuation system, the present invention differs from the conventional thinking of avoiding material saturation in traditional magnetic circuit design, and proposes a "magnetic saturation overflow" mechanism.

[0138] 1.5.1 Physical Contradictions and Design Philosophy in the Dilemma of Traditional Design In existing technologies, to prevent excessive magnetic reluctance, the magnetic guide teeth of the stator and rotor are typically designed to be wide enough to ensure smooth magnetic flux transmission within the metal, minimizing entry into the rheological medium layer with low permeability. This results in the effective magnetic flux density within the working gap often being far lower than the saturation magnetic induction intensity of the metal material, typically only 0.6T-0.8T, failing to fully activate the potential of high-performance magnetorheological fluids, whose saturation threshold can reach over 1.2T. The strategy of this invention: Active bottleneck construction: This invention artificially creates a "magnetic flux bottleneck" in the magnetic circuit by precisely controlling the geometric dimensions of the protrusions on the surface of the second field modulation structure (rotor).

[0139] 1.5.2 Principle Unveiled like Figure 4 and Figure 7 As shown, the magnetic circuit configuration of this invention follows the following inequality principle: the total input magnetic flux that can be transmitted from the first field modulation structure (stator) to the second field modulation structure (rotor) is "greater than" the maximum saturation magnetic flux (Tin>Tsat) that the discrete protrusions on the rotor surface can accommodate under the physical material limit, because the total area of ​​the protrusions on the surface of the first field modulation structure (stator) is greater than the total area of ​​the protrusions on the surface of the second field modulation structure (rotor). We can compare the magnetic circuit system to a fluid pipeline system, with the magnetic flux as water flow and the magnetically conductive material as the water pipe. Traditional designs use thick water pipes, allowing the water to flow smoothly without overflowing. The design of this invention connects a nozzle (rotor protrusion) with a narrow cross-section to the end of the main pipe (stator) with a large flow rate. When a huge flow of water rushes towards this small nozzle, because the nozzle instantly reaches its flow limit (magnetic saturation), the excess "water flow" is forced to "squeeze out" and overflow into the space around the nozzle.

[0140] 1.5.3 The Technical Value of Spillover Effects In this invention, the "overflow space" is precisely the working gap filled with the field-induced rheological medium (especially the internal region of the inverted trapezoidal groove). Flux redirection: Through this forced overflow mechanism, magnetic field lines that originally tended to flow into the metal are forcibly "driven" into the rheological medium. This causes the local magnetic induction intensity B in the medium region inside the groove to instantly surge to 1.0T or even 1.5T, far exceeding the average field strength of traditional designs. Synergistic effect: This high-intensity overflow magnetic field is concentrated precisely at the groove interface where mechanical interlocking occurs. It causes the ferromagnetic particles in the medium to not only reach magnetic saturation but also form extremely dense and hard particle clusters, constructing the aforementioned high-strength "solidified wedge".

[0141] 1.5.4 Results The small size and high torque are achieved thanks to this interface-adjusted and optimized magnetic field distribution strategy. This invention significantly increases the magnetic energy density of the effective working area without increasing the number of coil turns and current (i.e., without increasing volume and power consumption), combined with the grooved inverted trapezoidal design. This results in a very high torque density within a compact joint volume, resolving the contradiction of high-end robot joints that are both small and lightweight, yet also robust.

[0142] 1.6 In the design method of the excitation magnetic field circuit of the field-induced rheostat actuator of the present invention In one embodiment, the magnetically shielded break uses a magnetically shielding component, the material definition and significance of which are as follows: 1.6.1 The core feature of the magnetic shielding component of the present invention is that it is made of a material with extremely low relative permeability to form a high magnetic reluctance barrier in the magnetic circuit. The magnetic shielding material includes, but is not limited to, at least one of the following categories: (1) Non-magnetic metals and their alloys. These materials have both high mechanical strength and stable physical properties and are suitable for high-load joints: Austenitic stainless steel: such as 304, 316, 316L, 316Ti or 310S series stainless steel. Aluminum and its alloys: such as 6061, 7075 and other aerospace-grade hard aluminum alloys. Titanium and its alloys: such as TC4 (Ti-6Al-4V) and other biocompatible materials with high specific strength. Copper-based alloys: such as tin bronze, aluminum bronze, cupronickel or beryllium copper (which have both high strength and non-magnetic properties). Nickel-based superheat resistant alloys: such as the Inconel series, which are suitable for extreme high temperature or high corrosion environments. (2) High-performance engineering plastics and polymers: These materials are suitable for applications requiring lightweighting, electrical insulation, or biocompatibility: Special polymers: Polyether ether ketone (PEEK), polysulfide (PPS), polyimide (PI), or polyetherimide (PEI). Reinforced composites: Carbon fiber reinforced polymer (CFRP, note the orientation of the carbon fibers), glass fiber reinforced polymer (GFRP), or aramid fiber reinforced composites. Medical-grade elastomers: Medical silicone rubber, fluororubber (FKM), or thermoplastic polyurethane (TPU). (3) High-performance ceramics and inorganic non-metallic materials: These materials possess extremely high thermal stability and hardness, and are completely non-magnetic and non-conductive: Structural ceramics: Alumina, zirconium oxide, silicon nitride, or silicon carbide. Functional ceramics: Aluminum nitride (possesses high thermal conductivity and can also serve as a thermally conductive component). (4) Composite and functionalized materials: Metal-polymer hybrid materials: Heterogeneous components formed through injection molding or lamination processes. Porous or honeycomb structure materials: utilize air (with a relative magnetic permeability of about 1) as the main magnetic shielding medium.

[0143] 1.6.2 Physical Principles and Technological Significance Physical principles: such as Figure 7As shown, a "high magnetic reluctance" barrier is established near the equator of the joint socket to connect the aforementioned materials. Utilizing the low magnetic permeability (approximately 1), a magnetic circuit-breaking layer is artificially created at this location. When magnetic field lines encounter this high magnetic reluctance barrier on their transmission path, a circuit is broken, forcing them to deflect and penetrate into the working gap filled with a field-induced rheological medium.

[0144] Technical Significance: Magnetic Field Focusing and Gain: Significantly increases the effective magnetic induction intensity within the working gap, concentrating limited coil energy onto the medium and improving torque output efficiency. Hysteresis and Leakage Suppression: Eliminates parasitic magnetic fields near the equator, preventing joint control nonlinearity caused by magnetic circuit leakage and ensuring sensitivity of torque adjustment. Magnetic-Force Structure Decoupling: Allows the joint socket to maintain mechanical support in the equatorial region while achieving precise topology planning of the magnetic flux path, optimizing the overall power consumption of the actuation system.

[0145] 2. This invention provides a moving component for a field-induced rheological actuation system. 2.1 Fluid Dynamics Model and Self-Pumping Mechanism of Rotor Embedded Tunnel To address the challenges of thermal buildup and solid particle sedimentation in field-induced rheological actuation systems during high-frequency reciprocating motion, this invention constructs an adaptive circulation system based on fluid dynamics within the second moving component (rotor), such as... Figure 8-10 As shown.

[0146] 2.1.1 Self-pumping bidirectional adaptive flow mechanism The physical substrate (such as a joint ball head) integrates at least one medium circulation tunnel, the core technology of which aims to establish a heat-mass exchange pathway for the medium within the working gap. To achieve passive actuation, this invention utilizes the pressure difference generated during the movement of the actuation system. P) is the fluid-driven power source. In one embodiment, such as... Figure 8 and Figure 9As shown, one end of the tunnel opens in a region with a small rotor radius of rotation (such as near the pole of the ball head or near the axis, preferably at latitude 65 degrees), while the other end opens in a region with a large rotor radius of rotation (such as near the equator of the ball head or a large circumference, preferably at latitude 45 degrees). The tunnel opening layout and flow direction design have dynamic adaptability and automatically switch the flow direction mode according to the pressure gradient under different working conditions: (1) Centrifugal force driven mode (high speed / medium and low load working conditions): when the joint is moving at a high speed, the tunnel flow direction is dominated by centrifugal pressure difference. Since the rotation radius is large in the equatorial region, the medium obtains a large centrifugal kinetic energy. The medium usually enters from the place with a small rotation radius (such as near the pole or axis) and exits from the place with a large rotation radius (such as the equator). (2) Extrusion stress driven mode (low speed / heavy load / load working conditions): when the robot is under load or the joint moves slowly, the centrifugal force is weakened. At this time, the flow direction is dominated by geometric extrusion pressure. Due to the radial load generated by the load, there will be a significant non-uniform pressure distribution in the working gap. Typically, high hydrostatic pressure is generated in load-bearing areas (such as high-pressure areas near the equator). Fluid inside the tunnel may enter from the high-pressure equatorial opening and flow out from the low-pressure polar opening.

[0147] Technical value: Regardless of the flow direction, the tunnel achieves forced convection of the medium. This bidirectional flow is beneficial for local cooling of the medium and particle stabilization.

[0148] 2.1.2 Flow Resistance Analysis Low flow resistance bypass effect: To ensure fluid circulation within the tunnel rather than stagnation in the working gaps, this invention defines the tunnel's geometry. Equivalent hydraulic diameter definition: We characterize the tunnel's flow capacity using the equivalent hydraulic diameter (D), calculated as D... Where A is the tunnel cross-sectional area and C is the wetted perimeter. Flow resistance comparison: Working gap flow resistance: The scale (h) of the working gap is typically in the millimeter range (e.g., 1mm - 2mm). For high-viscosity rheological media, the friction loss within the gap is extremely high, and the fluid is mainly in a laminar shear state. Tunnel flow resistance: In this embodiment of the invention, the equivalent hydraulic diameter D of the tunnel is designed to be significantly larger than the characteristic scale h of the working gap (preferably D>5h). Technical effect: According to the Hagen-Poiseuille law, flow resistance is inversely proportional to the fourth power of the pipe diameter. Therefore, the internal tunnel, relative to the narrow working gap, constitutes a low-flow-resistance bypass in the fluid network. This is analogous to current preferentially flowing through a low-resistance wire; under pressure differential drive, the vast majority of the volumetric flow rate will preferentially circulate through the internal tunnel. This design ensures that even with high medium viscosity, as long as the rotor moves, the internal macroscopic displacement circulation remains effective, guaranteeing that the medium in the core working area remains in a uniform temperature and homogeneous state.

[0149] 2.2 Mechanism of Anti-settlement Turbation in Tunnel Inner Wall This invention addresses the problem of particle sedimentation and stratification that easily occurs in field-induced rheological media (especially magnetorheological fluids containing micron-sized iron powder) during long-term static or stable operation by designing the inner wall of the medium circulation tunnel using micro-dynamic principles.

[0150] 2.2.1 Boundary Layer Theory In traditional fluid channels, the fluid follows the no-slip criterion of the wall. A physical bottleneck arises when the medium flows through a smooth inner wall; the velocity gradient near the wall is extremely high, and in the laminar sub-layer region close to the wall, the velocity approaches zero. For magnetorheological fluids, because the density of iron powder particles (approximately 7.8 g / cm³) is much greater than that of the carrier oil (approximately 0.9 g / cm³), particles easily accumulate in the zero-velocity region of the wall under low-velocity or laminar flow conditions, forming a dense filter cake. This not only gradually clogs the tunnel but also reduces the effective particle concentration participating in the response within the working gap, leading to a decrease in joint torque.

[0151] 2.2.2 Turbulence Structure Design The inner wall of the medium circulation tunnel described in this invention is provided with microstructures or surface morphology features for disturbing boundary layer flow; in one embodiment, helical rifling is used, such as... Figure 10 As shown, to break the aforementioned static boundary layer, spiral grooves resembling gun barrel rifling are machined into the inner wall of the tunnel. When the medium flows through under pressure differential, the spiral grooves force the fluid to generate a rotational velocity component, creating eddies within the tunnel. In another embodiment, a biomimetic pit structure is employed: pits with a specific depth ratio are arrayed on the inner wall, simulating the surface structure of a golf ball.

[0152] 2.2.3 Physical Effects This non-smooth surface alters the fluid topology through hardware topology, producing the following effects: (1) Inducing lateral mixing: The turbulence structure creates additional lateral secondary flows and micro vortices outside the mainstream direction (Z-axis). (2) Entrainment effect: These micro vortices act as physical agitators, continuously entraining and ejecting heavy particles settled near the wall back into the mainstream region. (3) Shear activation: Even when the rotor rotates at low speed, these structures ensure that the medium inside the tunnel remains in a high shear rate state, preventing thixotropic thickening or permanent hard settling of the rheological medium.

[0153] 2.2.4 The essential difference between this and ordinary cooling holes Those skilled in the art should understand that the inner wall turbulence tunnel described in this invention is fundamentally different from the straight cooling holes commonly found in the field of electric motors: (1) Different purposes: Ordinary cooling holes only aim to reduce flow resistance to allow the cooling medium to pass through; while this invention actively increases local disturbance, and its core purpose is to maintain the physical homogeneity of multiphase fluids through fluid shear energy. (2) Different structural features: Ordinary cooling holes aim for extreme smoothness (Ra<0.8) to reduce pressure loss; this invention deliberately creates a non-smooth morphology, sacrificing a very small proportion of pumping pressure in exchange for the medium's anti-settling characteristics.

[0154] 2.3 Non-complementary spatial staggered configuration of magneto-fluid 2.3.1 Definition of non-complementary spatial interleaving in this invention This refers to a three-dimensional spatial topology where two or more physical functional paths (such as fluid transport paths and electromagnetic flux paths) are neither overlapping nor completely mutually exclusive in spatial distribution. Instead, they achieve independence and continuity of their respective physical characteristics through geometric phase differences. In this invention, the physical meaning specifically refers to the topological relationship between the medium circulation tunnel (fluid path) and the dominant magnetic circuit (field path) within the solid matrix.

[0155] 2.3.2 Specifically includes (1) Unlike traditional vertical drilling (i.e., the flow channel is perpendicular to the magnetic lines of force, resulting in greater magnetic resistance), the tunnel trajectory of this invention maintains a small angle deflection or local parallelism with the direction of the dominant magnetic lines of force in the spatial vector, thereby reducing the effective demagnetization area generated by the tunnel wall during the transmission of magnetic lines of force. (2) The tunnel is not intended to cut off the main magnetic circuit, but rather to penetrate the magnetic potential redundancy zone (i.e., the area with relatively low magnetic flux density or non-core conduction path) inside the solid matrix. When the magnetic flux encounters the tunnel space, it can adaptively bypass through the remaining solid material around the tunnel. By controlling the diameter and spacing of the tunnel, it is ensured that the local magnetic flux density after bypassing is still in the unsaturated region of the material, thereby maintaining the linearity of the overall torque output of the joint.

[0156] 2.3.3 In the embodiment of the spherical joint of the present invention, a medium circulation tunnel is constructed inside the solid matrix of the spherical rotor, such as... Figure 9 As shown, a structural coupling is achieved by optimizing the three-dimensional spatial topology of physical field paths (such as magnetic paths) and fluid trajectories.

[0157] (1) Field Circulation Protection Mechanism. In field-induced rheological actuation systems, the solid substrate typically functions as a magnetic conduction circuit. Traditional hole fabrication often leads to a surge in local magnetic reluctance due to the cutting of magnetic lines of force, thereby weakening the locking torque of the joint. The spatial trajectory of the tunnel described in this invention is defined as a non-complementary spatial interlacing relationship with the dominant field path (direction of main magnetic flux) within the solid substrate. In a spherical joint embodiment, the tunnel opening is at 45 degrees north latitude, diagonally upward, and another opening is at 65 degrees latitude.

[0158] (2) Synergy between "fluid penetration" and "field path bypass". The tunnel's orientation is not randomly distributed, but rather calculated topologically to ensure that its axis is located in a region with a smaller magnetic potential gradient than the magnetic flux. This "non-complementary interlacing" means that the tunnel does not create physical breaks in the main path of the magnetic circuit. When magnetic field lines encounter the tunnel, they can adaptively bypass it using the remaining solid material.

[0159] 2.3.4 Technological Advantages Experimental data show that the spherical joint with this non-complementary spatial staggered magnetic-fluid configuration has a static maximum locking torque attenuation rate controlled within 5%, maintaining the continuity of the field circuit and preventing structural collapse of electromagnetic performance.

[0160] 3. This invention provides an integrated thermal management system for a field-induced rheological actuation system. For field-induced rheological actuation systems that combine magnetorheological fluid with electromagnetic coils, and to address the performance degradation caused by excitation coil heating and dielectric shear heating under high load conditions, this invention proposes an integrated thermal management system with decoupled magnetic-thermal paths.

[0161] 3.1 Basic Structure of Integrated Magnet-Temperature Decoupling Thermal Management System The integrated thermal management system described in this invention aims to solve the problem of heat accumulation within high-power-density field-induced rheological actuation systems. Its specific structure and integration method are as follows: Figure 11-13 As shown: 3.1.1 Materials and interfaces of magneto-thermal composite structures.

[0162] Magnetic matrix material: The magnetic matrix is ​​composed of a material with high magnetic permeability, including but not limited to: electrical pure iron (such as DT4C), silicon steel sheet stacks, soft magnetic composite material (SMC), nickel-iron alloy or cobalt-iron alloy.

[0163] Heterogeneous integration of thermally conductive components: The thermally conductive component is integrated inside the magnetically conductive substrate. Along the magnetic flux direction in the magnetic circuit, without substantially damaging the effective magnetic conductivity, at least a portion of the thermally conductive component is exposed outside the magnetically conductive substrate and forms a thermally conductive connection with a heat dissipation component and / or the outer shell of the device to form an outward heat conduction path. Its material is selected from non-magnetic high thermal conductivity materials with a thermal conductivity-to-magnetic material ratio greater than 5:1. The thermally conductive component is preferably made of non-magnetic materials with a thermal conductivity greater than 150 W / (m·K), preferably including but not limited to: high thermal conductivity metals (such as copper, aluminum, silver and their alloys, aluminum-magnesium alloys, etc.), thermally conductive ceramics (such as aluminum nitride, boron nitride, etc.), carbon-based materials (such as graphene, high thermal conductivity carbon fibers, carbon nanotube composites, etc.), and heat pipe components based on the phase change principle. Furthermore, when the thermally conductive component is located in a strong alternating magnetic field region, it is preferable to use electrically insulating thermally conductive materials (such as aluminum nitride ceramics) to ensure heat extraction efficiency while suppressing the additional heat load generated by induced eddy currents. Spatial morphology: The heat-conducting components are not limited to columnar shapes within the substrate. They can be presented as three-dimensional mesh skeletons (3D Mesh), interpenetrating network structures, honeycomb grids, or branched biomimetic channels, achieving "volume absorption" of heat by increasing the contact area.

[0164] Electrical insulation structure design: At the contact interface between the thermally conductive component and the magnetically conductive substrate, an electrically insulating film (such as alumina, silicon dioxide, polyimide, etc.) with a thickness of 1μm to 50μm is formed through physical vapor deposition (PVD), chemical vapor deposition (CVD), anodizing, or polymer coating processes.

[0165] The 'integration' mentioned in this invention should be broadly understood as the physical bonding method between the thermally conductive component and the magnetically conductive substrate, including but not limited to mechanical inlay, interference fit, integral casting, brazing, diffusion welding, metal 3D printing, and physical connection achieved through a high thermal conductivity filling medium.

[0166] 3.1.2 Thermal flux polarization guided structure Thermal barrier structure: A thermal barrier layer is set between the inner side of the coil and the inner support structure, such as... Figure 11 As shown, low thermal conductivity materials are used, such as polyetheretherketone (PEEK), ceramic / glass fiber reinforced PEEK, ceramic fiber felt, aerogel thin layers, or composite polymers with porous structures. Thermal coupling connection: The excitation coil is thermally coupled to the thermally conductive component via a low-melting-point alloy, thermally conductive potting compound (such as alumina-filled silicone), thermally conductive pad, or a high thermal conductivity ceramic support. Heat dissipation terminal: The thermally conductive component passes through the magnetic substrate and is connected to the external heat sink fins, liquid cooling plate, or metal casing via threaded connections, interference fits, or heat pipe welding.

[0167] The low-melting-point alloy (such as a multi-element alloy of gallium, indium, and tin) is selected as a non-magnetic conductive medium. Its relative permeability approaches 1, thus forming a magnetic insulation with the main magnetic circuit in space. Furthermore, a thin-walled PEEK thermal insulation layer is provided between the low-melting-point alloy filling chamber and the inner support structure (joint socket). This PEEK layer not only prevents heat from flowing back into the internal core, but also, due to its extremely high dielectric strength and non-magnetic characteristics, acts as a dual magnetic and electrical insulation barrier, synergistically ensuring the precise directionality of magnetic field lines in the equatorial region, completely eliminating the risk of short-circuit leakage caused by magnetic flux crossing the heat dissipation channel.

[0168] 3.1.3 Diverse integrated manufacturing processes To ensure that the realization of this structure is not limited by the manufacturing process, this system supports the following multiple manufacturing methods: Split Embedded: Grooves or holes are pre-reserved in the magnetic substrate, and a thermally conductive strip with an insulating layer on its surface is pressed in using cold shrinkage or interference fitting. Additive Manufacturing (3D Printing): Utilizing multi-material metal 3D printing technology (such as laser cladding), spatial gradient or mesh-like interweaving of magnetic materials (pure iron powder) and thermally conductive materials (copper alloy powder) is achieved, and an insulating phase is generated in situ at the interface. Powder Metallurgy / Casting: A high thermal conductivity skeleton is placed as an embedded part in a mold, followed by hot pressing with injected soft magnetic composite powder, or composite formation is achieved through molten metal impregnation. Lamination Composite Process: Coated silicon steel sheets and insulating copper foils are alternately laminated to form a highly anisotropic magnetic / thermal composite structure.

[0169] 3.1.4 The specific structure of the spherical joint embodiment of the magnetorheological fluid combined with electromagnetic coil actuation system is as follows: Figure 11-12As shown, the gap between the inner side of the inner structure of the joint shell and the ball head is the magnetorheological working gap. The electromagnetic coil is positioned between the inner structure (such as 1018 steel) and the outer structure (such as aluminum alloy) of the joint shell, located near the equator inside the joint shell and outside the working gap. Here, the inner structure coil slot is first covered with an ultra-thin 0.2mm thick PEEK (polyetheretherketone) material for heat insulation. The coil is wound on the surface of the PEEK heat insulation material and surrounded by a low-melting-point alloy, which fills the gap between the inner and outer structures of the joint shell. The outermost layer consists of an electrical pure iron core with its two ends tightly connected to the magnetic poles formed by the joint socket, creating a magnetic circuit. Inside the electrical pure iron core, 4-6 unconnected copper heat-conducting strips are integrated along the magnetic field lines (meridian direction). These copper strips are not interconnected. A 0.05mm-0.1mm thick layer of high thermal conductivity structural adhesive (or thermally conductive insulating varnish) is coated between the electrical pure iron core and the copper heat-conducting strips. Considering the difference in thermal expansion coefficients between copper and electrical pure iron, the copper heat-conducting strips can be spaced 0.2mm-1mm apart at the equator. One end of each copper heat-conducting strip and electrical pure iron core is connected to the inner supporting component (such as 1018 steel) at the top of the joint socket (N pole), and the other end of both is connected to the inner layer material (1018 steel) at the opening of the joint socket. The electrical pure iron magnetic circuit and its internal copper heat-conducting strips fit tightly against the outermost aluminum alloy structure, facilitating heat dissipation.

[0170] 3.2 Principle Analysis and Technical Significance of Integrated Thermal Management System 3.2.1 Basic Principles and Technical Advantages of the Magnet-Thermal Decoupling Thermal Management System (1) Physical principle: Spatial functional decoupling of heterogeneous materials Thermal management of traditional electromagnetic actuation systems has long faced a material dilemma: materials with excellent magnetic permeability (such as electrical pure iron and silicon steel) often have limited thermal conductivity, while materials with high thermal conductivity (such as copper and aluminum) are magnetically insulating. Using metals with low magnetic reluctance in the joints results in insufficient heat dissipation, while using metals with high thermal conductivity presents the challenge of high magnetic reluctance, which has been a persistent problem in this field.

[0171] This invention constructs a heterogeneous composite structure, such as Figure 11-12As shown, the conduction decoupling of the magnetic field and thermal field is achieved at the physical level. Magnetic circuit guidance: A magnetically conductive matrix made of magnetic material serves as a high-permeability magnetic path, ensuring that the working magnetic flux can be closed with extremely low magnetic resistance. Heat flow extraction: Non-magnetic thermally conductive components embedded in the magnetically conductive matrix act as "channels" for heat. Utilizing the thermal conductivity of the thermally conductive components, which is much higher than that of the magnetically conductive matrix (e.g., more than 5 times higher), an independent low-resistance thermal network is established within the magnetically conductive matrix. The ingenuity of this design lies in the fact that, because the thermally conductive components are non-magnetic, their embedding does not interfere with the direction of the magnetic field lines like magnetic impurities; and although the magnetically conductive matrix is ​​"divided," the continuity of its spatial structure is preserved in the design, allowing the magnetic field lines to continue to transmit around the non-magnetic barrier. Therefore, in the core heated area of ​​the actuation system, heat no longer accumulates but spontaneously dissipates outward along the thermally conductive components.

[0172] The ball joint described above is an example of a heat dissipation method that primarily utilizes two pathways, such as... Figure 13 As shown, the first sequence is: coil → low-melting-point alloy → magnetic-thermal composite structure (electrical pure iron + copper strip) → aluminum alloy shell → air. The second sequence is: working gap → inner support structure → magnetic-thermal composite structure (electrical pure iron + copper strip) → aluminum alloy shell → air.

[0173] (2) Technological advantages Compared with traditional single-material heat dissipation, the magnetic-thermal decoupling system described in this invention has the following significant advantages: Eliminating dynamic errors caused by temperature drift: The viscosity of field-induced rheological media is extremely sensitive to temperature. Through magneto-thermal decoupling, the system can control the temperature rise of the working gap within a small range, ensuring that the joint maintains consistent torque feedback characteristics under different load conditions. This is crucial for the motion transparency required by precision surgical robots. Increasing power density: Without changing the motor volume, the system allows the coil to carry a larger drive current, thus generating higher burst torque in a short time, as internal heat can be "directly drawn" to the outer shell, without worrying about permanent magnet demagnetization due to overheating. Extending the service life of core components: Heat is preferentially guided to the outside, effectively suppressing heat penetration into the inner support structure and bearings. This protects the fitting clearances of the precision mechanical structure from changes due to thermal expansion and contraction, significantly reducing mechanical wear and maintenance frequency of the joint. Achieving structural-functional self-consistency: This design integrates the "heat sink" directly into the "magnetic circuit," eliminating the need for large external fans or water-cooling pumps, clearing the way for extremely lightweight and compact joint designs.

[0174] (3) Those skilled in the art should understand that limiting the ratio of thermal conductivity of the thermally conductive component to that of the magnetic material to 5:1 or higher is the key to achieving "miniaturized heat dissipation." This significant performance difference ensures that even in robot joints where space is extremely limited, only a small number of thermally conductive inserts are needed to achieve a large flow of heat dissipation, which is of great significance for maintaining long-term heat dissipation during the static holding phase. The thermally conductive component accounts for 5% to 40% of the total volume of the magnetic circuit assembly. Below 5%, an effective thermal bridge cannot be formed, while above 40%, the magnetic permeability will be severely diluted.

[0175] (4) By setting a micron-level electrically insulating structure at the interface of dissimilar metals (such as copper and pure iron), this invention physically cuts off the charge transfer path. Its significance is: A. Suppressing electromagnetic eddy currents: Cutting off the current path between dissimilar metal interfaces, preventing induced Joule heating under the action of high-frequency pulse fields, and ensuring the linearity of the magnetic circuit response; B. Blocking electrochemical corrosion: Eliminating the galvanic cell effect between copper and pure iron, preventing oxidation corrosion caused by potential difference at the interface.

[0176] 3.2.2 Configuration principle and technical advantages of internal and external linkage heat path In the above embodiments, the heat-conducting component (such as a copper heat-conducting strip) adopts a "both internal and external" topological connection method, such as... Figure 11 and 13 As shown, its specific benefits and physical principles are as follows: (1) Internal joint socket (e.g., 1018 steel): deep suction and thermal field homogenization The inner end of the heat-conducting component is deeply coupled to the solid interior of the joint socket (inner support structure) through high-pressure interference fit or brazing. Because the thermal conductivity of copper (approximately 390 W / (m·K)) is much higher than that of 1018 steel (approximately 60-80 W / (m·K)), a thermal funnel is created inside the joint socket. Technical advantages: Once the shear heat generated in the working gap (rheological medium layer) enters the inner shell of the joint socket, it is driven by the low thermal resistance effect and rapidly converges to the heat-conducting component, rather than accumulating on the joint surface. This effectively prevents kinetic failure of the rheological medium due to localized high temperatures (such as a sudden drop in viscosity or thermal degradation), maintaining the linearity and stability of the torque output.

[0177] (2) External heat dissipation casing (e.g., aluminum alloy): heat energy polarization discharge and heat sink expansion The heat-conducting component passes through the magnetic substrate and forms a large-area thermal contact with the aluminum alloy shell, which has a high surface area.

[0178] Technical advantages: The aluminum alloy shell is not only a mechanical enclosure structure, but also acts as an environmental heat exchanger. Heat is directly conducted to the outside along the high thermal conductivity path of the heat-conducting components, and the heat is ultimately released through natural or forced convection. This design gives the joint a high thermal load capacity, and even under long-term heavy-load operation, the core temperature can be maintained within a safe threshold.

[0179] 3.2.3 A thermal coupling structure in which the excitation coil forms a thermally conductive relationship with the heat-conducting component and / or the magnetic substrate. The excitation coil forms a thermally coupled structure with the thermally conductive component and / or the magnetically conductive substrate, which is not limited to traditional thermally conductive adhesives, but also includes composite resins containing thermally conductive particles, low-melting-point metal alloys, or high-thermal-conductivity ceramic pads. Preferably, the thermal conductivity of the filling medium is greater than 5 W / (m·K).

[0180] In a high power density implementation, to completely eliminate the thermal resistance bottleneck between the excitation coil and the heat-conducting component, this invention uses a low-melting-point alloy instead of traditional thermally conductive adhesive as the thermal coupling structure or medium, such as... Figure 11 As shown: (1) Material selection and physical properties Composition and formulation: The potting medium uses a low-melting-point eutectic alloy based on bismuth (Bi), indium (In), tin (Sn), or gallium (Ga) (such as an In-Bi-Sn alloy). The melting point of this alloy is set between 60°C and 120°C, and its thermal conductivity at room temperature ranges from 15 to 30 W / (m·K), which is approximately 10 to 20 times that of traditional silicon-based thermal conductive adhesives.

[0181] (2) Integration of potting process and structure Insulation Pretreatment: Before potting, the surface of the enameled wire of the excitation coil and the walls of the magnetic substrate grooves must be pre-coated with a high-temperature resistant, strong-adhesion insulating layer (such as polyimide or Teflon film) to prevent electrical short circuits caused by the metal alloy. Liquid Filling: After heating the alloy to a molten state, it is injected into the gap between the coil and the copper heat-conducting strip using a vacuum pressure potting process. After solidification, the alloy forms a continuous, non-porous, all-metal heat conduction network.

[0182] (3) Collaborative heat dissipation principle and technical advantages Metal-level thermal bridging: The alloy potting layer achieves "metal-bond-level" contact between the coil, the magnetic substrate, and the copper heatsink at the microscopic level. This allows the Joule heat generated by the coil to be conducted directly to the copper heatsink through the metal thermal bridge, without passing through a low-thermal-conductivity polymer medium. Phase change heat absorption buffer: By cleverly utilizing the low melting point of the alloy, when the joint is under extreme instantaneous overload (a surge in coil current), the alloy can absorb a large amount of instantaneous heat through phase change latent heat, maintaining itself near its melting point temperature. This provides a crucial temperature rise buffer period for the field modulation interface (rheological medium layer), preventing uncontrolled temperature rise in the joint. Stress self-relief: When the alloy is in a semi-molten or softened state, it possesses a certain degree of fluidity or plasticity, enabling it to absorb the mechanical vibrations and thermal expansion and contraction stresses generated by the coil during frequent commutation movements, protecting the integrity of the internal structure.

[0183] 3.3 Heat Flow Path Optimization and Active Thermal Isolation Strategy To further protect the precision components inside the joint (such as posture sensors and high-precision bearings) from the high temperature of the excitation coil, this invention implements a directional heat dissipation path design.

[0184] 3.3.1 Active heat flow path planning like Figure 11-13 As shown, this invention constructs a low thermal resistance internal source external exhaust channel. Its heat transfer path follows the logic as follows: (1) Heat source capture: The excitation coil, as the main electro-heat source, forms a large-area contact with the heat-conducting component through a high thermal coupling structure (such as a low melting point alloy or high thermal conductivity silicone grease). The end of the heat-conducting component is also connected to the joint socket formed by the inner support structure, which guides the heat from the working gap outward. (2) Directional conduction: By utilizing the radial or axial extension of the heat-conducting component (such as a copper thermal bridge) inside the magnetic substrate, the Joule heat generated by the coil and the working gap is quickly drawn to the joint shell. (3) High-efficiency heat dissipation: such as Figure 12 As indicated by the arrows, heat is ultimately dissipated into the external air environment through the high surface area of ​​the heat dissipation components or the joint shell (aluminum alloy), via convection, cooling, and radiation. The purpose of this design is to intercept and dissipate heat the moment it is generated, preventing heat buildup inside the joint.

[0185] 3.3.2 Thermal shielding strategy for critical internal areas A key feature of this invention is that, while guiding heat outwards, it also provides thermal insulation for the internal core area: For example... Figure 11As shown, when the system uses magnetorheological fluid, this invention sets a thermal barrier layer of low thermal conductivity material, such as polyetheretherketone (PEEK) or ceramic / glass fiber reinforced PEEK, between the inner side of the coil and the inner support structure (joint socket) and on the outer side of the inner support structure (the side with the joint layer material). This reduces the Joule heat of the coil being transferred inward to the joint socket, thereby reducing the amount of heat transferred to the working gap and helping to maintain the temperature of the medium. Significance: This "heat dissipation outward and insulation inward" architecture reduces the aging rate of precision components and extends the maintenance-free life of the joint in extreme environments such as aerospace and polar regions.

[0186] 3.4 Significance of thermo-magnetic-mechanical synergistic optimization Those skilled in the art will understand that the thermal management system described in this invention is not an isolated heat dissipation component, but rather an integrated solution deeply coupled with magnetic circuit design and structural support. The system-level optimization of this invention is manifested in the following way: through the deep integration of thermal, magnetic, and mechanical structures, this invention eliminates the chain reaction of "the more power, the lower the precision" found in general devices. This ensures that even under prolonged, high-intensity operating conditions, the actuation system maintains a safe temperature range for its internal precision sensing units and rheological media because the heat flow path is pre-programmed and directionally dissipated. This physical-level reliability guarantees that the robot's joints do not overheat and that its precision is maintained when performing tasks lasting several hours.

[0187] 4. Sealing scheme for field-induced rheological actuation system 4.1 A cascaded three-layer composite sealing structure To ensure the long-term reliability of the actuation system of the present invention under heavy loads, high altitudes, and harsh environments (such as high-altitude operations, robot loads, and industrial dust), in a preferred embodiment, taking a ball joint as an example, a cascaded three-layer composite sealing architecture is preferably adopted, such as... Figure 2 As shown, this architecture achieves the containment of the field-induced rheological medium without interfering with the magnetic circuit distribution at the field modulation interface.

[0188] (1) Inner layer: self-tightening scraper At the edge of the stator joint socket opening, a self-tightening scraper sealing ring made of wear-resistant polymer material (such as PTFE-filled material) is provided. Structural features: The sealing ring has a U-shaped or C-shaped cross-section, with the opening facing inwards towards the working gap. Physical functions: a) Pressure-driven self-tightening: When the pressure within the working gap increases with the load, the pressure acts on the sealing ring opening, forcing the lip to tightly adhere to the ball head surface, achieving an adaptive sealing effect of "the higher the pressure, the tighter the seal." b) Physical return: During the ball head's oscillation, the scraper mechanically scrapes the solidified media particles adhering to the surface back into the gap, preventing particles from escaping to the middle sealing area.

[0189] (2) Middle layer: Flexible metal bellows main sealing chamber A set of flexible metal bellows is connected between the stator housing opening and the rotor output rod. High-fatigue-resistant titanium alloy welded bellows form a completely airtight enclosure, completely locking all field-induced rheological media inside the system, achieving true zero leakage. Unlike magnetohydrodynamic permanent magnet seals, this bellows structure eliminates the need for permanent magnets at the opening, thus causing no interference with the magnetic circuit.

[0190] The bellows' stroke is designed with prestress compensation: to address the thermal expansion and contraction of materials caused by the severe temperature differences in space, the effective number of bellows layers and the corrugation spacing are set to absorb more than 5% of axial thermal deformation. Simultaneously, the bellows is filled with inert gas or is in a semi-vacuum state, working in conjunction with the internal heat dissipation system to form a temperature-controlled, pressure-constant cavity, ensuring consistent torque output at the field modulation interface within a ±150°C environment.

[0191] (3) Outer layer: dustproof cover The bellows is covered with a highly elastic fluororubber (FKM) spherical dust cover. This is primarily designed to protect against fine dust, oil, moisture, and chemical corrosion from the external environment. As the first line of physical defense for the joint, the dust cover effectively prevents external particles from entering the bellows gaps and causing metal fatigue failure, significantly extending the maintenance cycle of the entire sealing system.

[0192] In this embodiment, the flexible sealing component preferably forms a strong, integrated connection with the metal inner wall of the joint housing. Specifically, the root of the seal can be fixed to the metal substrate through chemical bonding, adhesive bonding, overmolding, or mechanical fitting, forming a tight, leak-free interface. This design ensures that the seal body remains in place and will not detach due to friction when the sealing lip slides close to the connecting rod.

[0193] 4.2 Other optional sealing embodiments 4.2.1 Integrated magnetic fluid dynamic sealing structure In one embodiment for a medical robot joint, the sealing assembly employs a combination of magnetic fluid sealing and a mechanical barrier: Structural features: A set of annular permanent magnet pole shoes is positioned at the edge of the field modulation interface. The resulting localized high-gradient magnetic field attracts the magnetic fluid into the gap between the rotor and stator, forming several liquid sealing rings. Technical principle: Utilizing magnetic fluid to achieve dynamic sealing with "zero wear and zero leakage." Due to the excellent physical compatibility between the magnetic fluid and the field-induced rheological medium, this structure completely prevents the entry of external particles and avoids the "stick-slip effect" generated by traditional sealing rings during micro-incremental movements, ensuring extremely high smoothness of the surgical robot during micrometer-level operations.

[0194] 4.2.2 Multi-level maze-like physical barrier In a general-purpose implementation focusing on long lifespan and low cost, the sealing assembly employs a non-contact labyrinth seal. Structural features: Interlocking annular textured surfaces are machined at the stator-rotor junction, forming a complex, narrow, tortuous channel. Technical principle: The drastic pressure drop and flow resistance generated when fluid flows through a narrow, tortuous path restrict the outward migration of the field-induced rheological medium. This embodiment, by eliminating sliding friction between materials, significantly reduces the no-load torque of the joint and eliminates the need for seal replacement, making it suitable for industrial collaborative robots with moderate sealing requirements but high energy efficiency requirements.

[0195] 4.2.3 Oleophobic / hydrophobic functionalized surface self-tightening seal In one embodiment pursuing lightweight and miniaturization, the sealing assembly includes an elastic sealing lip with a nanoscale functionalized coating: Structural features: The surface of the sealing lip is chemically grafted with an oleophobic nano-coating having low surface energy. Technical principle: By increasing the contact angle, the field-induced rheological medium exhibits a self-shrinking tendency at the sealing interface, reducing wetting. Combined with a self-tightening spring structure, the sealing lip can reliably intercept low-viscosity carrier fluid while maintaining low positive pressure, reducing frictional heat generation.

[0196] 4.2.4 High-Temperature and High-Pressure Integrated Medical Rubber Flexible Seal In a medical application implementation scheme with extremely high requirements for biocompatibility and absolute sealing reliability, the sealing component employs an integrated vulcanized flexible isolation bushing: Structural features: Medical-grade high-elasticity material (such as medical silicone rubber, polyurethane, or fluororubber) is used as the sealing medium. Using a high-temperature, high-pressure molding vulcanization process, the two edges of the flexible bushing are directly "attached" and fixed to the metal substrate of the moving rod (rotor) and the joint socket (stator), respectively. Physical morphology: The sealing structure is spatially pleated or corrugated, allowing the moving rod to swing or rotate freely within a preset stroke, while the rubber bushing undergoes flexible deformation accordingly. Technical principles and advantages: Seamless absolute isolation: Because the sealing element and the stator and rotor form a molecular-level bond (or high-pressure physical interlocking) through a high-temperature, high-pressure process, the leakage points of traditional dynamic seals are completely eliminated. The field-induced rheological medium is completely enclosed within the dead-loop space formed by the rubber bushing, preventing media leakage and contamination of the surgical environment, while also preventing medical disinfectants or bodily fluids from entering the joint cavity. Zero-start friction: Unlike sliding seals, this structure only involves the stretching of molecular chains within the rubber during actuation, eliminating sliding friction between solids. This eliminates frictional noise and resistance fluctuations at low speeds, providing the surgical robot with near-"pure" force feedback. Withstands high-temperature and high-pressure sterilization: Utilizing high-heat-resistant medical-grade rubber (such as liquid silicone rubber LSR), the entire joint can withstand multiple high-pressure steam sterilization environments, meeting the reusable standards for medical devices.

[0197] 5. Further explanation of the field-induced rheological system of the present invention and its performance differences from that of a traditional smooth ball head. A preferred embodiment of a spherical magnetorheological dielectric joint is described, comparing its specific design, maximum static holding torque, torque density, and performance with that of a smooth joint surface: 5.1 Overall Structure and Specific Design of a Spherical Magnetorheological Dielectric Joint (Example) The joint is a spherical magnetorheological fluid joint. The ball head is made of 17-4PH (H900) steel with a diameter of 60mm. The ball head connects to a 316L material moving rod at latitudes 75-90 degrees in the Southern Hemisphere (the working range of the ball head is from 75 degrees south latitude to 90 degrees north latitude, with a surface area of ​​11117mm²). The moving rod has a unidirectional range of motion of 35 degrees (a conical range of 70 degrees). The inner support structure of the stator forms a joint socket on its inner side, made of 1018 steel with a QPQ surface. The top of the joint socket at latitude 90 degrees is the magnetic north pole. Near the equator, the joint socket has a 4mm wide Inconel 718 (nickel-based high-temperature alloy) material, occupying ±4 degrees of equatorial latitude. To achieve the 35-degree unidirectional movement of the moving rod, the joint socket opens at latitude 40 degrees in the Southern Hemisphere (meaning the working range of the joint socket is 4-90 degrees north latitude and 4-40 degrees south latitude, with a surface area of ​​8498mm²). The excitation coil is a 0.5mm diameter, 220 turns, 6 ohms, 24V enameled copper coil, with steady-state energization. The magnetorheological fluid has a working gap width of 0.35mm and is selected from the MRF-140CG model (particle diameter of 8 micrometers) manufactured by Lord Laboratories, USA, with a magnetic saturation of 0.9T. The magnetic circuit is as follows: North pole of the joint socket (4-90 degrees) 1018 steel groove ridge → MR gap → 17-4PH ball head → MR gap → South pole (4-40 degrees) 1018 steel groove ridge → electrical pure iron magnetic circuit matrix → North pole of the joint socket.

[0198] The specific design is as follows: (1) Ball head. Material: 17-4PH (H900) steel, characterized by medium magnetic permeability and high hardness. The surface of the ball head has symmetrical inverted trapezoidal grooves along the latitudinal direction, with a wall inclination angle of 84°, a groove bottom radius of R0.1, a depth of 0.5mm, and a tooth pitch of 1.0mm (ridge width 0.6mm, groove opening width 0.4mm). The grooves in the meridian direction are consistent with those in the latitudinal direction. There are 3 tunnels with a diameter of 2mm, opening at 45 degrees north latitude on the ball head, running obliquely, and exiting at 65 degrees north latitude on the opposite side, not parallel to the equatorial plane.

[0199] (2) Working layer gap medium. Material: Magnetorheological fluid (MR) using carbonyl iron powder fluid, thickness: 0.35 mm, function: to generate shear force and form solidified wedges.

[0200] (3) Joint socket. The inner surface of the inner support component forms a joint socket. Material: 1018 steel, QPQ surface treatment for the entire joint socket surface. Features: The surface of the stator joint socket has symmetrical inverted trapezoidal grooves in the latitudinal direction, with an 80° bevel and a R0.1 rounded corner at the bottom of the groove. In the Northern Hemisphere, the groove depth is 0.5mm and the tooth pitch is 1.2mm (0.7mm ridge width, groove opening width 0.5mm) in the 4-60 degree latitude direction; in the Northern Hemisphere, the groove depth is 0.15mm and the tooth pitch is 1.2mm (0.8mm ridge width, groove opening width 0.4mm) in the 60-90 degree latitude direction; in the Southern Hemisphere, the groove depth is 0.5mm and the tooth pitch is 1.2mm (0.7mm ridge width, groove opening width 0.5mm) in the 4-40 degree latitude direction. The joint socket surface features a symmetrical trapezoidal groove along its meridian direction, with a wall inclination angle of 84° and a radius of 0.1mm. The groove depth is 0.25mm from 40° latitude in the Southern Hemisphere to 60° latitude in the Northern Hemisphere, and linearly transitions to 0.15mm from 60° to 90° latitude in the Northern Hemisphere. The tooth pitch is 1.2mm (0.7mm ridge width, 0.5mm groove opening width). The stator groove spatial period is 1.2:1 compared to the rotor groove spatial period.

[0201] (4) Medium circulation tunnel. At 45 degrees north latitude of the ball head, running obliquely, with the exit at 60 degrees north latitude on the opposite side, there are 3 tunnels with a diameter of 2 mm that are not parallel to the equatorial plane. The inner wall of the tunnel contains helical rifling.

[0202] (5) Magnetic shielding ring. A magnetic shielding ring is connected in the middle at the equator position of the inner support component (articular socket). Material: Inconel 718 (nickel-based high-temperature alloy). Advantages: It is both hard (wear-resistant) and magnetically shielded, and it is also a poor conductor of heat (protecting the MR fluid). Width: 4.0 mm, located at the equator at latitude ±4 degrees. Effect: It forms a magnetic circuit break, forcing magnetic lines of force to enter the ball head through the MR gap, and then return to the articular socket from the other end of the ball head through the MR gap.

[0203] (6) Excitation coil and surrounding heat insulation and heat conduction structure. Material: Enameled copper coil, 0.5mm diameter, 220 turns, 6 ohms, 24V voltage. Process: Here, the inner layer component near the equator coil slot is first covered with an ultra-thin 0.2mm thick polyetheretherketone (PEEK) material for heat insulation. The coil is wound on the surface of the PEEK heat insulation material and is located between the inner layer support component and the joint shell. The surrounding area is encapsulated with a low melting point alloy. Function: Magnetic source. (7) Magnetic Circuit Layer. Material: The magnetic circuit uses electrical pure iron (DT4C), and six unconnected copper heat-conducting strips are integrated along the meridian of the electrical pure iron. A 0.1mm thick layer of high thermal conductivity structural adhesive is applied between the copper strips and the electrical pure iron for insulation. Both are in close contact with the aluminum alloy shell for heat dissipation. Location: Tightly wrapped around the coil and located inside the aluminum alloy shell. The electrical pure iron magnetic circuit and the joint socket 1018 have a large area of ​​flat metal contact at the N and S end faces. Function: Magnetic current return path. It is the bridge connecting the N pole and the S pole, preventing the magnetic circuit from being broken.

[0204] (8) Outer shell. Material: Aluminum alloy (6061-T6), Position: Outermost layer, Function: Structural support, heat dissipation, weight reduction, high-frequency eddy current shielding, protection of electronic components.

[0205] (9) Thermal Management. A 0.2mm thick PEEK insulation layer is added to the surface of the coil slot of the inner support component to reduce heat conduction from the coil to the MR fluid. Furthermore, the inner joint socket of the PEEK layer is made of Inconel 718 (nickel-based high-temperature alloy) to further reduce heat conduction to the internal MR fluid. A low-melting-point alloy is filled into the gap between the inner support component and the outer material around the coil. The magnetic-thermal composite structure is made of electrical pure iron (DT4C) with six copper heat-conducting strips integrated along the meridian direction and attached to the aluminum alloy shell. Considering thermal expansion, the copper strips are separated by 1mm at the equator of the joint socket. Both ends of the copper strips are in contact with the 1018 steel of the joint socket, but are not connected to each other. There are two heat dissipation logics: the first is: coil → low-melting-point alloy → magnetic-thermal composite structure (electrical pure iron + copper strips) → aluminum alloy shell → air. The second part is: the copper heat-conducting strip is connected to the 1018 joint socket material, and the working gap is MR fluid → 1018 joint socket → magnetic-thermal composite structure (electrical pure iron + copper strip) → aluminum alloy shell → air.

[0206] (10) Sealing. It has three layers of sealing from the inside out: a self-tightening scraper sealing ring made of polytetrafluoroethylene (PTFE) → titanium alloy metal bellows → highly elastic fluororubber. 5.2 Comparison of the maximum static holding torque and torque density of the joint in this embodiment with those of a smooth articular surface joint. A 60mm ball-head magnetorheological joint is designed with the field-induced medium in a state of magnetic saturation. The working area of ​​the joint surface is 8498 mm², the working temperature is within the optimal range, and the yield stress of the MR is 60 kPa.

[0207] The static holding moment (MR total shear moment) of a perfectly smooth joint = MR yield stress × articular socket area × radius = 15.2964 N·m In this embodiment, the static holding torque = total MR shear torque + normal compressive torque of the inverted trapezoidal wedge mechanical interlock + deep groove geometric engagement locking gain = 15.3 + 15.3 / tan(6°) + 10.0 Ns = 170.65 N·m. Considering the medium filling rate and micro-slip, the actual torque of the entire system is taken as 70%, which is 119.5 N·m. This is 7.8 times that of a smooth sphere, and the volumetric torque density is 1.02 Nm / cm³. 3 .

[0208] The maximum static holding force of the ball joint is proportional to the cube of the ball head diameter. For an 80mm ball head diameter, the maximum static holding force in this embodiment is 36.3 + 36.3 / tan(6°) + 17.0Ns = 398.15N·m. Considering the medium filling rate and micro-slippage, the actual torque of the entire system is taken as 70%, resulting in 278.7N·m.

[0209] 6. Other embodiments of field-induced rheological systems (1) As another variation, in another embodiment of the present invention, the joint unit may adopt a rheological-mechanical hybrid locking architecture, that is, integrating a secondary mechanical locking component (including ratchet, wedge, or friction plate) on the basis of fluid damping. In this configuration, the control unit executes hierarchical logic: in the dynamic adjustment stage, variable damping is provided by utilizing the rheological properties of the medium; in the rigid locking or power-off stage, the mechanical components are driven to engage (e.g., pawl engages with tooth groove) by utilizing the rheological force of the medium. Although this combination sacrifices some of the continuity of stepless adjustment, it is still a variation of the present invention that uses mechanical engagement as an auxiliary locking mechanism. However, this increases the system backlash, and the preferred solution is still the above-mentioned direct interlocking of the medium.

[0210] (2) In an optional embodiment of the present invention, the field-induced rheological medium is a dry magnetic powder. The dry magnetic powder is composed of micron- or nano-sized soft magnetic particles (e.g., carbonyl iron powder, atomized iron powder, or iron-cobalt alloy powder). These powders are directly filled or pre-pressed into the working gap between the joint socket and the ball head.

[0211] To ensure the uniformity and flowability of the powder within the gap, miniature vibrators (such as piezoelectric ceramic plates) can be placed at the bottom or side of the joint socket, or specific internal cavity structures (such as miniature guide ribs or powder storage tanks) can be designed on the joint shell to prevent excessive powder aggregation due to gravity or vibration when not in operation. When the excitation field is energized to generate a magnetic field, the magnetic powder particles within the gap will rapidly align along the magnetic field lines to form chain-like or columnar structures, thereby generating significant shear resistance between the joint surfaces and achieving joint locking. The advantages of this scheme are that the medium is not easily leaked and the response speed is extremely fast.

[0212] (3) In another optional embodiment of the present invention, the excitation field is a permanent magnet assembly. This assembly is not a simple fixed permanent magnet, but refers to a permanent magnet mechanism in which the magnetic field strength or direction can be dynamically adjusted.

[0213] One specific implementation includes: one or a group of high-performance permanent magnets, such as neodymium iron boron magnets, and a precision micro linear actuation system (such as a lead screw slide driven by a micro stepper motor). The permanent magnets are mounted on the moving parts of the actuation system. The actuation system is fixed to a specially designed mounting cavity outside or inside the joint housing. By controlling the stroke of the actuation system, the spatial distance between the permanent magnets and the working gap can be precisely adjusted, thereby achieving stepless continuous adjustment of the magnetic field strength passing through the gap.

[0214] (4) Another implementation method is a rotating permanent magnet assembly, which includes a pair of fan-shaped permanent magnets with opposite polarities. The relative rotation of the magnets is driven by a micro motor, which changes the closed path of the magnetic field lines and the magnetic flux through the working gap, thereby achieving magnetic field regulation. The advantage of the permanent magnet assembly solution is that it does not consume electrical energy when maintaining the locked state, achieving true zero static power consumption lock-up, which is particularly suitable for portable devices with strict requirements for battery life.

[0215] (5) In another embodiment of the present invention, in order to adapt to composite fluid media with complex responses, the excitation field employs a composite field generator. This device is designed as an integrated mechanism capable of applying two or more different types of physical fields.

[0216] A typical configuration is a magneto-electric composite field generator, consisting of coaxially nested electromagnetic coils and ring electrodes. The electromagnetic coils are responsible for generating a strong magnetic field perpendicular to the joint working gap; the ring electrodes (e.g., a pair or more conductive copper rings arranged around the working gap) are used to establish a high-voltage electric field within the working gap. An electric field can be applied first to prestructure the current components, and then a magnetic field can be superimposed to further strengthen the chain bundle by adding magnetohydrodynamic components, thereby generating a synergistic rheological effect and obtaining an overall shear modulus far exceeding that of a single field action.

[0217] This design enables the joint unit of the present invention to fully utilize the performance potential of composite smart materials and achieve wider range and more precise damping control through multi-physics field collaboration.

[0218] 7. Detailed description of the basic hardware structure and principle of the intelligent robotic arm system of the present invention. The basic architecture of an intelligent robotic arm system, such as Figure 16 As shown: This embodiment provides an intelligent robotic arm (fixed arm) system for surgical instrument positioning. The system mainly consists of a robotic arm, a base unit, and a control unit. The core structure of the robotic arm is a field-induced rheological joint unit. It should be noted that the 'intelligent robotic arm system' described in this invention is structurally a multi-degree-of-freedom serial robotic arm. It is called a 'fixed arm' to emphasize its application in surgery, but this does not preclude it from possessing general functions such as active motion, teleoperation, and trajectory tracking.

[0219] 7.1. Robotic Arm Structure The robotic arm employs a modular, serial design, consisting of multiple field-rheological joint units and connectors (links) alternately connected. One end of each link is sealed and rotatably connected to one of the joint units, while the other end is connected to the outer structure of another joint unit facing the external environment. This alternating "joint-link-joint" distribution structure provides high mobility (multi-degree-of-freedom), enabling it to simulate the joint movements of a human arm and meet the needs of different postures during surgery.

[0220] Additionally, a sterile barrier interface is provided on the system surface for use with sterile isolation covers, facilitating use in surgical settings.

[0221] 7.2 Base unit, such as Figure 16 As shown: To accommodate operating tables of different brands and structures (such as MAQUET and Stryker), the base unit uses a universal connector with interchangeable mounting modules.

[0222] Interchangeable mounting modules for the connectors can be secured to a support platform (such as the edge of an operating table) using one or more of the following methods: C-clamps, quick-clamping clamps, bolt fastening mechanisms, or magnetic adsorption mechanisms. This design gives the system a high degree of versatility, enabling rapid deployment in various operating room environments.

[0223] Preferably, the base unit also serves as a housing space, which can be equipped with a control unit, a battery and a charging port for charging the battery, as well as a power cord for direct connection to an external power source.

[0224] 7.3 Control Unit Configured to receive user commands and independently adjust the physical field intensity of each joint unit to achieve continuous damping adjustment from a low-damped movable state to a high-damped rigid locked state. Preferably, it is installed within the base unit.

[0225] The control unit independently adjusts each joint, breaking through the traditional fully open and closed joint unit mode. This allows for more precise adjustments, not only compensating for the gravitational torque of different joints based on the real-time posture of the robotic arm, providing doctors with a smooth dragging feel like 'zero gravity'; but also combining posture perception data to physically filter out the operator's high-frequency physiological tremors by adjusting fluid viscosity; and further, in remote operation, implementing 'selective damping distribution' for different joints to construct a tactile guidance path that conforms to the geometric constraints of the remote motor center (RCM) and virtual safety boundaries, so as to achieve a leap from passive fixation tools to active safe collaboration.

[0226] The control unit provides the field generator with a continuously variable effective value of excitation current or voltage by adjusting the duty cycle of the pulse width modulation (PWM) or the output amplitude of the digital-to-analog converter (DAC). The control unit utilizes the physical characteristic that the yield stress of the field-induced rheological medium and the field strength exhibit a quasi-linear or monotonically increasing relationship within the operating range to achieve continuous damping adjustment.

[0227] 7.4 End effector To facilitate intuitive, ergonomic control of the robotic arm by doctors, an end effector is provided at the end of the robotic arm (i.e., at the last link or joint), such as... Figure 16 As shown.

[0228] This end effector integrates a human-machine interface (HMI) module that communicates with the control unit. To adapt to different surgical scenarios and aseptic requirements, the HMI module includes, but is not limited to: a) Physical buttons / touch switches: used to trigger "one-click release" or "one-click lock" commands. For example, when the button is pressed and held, the control unit places all joints in a zero-field, low-damping state (motion phase), allowing the surgeon to drag freely; when the button is released, the system automatically enters a high-damping, locked state. b) Damping adjustment knob / slide: used to send continuous damping adjustment signals. The surgeon can continuously adjust the joint's viscous resistance by rotating the knob, freely switching between a "light and agile" and a "stable and viscous" feel to assist in precise operations. c) Voice control module: built-in or connected to a microphone array to recognize specific voice commands (such as "lock," "release," "increase damping"). d) Force / torque sensor interface: detects the surgeon's pushing and pulling intentions, achieving power assistance under admittance control.

[0229] 7.5 Aseptic Design To ensure convenient use in sterile settings such as surgery, the robotic arm employs one or a combination of the following sterile protocols: (1) End-of-line sterile sleeve disinfection protocol The end effector adopts a modular design, allowing for easy separation between its working part (head end) that directly acts on the surgical object and its handheld part (tail end). The handheld part can withstand aseptic sterilization processes involving high temperature, high pressure, or chemical reagents. After sterilization, it can be reconnected to the working part via quick-connect interfaces such as snaps, threads, or magnetic attachments. Furthermore, the end effector or robotic arm is equipped with a sterile barrier interface for attaching a disposable sterile isolation shield, achieving isolation from the surgical area.

[0230] (2) Overall one-time use plan The robotic arm is manufactured as a single-use sterile component. It connects to a reusable main unit containing drive and control units via a quick-release interface integrating electrical communication and mechanical locking functions. After a single surgery, the interface can be disconnected, the robotic arm can be discarded, and the main unit can be processed for future use.

[0231] 8. The intelligent robotic arm system of the present invention further integrates advanced system configurations such as pose perception, force feedback, safety monitoring, drive components and communication modules, as well as two of their effects.

[0232] like Figure 1 As shown: This embodiment illustrates a fully integrated configuration of the present invention. In this embodiment, the system further integrates a pose perception module, a force feedback module, a safety control unit, a drive component coupled to the robotic arm, and a communication module on top of the basic architecture, and executes corresponding intelligent control logic.

[0233] Preferably, the multi-degree-of-freedom robotic arm is equipped with a pose sensing module and a force feedback module, and the drive components are located on the base unit and coupled to the robotic arm via cables. Inside the base unit, in addition to a control unit, a battery and a charging port for the battery, and a power cable for direct connection to an external power source, a safety control unit and a communication module are also added.

[0234] In a specific embodiment comprising three field-induced rheological medium joints, the robotic arm employs a centralized tendon-driven design, integrating all three motors within the base, significantly reducing the inertia of the moving parts. The drive system utilizes a total of six steel cables, each driven by a corresponding motor. The cable for the first joint extends directly from the base; the cables driving the second and third joints pass through the rotational axis of their respective upstream joints, ensuring a constant path length during joint movement, thereby stably transmitting power to the drive wheels of their respective joints.

[0235] Its working principle is as follows: the motor drives a pull-pull system by winding and unwinding pairs of steel cables, thereby precisely controlling the rotation of each joint. This design achieves motion decoupling, enabling the robotic arm's end effector to flexibly and accurately reach a wide workspace, including all eight quadrants, in three-dimensional space, while ensuring the system's response speed and reliability.

[0236] 8.1 Overall Fail-Safe Mode of the Invention To achieve a fail-safe design, this system is equipped with an independent backup power module (such as a battery). When the system detects a main power failure, the backup power module is automatically activated, continuously supplying power to the field generator for a preset duration, ensuring that all field-induced rheological joint units remain in a highly damped, rigidly locked state. This mechanism provides crucial protection against instrument slippage due to power failure and provides a time window for executing safety procedures (such as system reset or activation of auxiliary braking).

[0237] 8.2 Cabling scheme for overall system integration of the present invention The control unit, field generator, drive components, pose sensing module, and actuator in the system achieve power distribution and data interaction through an electrical interconnection architecture.

[0238] Preferably, in one specific embodiment, to ensure the reliability of the robotic arm during multi-degree-of-freedom motion and to avoid interference, the electrical interconnection lines are integrated inside the robotic arm body. Specifically, the lines can be arranged in the hollow cavities of the connecting rods and field-rheological joint units, and a dynamic wiring design (e.g., through slip rings or flexible wire harnesses) is used at the joint movement points to ensure continuous electrical connection.

[0239] System cabling scheme The system's control unit, field generator, drive components, posture sensing module, force feedback module, safety control unit, communication module, end effector, battery, and other electrical components are integrated into a single electrical interconnection architecture to achieve power distribution and data communication.

[0240] Preferably, to ensure the reliability of the robotic arm during multi-degree-of-freedom motion and to avoid motion interference, all electrical wiring is integrated inside the robotic arm body. Specifically, power lines and signal lines can be routed within the internal cavities of the linkages and field-rheological joint units or in dedicated cable trays. At joint movement points, dynamic wiring designs (e.g., through slip rings, flexible printed circuits, or dedicated flexible cable harnesses with reserved redundant lengths) are employed to ensure the continuity and reliability of electrical connections.

[0241] 8.3 The adaptive flutter suppression mechanism based on physical impedance modulation in this invention This invention provides a flutter suppression scheme that utilizes field-induced rheological medium property modulation to achieve energy dissipation, such as... Figure 17 As shown, its core logic lies in converting high-frequency vibration kinetic energy into physical heat energy, rather than relying on the motion compensation of the drive components.

[0242] (1) Signal acquisition and spectrum separation: The system acquires spatial micro-motion data in real time through a pose sensing module (with a high sampling rate of 1000 Hz) deployed on the end of the robotic arm or key links. The control unit uses a bandpass filtering algorithm to accurately separate the 8-12 Hz physiological tremor signal from the <2 Hz operation intention signal.

[0243] (2) High-frequency field impedance modulation: Once the flutter amplitude exceeds the preset safety threshold, the system does not trigger the reverse compensation of the drive motor, but instead adjusts the excitation current of the field generator through the control unit at high frequency. Physical principle: Utilizing the millisecond-level viscosity adjustability of the field-induced rheological medium, a dynamic energy dissipation barrier is formed inside the joint. When the flutter energy attempts to be transmitted through the joint, the medium in the intermediate viscous state, combined with the protruding topology of the surface, generates extremely high local shear resistance. This resistance is proportional to the flutter velocity, thereby efficiently absorbing and dissipating the flutter kinetic energy.

[0244] (3) Technical advantages and beneficial effects: Unlike traditional motor reverse drive schemes, this scheme belongs to "passive / semi-active energy consumption braking", which does not involve the phase lag problem of the control system in closed-loop feedback, fundamentally eliminating system oscillation or instability caused by compensation delay. Tactile transparency: Since the modulation frequency is much higher than the bandwidth of human tactile perception, doctors can only feel the joints becoming "silky and heavy" during operation, without perceiving discrete adjustment pulses, which significantly improves the immersion and safety of the operation. Lossless suppression: By converting kinetic energy into a small amount of heat energy and quickly dissipating it through the aforementioned heat-conducting components, a long-term and stable vibration filtering effect is achieved.

[0245] 8.4 This invention is based on a force feedback and "virtual wall" security mechanism using active impedance modulation. This invention provides operators with real-time force perception through continuous impedance adjustment of field-induced rheotropic media and constructs a physical-level safety defense boundary, such as... Figure 18 As shown. The system integrates a pose sensing module, a force feedback module, a safety control unit, and a control unit.

[0246] (1) Progressive force feedback (“quagmire” effect): The system utilizes a force feedback module and a pose sensing module deployed at the end effector for multi-source data fusion: Dynamic impedance mapping: When the end effector is detected approaching a preset spatial safety boundary (such as the edge of the RCM constraint range or the anatomical structure buffer zone), the control unit does not immediately brake, but instead proportionally increases the field intensity of the corresponding joint unit according to the distance / torque gradient curve. Physical sensing: As the damping coefficient increases nonlinearly, the operator will feel a unidirectional, gradually increasing viscous drag. This drag is physically provided by the shear stress of the medium, simulating a "virtual viscous fluid" texture, intuitively reminding the operator that they have entered the warning zone, achieving a smooth transition from free movement to restricted movement.

[0247] (2) Instantaneous rigid locking (“virtual wall” effect): When a risk of extreme obstacle crossing occurs, the system performs a step switch from "energy dissipation" to "pose fixation": Threshold-triggered forced locking: Once the applied force or displacement exceeds the preset safety limit (critical threshold), the safety control unit instantly switches the relevant joints to high field strength mode. Physical interference locking: At this time, the field-induced rheological medium undergoes a solid-state-like phase transition, and together with the grooved topology of the surface, forms a physical-level mechanical engagement. This locking has high static stiffness, which can effectively counteract the motion inertia of the robotic arm and external misoperation forces, forming a physically insurmountable "virtual wall" to ensure that the device never enters the restricted area.

[0248] (3) Beneficial effects: Intrinsic Safety: Unlike virtual walls defined by pure software algorithms (which are prone to failure due to motor overshoot), the safety boundary of this invention is supported by the physical properties of the medium, possessing extremely high reliability and real-time response capabilities. Tactile Transparency and Interaction Depth: This feedback based on physical impedance eliminates the step oscillation sensation of traditional motor brakes, providing doctors with a more delicate and realistic force feedback experience, greatly reducing the cognitive load during complex surgeries.

[0249] 9. This invention also provides a hybrid drive energy-saving control method based on property-based phase feedback, such as... Figure 19 As shown 9.1 Further, a drive component (such as an electromagnetic drive component), a communication module and a communication device are configured within the base unit. The drive component (such as an electromagnetic drive component) is coupled to the multi-degree-of-freedom robotic arm. For an embodiment of this system that includes coupling of an electromagnetic drive component (such as a servo motor) and a field-induced rheodynamic joint (such as a magnetorheological joint), the control unit is further configured to execute a hardware-and-timing coordinated 'motion-locking time-sharing multiplexing' hybrid drive energy-saving control method.

[0250] 9.2 This embodiment details how the control unit collaboratively manages power drive components (such as servo motors) and field-rheological joint units to achieve optimal configuration of system-level energy efficiency. The core logic of this method lies in functionally decoupling the two physical tasks of "dynamic driving" and "static maintenance".

[0251] (1) S1 dynamic motion stage: dynamic response optimization Upon receiving a continuous motion command, the control unit enters the power output mode. At this time, the power drive component receives its rated voltage to output torque. Simultaneously, the field generator remains deactivated, keeping the field-induced rheological medium (such as a magnetorheological fluid) in a low-viscosity state.

[0252] Technical benefits: This configuration minimizes resistance within the joints, improves the dynamic response speed of the robotic arm, and reduces instantaneous power consumption during movement.

[0253] (2) S2 damping braking and switching sequence: smooth torque transfer When the joint position sensor detects that the robotic arm has reached the target coordinates (such as entering the preset micron-level error bandwidth), the control unit activates the "power-damping balance" switching logic.

[0254] Step 1 (Physical Intervention): The field generator receives the excitation signal, and the medium solidifies instantaneously. At this time, the shear force generated by the phase change of the medium and the mechanical interlocking effect of the groove array together construct a "physical impedance barrier".

[0255] Step 2 (Load Confirmation): The control unit continuously monitors the feedback current of the drive motor (the current value represents the current holding torque) and gradually reduces the motor power to zero. If the position can still be maintained, it indicates that the physical locking torque has successfully borne the external load (such as the weight of surgical instruments).

[0256] Step 3 (Power Cut-off): After confirming that the position is stable and there is no slippage, the system completely cuts off the power supply to the power drive components.

[0257] (3) Zero-power static holding phase of S3 drive component: intrinsically safe locking During the lockout phase, the system enters a low-energy state. At this time, the power drive components are in a zero-energy standby mode, eliminating Joule heating generated by the motor coils due to prolonged stall.

[0258] 9.3 Beneficial effects: (1) The joint of the present invention has a strong static torque through the combined effect of mechanical interlocking and the shear resistance of the medium, so the motor can still be shut off under high load conditions. This solves the problem of traditional servo motor joints being locked for a long time to maintain posture and the coils being severely overheated (the paradox of static and energy consumption). This design significantly reduces the energy consumption during the static holding phase (only the magnetorheological joint magnetic field needs to be maintained), avoids the risk of motor overheating, and is particularly suitable for surgical robots, industrial robots, robotic arms, humanoid robots, wearable exoskeletons, camera gimbals, etc., which need to maintain a fixed posture for a long time.

[0259] (2) Filtering out “motor ripple” interference: In high-precision applications (such as microsurgery), the tiny vibrations (ripples) of the motor can be amplified to the end. In this embodiment, the motor is shut down during the locking phase, and the physical rigidity of the solidified medium is used to eliminate electronic vibrations, providing a basis for absolute silence for precision operations.

[0260] 10. This invention also provides a motion control method based on local real-time calculation and physical safety constraints, such as... Figure 20 As shown 10.1 The method in this embodiment achieves a safe mechanism that transforms digital instructions and geometric constraints into local real-time solutions and physical impedances through the synergistic effect of the local control unit and the field-induced rheological joint unit.

[0261] In this specification, the term "real-time" specifically refers to the low-latency response ensured by local edge computing, in stark contrast to control systems that rely on remote communication. "Real-time" here does not mean absolute zero latency, but rather that its response latency (e.g., less than 10 milliseconds) is far below the perception threshold of human operators and the critical requirements of surgical safety scenarios, thus achieving an equivalent of "zero latency" in terms of user experience and system safety. The local control unit directly processes information and drives the joints; this localized computation eliminates packet loss, latency, and uncertainty in remote communication links, forming the basis for achieving physical-level security boundaries.

[0262] 10.2 Detailed Step-by-Step Explanation: S1: Receive target motion commands. The local control unit receives motion target commands from a remote console, local human-machine interface device, automated planning algorithm, or real-time teleoperation signals.

[0263] S2: Obtain spatial geometric constraints. The system loads a preset or real-time generated geometric constraint model, the types of which include, but are not limited to, point constraints (such as RCM), surface constraints (such as virtual safety boundaries), or path constraints.

[0264] S3 and S4: Local Motion Calculation and Constraint Conflict Prediction. The local control unit performs real-time inverse kinematics calculation, decomposing the desired end-effector motion into desired motion commands for each joint. Based on the calculation results, the actual trajectory of the robotic arm's end-effector is predicted proactively. One or more critical conflict joints that will cause the end-effector to violate the spatial geometric constraints are identified.

[0265] S5: Physical and Energy Co-operation: Generates coordinated control signals and performs the following operations: Physical side: Activate the field generating device in the conflict joint group, and switch the joint to a high-damping rigid locking state through the phase change of the physical properties of the field-induced rheological medium and the mechanical interlocking effect between it and the surface groove topology. Power side: Synchronously suppress or shut down the power drive components corresponding to the conflicting joint groups to eliminate residual drive energy.

[0266] This forces the end effector's motion trajectory to conform to the spatial geometric constraints, while the remaining non-conflict joints maintain their degrees of freedom to preserve local flexibility.

[0267] 10.3 In one advanced embodiment of the present invention, the local control unit further integrates an energy feedback braking circuit. This circuit deeply couples the deceleration braking process of the motor with the curing process of the field-induced rheological medium at the electrical level: Kinetic energy-excitation conversion logic: When the system identifies a critical joint and executes a safety constraint command, the drive motor enters an external braking or reverse electric state. At this time, the reverse electromotive force generated by the motor's inertial rotation is not dissipated through resistance, but is directly pumped to the field generation device (excitation coil) of the joint via the conversion circuit.

[0268] Physical effect – “self-excited” instantaneous locking: Response multiplication: The greater the kinetic energy of the motor, the stronger the instantaneous induced current generated. This means that when a joint encounters a safety boundary during high-speed movement, the field generator can obtain a stronger instantaneous pulse current than a conventional power supply, thereby significantly accelerating the phase transition speed of the rheological medium from "liquid" to "solid".

[0269] Forced physical energy dissipation: This mechanism essentially converts the residual mechanical kinetic energy of the robotic arm into the potential energy and frictional heat of the field-induced rheological particles. The solidification process of the medium directly absorbs the inertia of the motor, achieving simultaneous completion of "physical energy dissipation - rigid locking". Technical significance: It avoids the resistance temperature rise caused by traditional energy-consuming braking, concentrates energy for field modulation, and reduces the instantaneous pressure on the internal integrated thermal management system.

[0270] 10.4 The technical advantages of this method are: 1) Inherent High-Reliability Security Constraints: The security mechanism of this invention is achieved through a combination of local computing power and the physical characteristics of the joints. Geometric constraints are transformed into physical barriers through the instantaneous solidification of the field-induced rheological medium and the mechanical interlocking effect. This mechanism does not rely on continuous software instruction loops or remote communication, thus it can withstand software anomalies, system failures, and network interruptions, providing a higher level of inherent security assurance.

[0271] 2) Ingenious configuration and selective locking capability: Based on the composite function of field-induced rheological joints, the system structure is simplified and lightweight. By independently and precisely adjusting the damping state of each joint, "selective regional physical locking" can be achieved. This means that during the movement of the robotic arm, joints that violate safety constraints can be dynamically and physically frozen, while the remaining joints retain full degrees of freedom of movement. This enables flexible local movement while ensuring overall safety, greatly expanding the operational capabilities in complex and confined spaces.

[0272] 11. The present invention also provides a method for positioning surgical instruments, (e.g.) Figure 19 (As shown) An embodiment of a surgical instrument positioning and interactive control method: This invention provides a precise positioning method for surgical instruments based on field-induced rheological physical properties. Its core lies in utilizing the adjustable rheological properties of the medium and the geometric interference effect of the surface to achieve a dynamic balance between "lightweight adjustment" and "absolute locking".

[0273] (1) Posture Adjustment Stage: Reconstruction of Degrees of Freedom and Optimization of Tactile Sensation In the S1 adjustment stage, the system performs differentiated control according to the doctor's operational intention: Drag-and-reconstruction mode: When a full-position adjustment command is received, the local control unit synchronously reduces the excitation current of each joint field generator. The field-induced rheological medium quickly switches to a low-viscosity flow state, allowing doctors to overcome minute viscous forces through external force (hand dragging), enabling rapid and smooth displacement of the robotic arm end effector in three-dimensional space.

[0274] Localized micro-adjustment: In a preferred embodiment, the system supports “selective degree-of-freedom release.” By reducing the damping of only specific joint units while keeping the remaining joints in a highly damped locked state, the surgeon can make precise, one-dimensional adjustments to the insertion depth or rotation angle of the instrument while maintaining the surgical access path (RCM) unchanged.

[0275] Physical vibration filtering mechanism: To further optimize surgical precision, this method supports "damping adaptive adjustment." By maintaining the field strength at an intermediate energy level, the medium is kept in a semi-solid intermediate viscous state. This state utilizes the high-frequency shear energy dissipation characteristics of fluids to construct a physical-level low-pass filter that can effectively absorb and dissipate physiological tremors from the operator's hand (typically high-frequency micro-amplitude jitters of 4-12Hz), providing doctors with stable and smooth visual and tactile feedback.

[0276] (2) Position Locking Stage: Based on geometric interference, zero-drift fixation occurs during the S2 locking stage. The system executes a step excitation response: when the instrument reaches the predetermined target position, the system instantaneously activates the field generator. The field-induced rheological medium completes the phase transition from fluid to solid state within milliseconds, resulting in an order-of-magnitude increase in its shear yield strength. Unlike traditional braking methods that rely on friction, this invention utilizes the spatial physical interlocking between the solidified medium and the surface groove / protrusion topology. This "geometric interlocking" effect provides the joint with high static stiffness, eliminates minute displacement drift caused by gravity loads or external thrust, and ensures the absolute stability of the spatial coordinates of the surgical instrument during long-term operation.

[0277] Typical application scenarios: The actuation system based on field-induced rheological effect, the intelligent robotic arm system, the hybrid drive energy-saving control method based on material property phase feedback, and the motion control method based on local real-time calculation and physical safety constraints of the present invention have wide applicability.

[0278] Scenario 1: Application Solution of Bionic Energy-Saving Joints for Humanoid Robots Application Background and Industry Pain Points: When humanoid robots operate in unstructured environments (such as homes, factories, and outdoors), their joint systems face extremely high dynamic challenges: Energy loss and impact in the dynamic phase: When the heel touches the ground, the transient shock wave from traditional rigid transmission directly acts on the precision reducer, easily causing gear breakage; and the internal resistance of the motor during the swinging process leads to a bottleneck in endurance. The "energy consumption paradox" in the static phase: When standing still or maintaining posture under load, traditional servo motors must continuously output stall current. This "power consumption for stillness" mode results in short robot endurance and significant joint temperature rise, severely affecting the detection accuracy of precision encoders.

[0279] The system integration scheme of this invention integrates the field-induced rheological actuation system (hereinafter referred to as the "actuation unit") described in this invention into the hip, knee, and ankle joints of a humanoid robot. The actuation unit and the servo motor form a hybrid drive architecture of "dual power source / dual braking source".

[0280] Field-structure coordinated operation strategy (S1-S4) S1: Description of "Bio-grade" compliant cushioning during dynamic walking: transition from heel contact to support phase. Physical implementation: The control unit adjusts the field strength within the working gap in real time. Controlled microvortices are induced within the medium using the discontinuous height undulation microstructure described in this invention. Technical advantages: The actuation unit then acts as a "variable stiffness damper," absorbing the peak impact of ground reaction force within milliseconds. This physical energy absorption mechanism protects the harmonic reducer, simulates the eccentric contraction cushioning of human muscles, and achieves a biomimetic compliant walking feel.

[0281] S2: Description of "Zero Energy Consumption" Physical Interlocking Working Condition under Static Support: Standby with both feet upright, maintaining stillness while carrying heavy objects, or unexpected power failure. Physical Implementation: The control unit detects that the angular velocity is zero and immediately increases the field strength to the saturation threshold. Interlocking Mechanism: The medium rapidly solidifies within the inverted trapezoidal groove, forming a virtual rigid wedge. Subsequently, the system executes the "motor sleep" sequence. Technical Advantages: The joint torque is provided by the physical layer of "field-induced mechanical interlocking". Due to the self-locking effect of the β angle, only a very weak holding current (or even the permanent magnet bias field) is needed to counteract the huge gravitational torque. Experiments show that standby energy consumption is reduced by more than 95% in this mode, and due to the absence of current heat loss, the zero-point drift problem caused by temperature rise of the sensor is completely solved.

[0282] S3: Thermodynamic Challenges under Complex Gait: During continuous mountain climbing or rapid running, frequent coil excitation generates a large amount of heat. Solution: Utilizing the magnetic-thermal decoupling conduction path of this invention. Technical Advantages: The generated Joule heat is rapidly and directionally pumped to the joint's aluminum alloy shell through a three-dimensional interpenetrating network heat-conducting component. Even during high-temperature outdoor operations in summer, the encoder and drive circuit inside the joint are always protected by a thermal barrier structure, ensuring long-term stability of complex gait control.

[0283] S4: Reliability Assurance for Long-Term Operations. Operating Condition Description: The robot is started after a long period of inactivity, or operates in extremely low-temperature environments. Physical Implementation: Utilizing the centrifugal pressure gradient generated by rotor rotation. Technical Advantages: The medium within the circulation tunnel spontaneously circulates from the initial stage of movement; the micro-textures on the inner wall induce secondary flow, rapidly activating any potentially deposited solid particles. This ensures that the actuation system does not suffer from the risk of jamming due to "hard settling," enhancing the robot's deployment capabilities in extreme environments.

[0284] Solution Summary Compared to traditional hydraulic or pure electric motor solutions, this invention achieves the following leaps in humanoid robot joints: Ultra-high torque density: Utilizing the magnetic flux overflow effect, it provides holding force more than three times that of traditional magnetorheological joints within the same volume. Intrinsically safe: The self-locking function under power failure protection prevents the robot from being damaged by a "kneeling" fall. Extremely simplified control: By achieving preset damping characteristics at the physical level through spatial gradient distribution, it reduces the computational burden on the host computer control algorithm.

[0285] Scenario 2: High-end film and television shooting and photoelectric tracking gimbal ultra-stabilized imaging application solution 1. Application Background and Technical Challenges In applications such as high-speed vehicle tracking, astronomical observation, and long-range photoelectric tracking, gimbal systems need to support sophisticated telephoto optical equipment, presenting extremely demanding challenges: Motor Ripple Interference: Traditional direct-drive motors, when stationary, generate micro-vibrations at the micrometer level due to dead zones in current regulation and cogging torque pulsations. These micro-vibrations are amplified into severe image jitter at the telephoto end, leading to failure in long exposures or high-magnification monitoring. Energy Consumption and Overheating under High Wind Loads: In vehicle-mounted camera movements or strong winds in the wild, the motor consumes a huge current to combat wind resistance. This not only leads to a sharp drop in battery life but also generates heat that can cause thermal distortion in the optical lens assembly, affecting image quality. "Dry-Back" and Start-up Shock: Traditional mechanical gear transmissions have physical gaps, generating shocks during reversals, disrupting the smoothness of the image.

[0286] 2. Based on the implementation scheme of the present invention, the actuation system with asymmetric field modulation interface described in the present invention is integrated into the pitch axis and yaw axis of the gimbal as a parallel power coupling unit of the servo motor.

[0287] 3. Core operating mode and physical advantages (S1-S2) S1: Dynamic Camera Movement Stage – Simulating the silky-smooth damping control logic of “top-tier hydraulics”: When the photographer pans or tracks a target, the control unit sets the field strength to a low to medium level. Physical Mechanism: Utilizing a non-integer ratio design of the first and second spatial cycles (P1 / P2). Technical Advantages: Elimination of Physical Dead Zones: Due to the field-induced rheological medium filling the working gap, this continuous liquid contact completely eliminates the “backlash” of mechanical transmission. Vernier Smoothing Effect: The non-integer ratio cycle design ensures that the damping torque remains constant at any relative angle. It exhibits a “viscous texture” similar to a high-end hydraulic gimbal, effectively filtering out discrete jumps and hand tremors generated by the motor control algorithm. The camera movement presents cinematic-level linear acceleration and deceleration effects, requiring no post-production software stabilization.

[0288] S2: Static Gazing Phase – “Zero Vibration” Physical Freeze and Wind Resistance (Core Advantage) Control Logic: When composition lock is detected or long exposure shooting begins, the “field strength focusing – power supply shutdown” sequence is executed. Physical Mechanism: Utilizing the magnetic flux overflow effect, a virtual rigid wedge is instantly induced within the gap, forming a physical engagement with the inverted trapezoidal groove. Technical Advantages: Pixel-level Image Stabilization (Vibration Reduction): After confirming physical lock establishment, the servo motor power is completely shut off. Since the pose is maintained by the fixed “field-induced mechanical interlock” structure, there is no current ripple or electromagnetic noise within the system. This “absolute stillness” eliminates micro-vibrations at the physical source, ensuring pixel-level clarity during long exposure shooting. High Rigidity and Wind Resistance: Thanks to the self-locking mechanism of the β angle (2°<β<35°), the joint possesses extremely strong torsional rigidity. Even in high-speed vehicle-mounted tracking shooting or in wind conditions of force 8, the gimbal remains as stable as a rock, without consuming battery power to combat external wind loads, increasing endurance several times over.

[0289] 4. Defense Logic Summary for the Film and Optoelectronics Industries: Surpassing the Stability of "Pure Electric Drive": Comparative experiments demonstrate that this invention solves the most troublesome "motor micro-vibration" problem in telephoto photography by replacing "current stall" with "physical locking." This is a significant improvement over existing gimbal technology, demonstrating a high level of innovation. Thermal Shielding Protection for the Optical System: Utilizing a thermal barrier structure, heat generated by the actuation system is prevented from being conducted to the sensitive optical CCD or lens group, avoiding heat-induced image drift and chromatic aberration—a mandatory requirement for professional optoelectronic tracking equipment. All-Weather Operation Capability: Secondary flow induced by the internal wall microstructure ensures that the actuation system can still instantly activate and cycle even at low temperatures or after long-term static placement in the field, without gimbal "stuttering" or starting shock due to media sedimentation.

[0290] Scenario 3: High-fidelity haptic rendering solution for metaverse / VR force feedback interaction devices 1. Application Background and Haptic Rendering Bottlenecks In VR exoskeleton gloves, force feedback master hands, or medical surgical simulators, ideal haptic rendering requires an extremely wide dynamic impedance range: Low impedance requirement (transparency): When a user waves their hand in virtual space, the joint must be "transparent," without any mechanical resistance interference. High impedance requirement (rigidity limit): When a user grasps a "virtual rigid body" (such as an iron bar or stone) or strikes a "virtual wall," the joint must instantly provide extremely high rigidity locking. Existing technology limitations: Traditional magnetorheological joints use smooth interfaces, and their maximum resistance is limited by the shear yield strength of the material itself. Under high-intensity gripping, the smooth interface will experience "viscous slippage," and the user will not feel a "rigid hard object," but rather a creeping sensation similar to "extremely hard paste" or "thick rubber," leading to a complete breakdown of immersion.

[0291] 2. The system integration scheme of the present invention integrates the actuation unit with the asymmetric field modulation interface described in the present invention into the nodes of the finger joints of the exoskeleton glove and the force feedback robotic arm.

[0292] 3. Core Haptic Rendering Timing and Physical Advantages (S1-S3) S1: High transparency and fine graininess simulate scene description: A finger moves in virtual air, or touches objects with slight resistance such as silk. Control logic: The field generator is in a zero-field or extremely weak-field state. Physical advantages: Benefiting from the non-integer ratio design of the first and second spatial cycles (P1 / P2). Technical effects: This design physically eliminates the "groove feel" of traditional motors or symmetrical structures. When the user's finger moves, the field impedance remains highly uniform, ensuring extremely low noise resistance at the joint in the zero-field state, achieving high-transparency motion tracking, and perfectly recreating a "light" tactile sensation.

[0293] S2: A linear transition from "flexible" to "viscous," scenario description: pressing a sponge, stirring a viscous liquid. Physical implementation: utilizing the spatial gradient distribution of microstructural features. Technical effect: as the user's grip depth increases, the joint enters different field impedance gradient regions. The control system does not require high-frequency current adjustment; it only relies on the gradient change of the geometric topology to achieve nonlinear damping force that automatically changes with displacement, simulating the realistic feedback of elastic bodies and viscous fluids in the physical world.

[0294] S3: Transient Rigid Collision and "Zero Slip" Locking Scene Description: Gripping a steel pipe, punching a wall, or operating a virtual scalpel to touch bones. Physical Mechanism: Upon detecting a collision, the field strength rapidly rises to the saturation threshold. Field-Structure Synergy: Utilizing the magnetic flux overflow effect, the solidified medium rapidly aggregates into clusters within the inverted trapezoidal groove, forming a virtual rigid wedge. Technical Effects: Breaking Through the Physical Limits: The torque mechanism transitions from "shearing" between fluid layers to "mechanical interlocking" of the structure. Absolute Rigidity: Thanks to the self-locking effect of the β angle (2° < β < 35°), the joint instantly generates extremely high anti-slip stiffness. Users experience an insurmountable hard barrier, just like in the real physical world, completely eliminating the "viscous slip" feeling of traditional MR joints and achieving a true "iron rod" feel in the rendering.

[0295] 4. The defense logic for the VR / haptic industry addresses the common industry problem of "rigid bodies not being rigid": By combining "virtual rigid wedges" with "asymmetric textures," the field-induced rheological medium is endowed with mechanical properties exceeding the limits of its material properties. High-frequency response and low latency: Utilizing the overflow field induced by local magnetic saturation accelerates the solidification process of the medium at the groove opening, significantly shortening the latency of haptic feedback and improving the real-time performance of the interaction. Miniaturization and wear-free operation: The curved transition design of the groove bottom ensures structural strength even with a small configuration. Due to its non-contact locking, the device maintains its original accuracy after millions of "collision" tests, solving the pain points of traditional mechanical locking devices such as easy wear and short lifespan.

[0296] Scenario 4: Energy-saving joint-assisted application solution for wearable exoskeleton robots 1. Application Background and Technical Challenges: In industrial heavy-duty applications, military reconnaissance, and rehabilitation medicine, exoskeleton robots need to assist the human body in bearing enormous vertical loads. Traditional solutions suffer from the following bottlenecks: "Zero-speed, high-torque" energy consumption trap: When the user maintains a stationary posture such as a semi-squatting position for lifting or waiting to be lifted, traditional electrically controlled joints require the motor to continuously output peak current to counteract gravity, causing the battery to be depleted in a very short time. Risk of thermal burns: Because the motor is extremely inefficient under high load and stationary conditions, a large amount of electrical energy is converted into Joule heat. Excessive temperature rise of structural components in close contact with the human body can directly cause thermal damage or severe discomfort to the wearer. Inconsistent mechanical locks: While traditional ratchet locks can save power, they are "stepped locks," meaning the user cannot stop at any natural angle, and the mechanical impact during unlocking can easily disrupt the balance of human-robot collaboration.

[0297] 2. Based on the implementation scheme of the present invention, the actuation system with asymmetric field modulation interface described in the present invention is integrated into the knee joint, hip joint and elbow joint of the exoskeleton.

[0298] 3. Core operating mode and physical advantages (S1-S3) S1: Dynamic Following Stage – “Transparent” Follow-up and Zero-Sensitive Assist Control Logic: When the sensor array detects a stepping or arm-swinging signal, the control unit sets the field strength to zero. Physical Advantages: Thanks to the non-integer ratio design of the first and second spatial cycles (P1 / P2), the residual magnetoresistive torque of the joint in the zero-field state is extremely low. Technical Effects: Eliminates the “cogging sensation” of traditional gear reducers, resulting in excellent smoothness during joint movement. Users do not feel the physical constraints of the exoskeleton, and the servo motor can output dynamic assistance more efficiently, achieving true “human-machine integration.”

[0299] S2: Static Support Phase – “Stepless Locking” and Zero Energy Consumption Maintenance (Core Advantage) Control Logic: Upon detecting a human body entering a static load-bearing posture, the “field strength activation – motor sleep” sequence is executed. Physical Mechanism: The medium instantly forms a large number of virtual rigid wedges within the inverted trapezoidal groove. Technical Effects: Stepless Locking at Any Angle: Due to the asymmetric microstructure distributed across the entire circumference / sphere, the joints can achieve instantaneous locking at any position throughout the entire stroke. The physical interlock can be established at any angle the worker wants to stop at. Energy Revolution: Due to the self-locking force component mechanism of the β angle (2° < β < 35°), the torque required to maintain the load is entirely provided by the normal pressure of the microstructure sidewalls, rather than energy consumption. After the motor power supply is cut off, the robot enters the “physical skeleton support mode,” increasing endurance by over 300%, and the joint area temperature remains within a comfortable range for the human body.

[0300] S3: Emergency Fall Protection – Physically-Level Intrinsic Safety Detection: The system detects instability or accidental fall. Control Strategy: The control unit rapidly switches field strength using spatial gradient distribution. Physical Advantages: Joints do not instantly "lock" like traditional mechanical locks, preventing secondary fractures, nor do they "lose power" like pure motors. It utilizes the viscoelasticity of the field-induced rheological medium to provide a progressive safety buffer damping. Technical Effects: Like a parachute, it absorbs falling energy, slowing the joint collapse speed and providing "soft landing" protection for the user. This safety guarantee based on physical characteristics is unmatched by traditional rigid transmission systems.

[0301] 4. Breakthrough in overcoming the limitations of "leveled locking" in response to competitors' defense logic: Emphasizing that our texture design achieves a unity of "fluid-level flexibility" and "mechanical-level rigidity," refuting competitors' claims that it is "not as robust as mechanical locks" or "not as smooth as motors." Physical guarantee of thermal comfort: Utilizing an integrated thermal management system, we clearly define the protection of the human body by heat-conducting components, a mandatory threshold for the civilian and safe application of exoskeletons. Long-term maintenance-free operation: Through media circulation tunnels and secondary flow design, we ensure that the exoskeleton will not fail due to media sedimentation in complex environments such as the field and construction sites, establishing an industrial-grade reliability standard.

[0302] Scenario 5: Aerospace Solar Panel Deployment and On-Orbit Locking Application Solution 1. Application Background and Aerospace-Grade Pain Points: The deployment mechanisms of solar panels (energy wings) in spacecraft such as artificial satellites and deep space probes operate under extremely harsh environmental conditions: Vacuum cold welding risk: In a high-vacuum environment, once the oxide layer on the metal surface wears away during launch vibrations, the exposed metal atoms will spontaneously diffuse and adhere. The hard contact of traditional mechanical locks (such as ratchet or pin) can easily induce this irreversible jamming, preventing the solar panels from fully deploying and even causing complete mission failure. Mechanical impact during launch: The rocket's ascent phase is accompanied by severe high-frequency vibrations and impacts. Traditional rigid locking mechanisms, due to their "hard-on-hard" contact, lack energy dissipation capabilities, easily leading to fatigue cracks in the battery array. The contradiction between lightweight design and multi-functionality: Spacecraft are extremely sensitive to loads. Existing technologies often require two independent systems: a "vibration damper" and a "locking device," which not only increases mass but also reduces system reliability due to structural complexity.

[0303] 2. Based on the implementation scheme of the present invention, the field-induced rheological actuation system with an asymmetric field modulation interface described in the present invention is used as the core of the unfolding hinge. A special field-induced rheological medium with low volatility and radiation resistance (such as perfluoropolyether-based PFPE fluid) is selected.

[0304] 3. Core operational strategies and physical advantages (S1-S3) S1: Launch Phase – Physical Implementation of "Omnidirectional Energy Absorption Protection" Based on Fluid Viscosity: During rocket ignition and ascent, the control unit adjusts the field intensity to a preset moderate level. Technical Advantages: Utilizing the confined shear flow generated by the fluid medium within the microstructure undulations. The actuation system is transformed into a high-performance "nonlinear damper," converting high-frequency vibration energy into heat dissipation. Compared to traditional mechanisms, its physical compliance provides excellent dynamic load filtering for the precision solar array, avoiding rigid impacts.

[0305] S2: Deployment Stage – The Physical Mechanism of the “Non-Contact Physical Barrier” Against Cold Welding: Thanks to the non-contact working gap defined in this invention, the rotor (solar plate connector) and stator (satellite substrate) are always isolated by a dielectric layer. Technical Advantages: This “metal-fluid-metal” interface architecture physically severs the path to atomic-level metal contact. Even under extremely high vacuum, the dielectric layer, acting as a natural physical barrier and lubricating film, completely eliminates the physical conditions for vacuum cold welding, ensuring the determinism and high reliability of the deployment process.

[0306] S3: On-orbit Phase – Zero-Drift Rigid Locking Based on Mechanical Interlocking (Core Innovation) Locking Operation: After the solar panel is deployed, the magnetic flux overflow effect is activated, followed by the execution of a hybrid drive energy-saving sequence. Interlocking Mechanism: The medium solidifies in the inverted trapezoidal groove, forming a virtual rigid wedge that deeply engages with the textured surface. Technical Effects: Qualitative Change in Static Holding Torque: Utilizing the self-locking effect of the β angle, the system switches from fluid mode to physical locking mode. The structural shear resistance (>100 N·m) provided far exceeds that of traditional smooth surface media, achieving gapless rigid locking in orbit. Zero Power Consumption and Thermal Stability: Relying on the physical structure to maintain the lockout, there is no need to continuously consume the satellite's precious electrical energy. Simultaneously, utilizing the magnetic-thermal decoupling conduction path, the system can still maintain extremely high dimensional stability under drastic diurnal temperature variations, avoiding solar panel vibration caused by thermal stress. 4. A summary of system-level advancements in aerospace defense logic: The invention emphasizes to the examiner that it simultaneously solves three contradictory problems—"cold welding resistance," "flexible vibration resistance," and "rigid interlocking"—with a single hardware solution. This highly integrated design concept represents a significant leap in innovation compared to the simple superposition of multiple traditional systems. Full lifecycle protection of the physical interface: Because the system remains non-contact in all motion states, there is no mechanical wear on the microstructure surface. This means that its mechanical properties will not degrade due to the severe vibrations during launch, addressing the pain point of spacecraft being "unrepairable after launch." Breakthrough in material limitations: The inverted trapezoidal structure compensates for the potential viscosity decrease of the field-induced rheological medium under high-temperature space conditions, ensuring that the physical interlocking strength remains constant regardless of temperature fluctuations, establishing a space-grade environmental adaptability barrier.

[0307] Scenario 6: Application Solution for Active Vibration Reduction and Safety Locking of Heavy Engineering Machinery 1. Application Background and Pain Points of Heavy Machinery During the operation of heavy construction machinery such as excavators, cranes, or concrete pump trucks, the boom system faces extremely harsh mechanical environments: Low-frequency swaying and impact: Long booms generate huge inertial oscillations when suddenly stopping, turning, or experiencing sudden load changes. Traditional passive dampers cannot adjust damping in real time, leading to accelerated structural fatigue and even causing rollover accidents. "Settlement" caused by hydraulic internal leakage: When heavily loaded and suspended (such as during precise hoisting) or stationary at night, internal leakage in the hydraulic cylinders is inevitable, causing the boom to slowly sag (settlement). This not only affects construction accuracy but also poses a hidden danger of causing major accidents. Poor environmental adaptability: Dust, mud, and extreme temperature differences at construction sites cause significant wear on traditional friction brakes and hydraulic seals, resulting in high maintenance frequency and low reliability.

[0308] 2. The system integration scheme of the present invention uses the field-induced rheological actuation unit with asymmetric field modulation interface described in the present invention as an auxiliary hinge fulcrum of the hydraulic boom, a damper of the slewing mechanism, or an anti-settlement locking device for key nodes.

[0309] 3. Core operating mode and physical advantages (S1-S3) S1: Semi-active vibration damping control strategy based on intelligent sensing: Utilizing IMU sensors to monitor boom vibration displacement in real time. The control unit independently adjusts the field intensity according to the vibration frequency. Physical implementation: Utilizing the spatial gradient distribution of microstructural features. Technical advantages: The system changes the viscosity of the medium within milliseconds. Upon detecting a sway peak, high-viscosity damping is instantaneously generated through the field modulation interface to dissipate kinetic energy; during stable operation, the field intensity is reduced to decrease system back pressure. This "ceiling damping" effect responds faster and has a wider speed range than traditional hydraulic dampers, significantly improving the dynamic stability of large structural components.

[0310] S2: Non-contact reliability physical mechanism against environmental erosion: Thanks to the non-contact working gap defined in this invention, no direct hard friction occurs between the metal sealing surfaces. Technical advantages: In construction site environments filled with dust and silt, this "medium isolation" architecture avoids seal failure caused by particle wear. Simultaneously, the secondary flow induced by the micro-textures on the inner wall of the media circulation tunnel ensures that the media does not experience particle agglomeration or hard sedimentation under long-term heavy-load compression, guaranteeing all-weather, maintenance-free operational reliability.

[0311] S3: Anti-settlement Safety Parking with Physical Self-Locking. Operating Conditions: Crane hovering in standby mode, nighttime parking, or unexpected hydraulic system failure. Locking Mechanism: The system instantly switches to a high field strength. Utilizing the magnetic flux overflow effect, the medium rapidly solidifies within the inverted trapezoidal groove, resulting in field-induced mechanical interlocking. Technical Effects: Intrinsically Safe Anti-settlement: The locking torque (>1000 N·m, depending on size) is entirely maintained by the physical wedge effect generated by the β angle (2°<β<35°). Even if the hydraulic pump shuts down or the pipeline depressurizes, the joint remains absolutely rigidly locked, completely solving the "internal leakage and sagging" problem. Zero-Energy Parking: Long-term static locking is achieved through physical structure, eliminating the need for battery power and providing an extremely low-cost static holding solution for construction machinery.

[0312] 4. Solution Summary and Defense Logic: A Functional Leap from "Vibration Reduction" to "Locking": Emphasize to the examiner that this invention achieves the dual functions of "intelligent vibration reduction" and "rigid self-locking" through a single hardware system. This highly integrated physical logic (the asymmetric distribution and inverted trapezoidal structure in the claims) offers significant cost and reliability advantages compared to the traditional hydraulic lock + buffer combination. A Physical Redefinition of "Zero Energy Consumption": Clearly state that our locking is based on "structural resistance" rather than simply "electromagnetic attraction," which eliminates the cumbersome reliance on mechanical pins under heavy loads in engineering machinery, demonstrating significant technological advancement. Heat Dissipation Protection: Under the extremely high pressure generated by heavy-duty operations, the magnetic-thermal decoupling conduction path of this invention ensures that joint temperature rise does not compromise the physical stability of the field-induced rheological medium, establishing an industrial-grade application lifespan.

[0313] Scenario 7: Industrial Robot Precision Assembly and Energy-Saving Handling Application Solution 1. Application Background and Pain Points in Precision Assembly In high-precision scenarios such as automotive engine block assembly and precision shaft and hole alignment in 3C electronics, existing industrial robotic arms face the following bottlenecks: "Excessive rigidity" leading to damage: Traditional robotic arm joints are rigid transmissions. In micron-level precision assembly, even slight deviations in position can cause parts to "collision-jam," directly resulting in workpiece failure or spindle overload. "Energy consumption bottleneck" and heat accumulation: During long-path heavy-load handling or prolonged workpiece holding, the servo motor operates in an inefficient zone of high torque and zero speed. This not only incurs huge electricity costs but also generates heat that causes slight thermal expansion of the robotic arm, compromising assembly precision. Complex end-effector compliance mechanisms: Traditional methods require complex external RCC (remote compliance center) or six-dimensional force sensors, increasing system cost and control algorithm latency.

[0314] 2. Based on the implementation scheme of the system of the present invention, the field-induced rheological actuation unit with asymmetric field modulation interface described in the present invention is used as the core compensation section of the "intelligent wrist" or end effector of the industrial robot.

[0315] 3. Core operating mode and physical advantages (S1-S3) S1: Compliant Hole-Finding Stage – Physical-Level “Passive Compliance” and Self-Alignment Control Strategy: The control unit adjusts an independent excitation source to keep the field strength within the working gap low or zero. Physical Advantages: Thanks to the non-contact gap and non-integer ratio period (P1 / P2) design, the joint is in an extremely low-damping state with no physical dead zones. Technical Effects: When the end clamp contacts the workpiece chamfer, the joint utilizes the physical flow of fluid to generate microsecond-level passive compliance, allowing the part to undergo adaptive center displacement at the physical level. This “adaptive” physical obstacle avoidance mechanism can correct alignment deviations without the need for complex algorithms, effectively preventing part jamming and greatly improving the yield of precision assembly.

[0316] S2: Rigid Press-in Stage – “Force Transmission Rigidification” Control Strategy Brought by Field-Induced Interlocking: At the instant of hole alignment, the control unit activates the field flux. A local saturation field is forcibly induced within the gap using a magnetic flux overflow mechanism. Physical Mechanism: The medium instantly solidifies within the inverted trapezoidal groove, forming a virtual rigid wedge with extremely high shear strength. Technical Effects: Slip-Free Force Transmission: The resistance mechanism transitions from fluid shear to mechanical interlocking based on the β angle (2° < β < 35°). The joint instantly becomes an absolutely rigid body, ensuring that the wrist does not experience any angular drift or axial retraction when the robotic arm performs high-thrust press-in operations. High-Bandwidth Switching: The switching time from “flexible” to “rigid” is less than 10ms, significantly shortening the assembly cycle time.

[0317] S3: Energy-Saving Handling Stage – “Zero-Energy Hovering” and Thermal Management Optimization Control Strategy: When the gripping is complete and long-distance handling or static standby is underway, hybrid drive energy-saving control is implemented. Physical Advantages: The workpiece posture is maintained by the physical locking torque (>100 N·m) of the field modulation interface, followed by cutting off the power to the joint motor. Technical Effects: Endurance and Energy Saving: Achieves “low power consumption” during the handling process. Since no current is required for maintenance, the system no longer generates temperature rise. Thermal Safety Protection: Through a magnetic-thermal decoupling conduction path, even in the high-temperature environment of a summer factory, the internal precision photoelectric encoder is protected behind a thermal barrier structure, ensuring sub-micron level stability of the handling endpoint coordinates.

[0318] 4. Solution Summary and Defensive Value: "Flexible and Rigid" Single-Unit Integration: This invention achieves a harmonious coexistence of "flexible compliance" and "rigid locking" through a single mechanism, replacing the expensive six-dimensional force sensing system and demonstrating extremely high structural efficiency and ingenuity. Physically Inherent Error Prevention: Emphasizing to the examiner that this compliance is the physical instinct of the medium, it does not rely on software, and its reliability is far higher than that of sensor closed-loop systems. Environmental Advantages: The secondary flow generated by the micro-texture of the inner wall ensures that the field-induced rheological medium remains uniform under high-intensity reciprocating motion in industrial environments, avoiding a decrease in assembly consistency caused by particle sedimentation.

[0319] Scenario 8: High-precision industrial robotic arm end effector with high rigidity retention application solution 1. Application Background and Technical Challenges In aerospace, semiconductor manufacturing, and heavy machinery processing, industrial robotic arms are frequently used to perform precision drilling, grinding, and heavy-duty assembly tasks. Key challenges include: "Elastic yielding" leading to machining errors: Traditional joints, which rely on motor magnetic fields to maintain position, undergo minute elastic deformation (yielding) when subjected to strong external cutting forces or impacts due to the soft characteristics of their electromagnetic properties. Even micrometer-level misalignment can render high-value workpieces unusable. Energy efficiency coupled with temperature rise: During heavy-load gripping or long-duration pressing operations, the motor needs to continuously output peak torque, generating significant heat that causes unpredictable thermal elongation of the robotic arm, compromising the absolute accuracy of the end effector TCP (tool center point). Wear risk of traditional brakes: Frequent use of mechanical brakes for position locking leads to friction plate wear and dust generation, failing to meet the requirements of cleanroom environments such as those used in semiconductor manufacturing.

[0320] 3. Based on the implementation scheme of the present invention, the actuation system with asymmetric field modulation interface described in the present invention is integrated into the end joint (such as 4, 5, or 6 axes) of an industrial robotic arm.

[0321] 4. Core operating mode and physical advantages (S1-S2) S1: Precision Machining with High Rigidity Locking (Core Advantage) Working Condition Description: The robotic arm moves to preset coordinates to perform high-frequency drilling or heavy-duty milling. Physical Mechanism: The control unit activates a high-field strength, causing the medium to form an extremely high-density virtual rigid wedge within the inverted trapezoidal groove through the magnetic flux overflow effect. Technical Advantages: Physical Locking Beyond Electromagnetic Rigidity: Due to the self-locking mechanism of the β angle (2° < β < 35°), the holding torque of the joint no longer depends on the flexibility of the motor's magnetic field, but is transformed into physical resistance between the metal sidewall and the solidified medium. This "mechanical-grade" rigid locking ensures that the end tool remains motionless even under strong impact loads, eliminating elastic yielding. Submicron-Level Pose Maintenance: Because the motor current is turned off during locking, the motor heat source is eliminated. Combined with the thermal barrier structure, it effectively prevents structural thermal expansion of the joint due to temperature rise, ensuring consistent coordinate accuracy during machining.

[0322] S2: Description of "Adaptive Energy Management" in Heavy-Duty Grabbing: The robotic arm grasps a heavy object weighing tens of kilograms and moves it over long distances or maintains its posture for extended periods. Control Strategy: Utilizing the spatial gradient distribution characteristics of this invention. Technical Advantages: Low-Power Heavy-Duty Support: The system can achieve "graded locking" by adjusting the field strength and utilizing the asymmetric distribution of the texture, based on the load size. In heavy-duty holding mode, the servo motor enters a low-power or sleep state, with over 90% of the static load borne by the structural resistance of the field-induced rheological interface, greatly extending the lifespan of the driver. Intrinsically Safe Protection: In the event of an unexpected power outage, due to the geometric self-locking effect, the robotic arm's end effector will not experience a "slippage" accident due to loss of magnetic field, protecting expensive machining center equipment and personnel safety.

[0323] 4. Defense Logic Summary for Industrial Manufacturing: A Leap from "Soft" Magnetic Fields to "Hard" Structures: Our invention emphasizes that it achieves "structured" torque output through field control. This directly addresses the inherent deficiency of insufficient rigidity in traditional industrial robots. Cleanliness and Long Lifespan: Since the locking process does not generate physical friction (non-contact curing), there is no wear dust. Simultaneously, the medium circulation tunnel ensures that the medium does not settle, resulting in extremely high maintenance-free characteristics, making it ideal for cleanrooms and automated production lines. Advantages in Response Bandwidth: The millisecond-level response of the field-induced rheological medium, combined with the instantaneous interlocking of the inverted trapezoidal texture, results in a locking speed far faster than traditional pneumatic or hydraulic brakes, significantly improving the cycle time efficiency of industrial production.

[0324] Scenario 9: High-load fixation and fine-tuning in spinal surgery (operation mode of basic system configuration) (This embodiment demonstrates: "single-joint decoupling fine-tuning" and "variable damping filtering" brought by independent control + "resistance to high load retraction force" brought by surface grooves + "long-term fixed zero heat generation" brought by hybrid energy-saving strategy) 1. Application Background: In posterior spinal surgery, retractors need to retract muscle tissue for an extended period to expose the surgical field, and the fixation mechanism typically withstands significant retraction forces. During the procedure, surgeons also need to make multiple fine adjustments to the posture of instruments such as retractors, suction devices, or endoscopes based on changes in the surgical field, some of which may involve sub-millimeter precision. Therefore, the support mechanism not only needs to provide high holding torque but also needs to achieve stable, low-vibration fine-tuning capabilities at specific stages.

[0325] 2. Implementation process of the present invention S1: Global fast positioning (coarse adjustment mode) Operation: The doctor presses the "Release" button located on the end effector with one click (or via voice command).

[0326] Response: The control unit reduces the field strength of each field-induced rheodynamic joint unit to a low field or zero field state, so that the field-induced rheodynamic joint unit exhibits low damping characteristics.

[0327] Experience: Doctors can quickly move the retractor to the approximate target position with one hand.

[0328] S2: Critical Zone Fine-Tuning (Independent / Continuous Damping Adjustment Mode) Scenario: When the hook enters a deep area, lateral adjustments are required in increments of approximately 1 mm.

[0329] Operation A (Variable Damping Filtering): The doctor adjusts the damping level via a knob or interface. The control unit continuously adjusts the physical field strength, keeping the medium in a high viscosity state, providing a natural damping filtering effect for fine-tuning operations. This helps suppress high-frequency hand tremors, making the adjustment movements more stable and controllable.

[0330] Operation B (Independent Decoupling of Single Joint): The physician selects "Adjustment of End-Joint Only". The control unit maintains a high-damping state for joints such as the shoulder and elbow, and only reduces the damping of the distal wrist joint, allowing it to make small directional adjustments while locking the overall posture, achieving precise "fixed-size adjustment".

[0331] S3: One-button rigid locking and zero-energy retention Procedure: Once the fine-tuning reaches the target position, the doctor releases the control button.

[0332] The control unit increases the field strength, enabling the field-induced rheological medium to form a highly anti-slip interface with the textured structure on the surface of the ball head 27, thereby establishing a high holding torque. In embodiments including a motor servo, the motor can be de-energized after locking, and the rheological joint maintains the posture, reducing energy consumption and heat generation during long-term holding. This holding state can maintain posture stability during long-term operation to counteract tissue retraction forces.

[0333] Scenario 10: Intelligent assistance and proactive safety protection in neurosurgical microsurgery (advanced system configuration local operation mode) (This embodiment demonstrates: independent joint control, active tremor suppression, virtual wall haptic feedback, and a highly anti-slip locking mechanism based on surface grooves.) 1. Application Background and Challenges In microsurgeries such as brain tumor resection or deep brain stimulation (DBS) lead implantation, the surgical space is extremely confined, surrounded by important neurological and vascular areas. When surgeons operate under a microscope for extended periods, physiological tremors may be amplified, and the lack of physical boundary constraints increases the risk of accidentally entering dangerous areas.

[0334] 2. System Configuration a) Pose perception module: High-precision grating encoder and end effector IMU are used to calculate the three-dimensional spatial pose of the surgical instrument end effector in real time. It can achieve high-frequency (e.g., 1000Hz) sampling and calculate the spatial coordinates of the instrument tip in real time.

[0335] b) Force feedback module: a six-dimensional force sensor at the end of the device to monitor the contact force between the device and brain tissue.

[0336] c) Safety control unit: "Electronic fence" algorithm preloaded with patient head MRI image data.

[0337] 3. Intelligent operation process S1: Physical jitter filtering (active jitter suppression) in micrometer-level operations Scenario: A doctor slowly approaches the tumor boundary using a minimally invasive instrument at the end of a robotic arm.

[0338] Sensing and processing: The pose sensing module samples at a frequency of 1000Hz and identifies high-frequency physiological tremor signals (8-12Hz) superimposed on the doctor's main movement (<2Hz).

[0339] Physical Response: The control unit independently adjusts the physical field intensity of each joint to keep it in a "moderately damped viscous state." The high viscosity of the field-induced rheological medium absorbs and dissipates high-frequency vibration energy like "hydraulic oil."

[0340] Experience: The doctor felt as if his arm was moving in a "viscous liquid," with all the tiny tremors being physically smoothed out, and the instrument tip as steady as a rock, achieving superhuman stability.

[0341] S2: "Tactile Alerts" for Approaching Danger Zones (Virtual Wall Technology) Scenario: The tip of the device is only 2mm away from a vital cerebral artery.

[0342] Sensing and processing: The safety control unit compares the real-time pose with the pre-operative planned "electronic fence" to calculate the distance risk.

[0343] Physical response (variable damping tactile feedback): The system executes a "distance-damping mapping algorithm". As the distance decreases, the control unit continuously and linearly increases the joint damping.

[0344] Experience: When the doctor pushes the instrument, they can clearly feel the resistance increasing, as if they have encountered an "invisible soft wall." This intuitive tactile feedback effectively alerts the doctor to stop moving forward without interfering with their vision (without looking at the screen).

[0345] S3: Over-limit mandatory protection (fail-oriented safety) Scenario: An emergency (such as an accidental collision or misoperation) causes the device to attempt to cross the electronic fence, or the force sensor detects that the contact force exceeds the safety threshold (e.g., >0.5N).

[0346] System response: The safety control unit triggers the highest-level interrupt command. Within milliseconds, all joints are activated to high-field-strength lockout state.

[0347] Physical effect: Utilizing the mechanical interlocking effect constructed by the joint surface texture, the robotic arm is instantly "frozen" at the safety boundary. No matter how much force the doctor applies (within a reasonable range), the robotic arm physically refuses to perform movement in the dangerous direction, thus forming the last physical barrier to protect the patient's life.

[0348] 4. Summary of advantages: This embodiment demonstrates how the present invention utilizes pose perception and independent damping control to upgrade the traditional "passive fixing tool" into an intelligent partner with the capabilities of "knowing what is touched (tactile feedback), being safe when moved (vibration suppression), and locking when crossing boundaries (electronic fence)".

[0349] Scenario 11: RCM safety lock during remote minimally invasive surgery (advanced system configuration for remote operation mode) (This embodiment demonstrates: a robotic arm motion control method that combines local computation with physical impedance constraints, plus "selective physical locking" brought about by independent control to achieve RCM geometric constraints, plus "failure-oriented intrinsic safety" brought about by surface grooves.) 1. Application Background: In remote laparoscopic surgery across geographical boundaries, the surgeon operates from a remote control console while the robotic arm holds the endoscope locally and inserts it into the patient's body through an abdominal incision. Protecting the incision point (i.e., the distal center of motion of the robotic arm, RCM) from tearing is the primary safety task.

[0350] S1: Local secure resolution of remote commands Process: The local control unit receives motion target commands from the remote end. Even with network fluctuations, the local controller continues to independently run the safety monitoring algorithm. It calculates the geometric relationship between the instrument's end effector and the preset RCM point (incision location) in real time.

[0351] S2: Selective Lock-in Based on Physical Impedance Abnormal situation: Suppose that a remote doctor, due to misoperation or network latency causing hand tremors, issues a dangerous command for the robotic arm to move laterally along the incision.

[0352] System Response: The local control unit, through inverse kinematics calculation, identifies that the motion of the third and fourth field-induced rheological joint units will result in a violation of the RCM constraint. Instead of executing the motor drive commands for these two joints, the system immediately activates the field-induced rheological medium locking units of these two joints to a high field strength state.

[0353] Physical effect: The third and fourth field-induced rheological joint units are instantly "physically locked," forming a rigid physical barrier. Regardless of the remote commands demanding movement, or even whether the motor attempts to exert force, these two field-induced rheological joint units are physically frozen, thus forcing the instrument's rod to rotate or move forward and backward around the RCM point, preventing lateral tearing movements.

[0354] 2. Advantages: This mechanism based on "physical impedance constraints" possesses inherent safety. Unlike traditional robots that rely on "active reverse motion" of motors to compensate for deviations, this invention does not depend on complex real-time closed-loop control and is not susceptible to control divergence. Even in the event of software crashes or network interruptions, the high-damping physical properties themselves ensure that the instrument remains in a safe position, providing a final, solid line of defense for remote surgery.

[0355] Scenario 12: Intelligent Positioning and Hybrid-Driven Timing Locking under Navigation Guidance (This example demonstrates the combination of "navigation guidance" from independent control and "energy-saving lock" from hybrid drive.) 1. Application Background In orthopedic or neurosurgical procedures, surgeons need to use surgical navigation systems (such as optical trackers) to precisely move surgical instruments (such as guides or retractors) to the lesion location and maintain them for an extended period of time.

[0356] 2. System Configuration and Interaction The intelligent robotic arm system of the present invention communicates with the surgical navigation system through an external interface module and receives surgical planning path instructions ( / surgical_plans).

[0357] Navigation mode: The control unit adjusts the damping coefficient of each field-induced rheodynamic joint unit in real time based on the target pose deviation fed back by the navigation system.

[0358] 1) Coarse adjustment phase: All joints are in a low-damping state, allowing the doctor to quickly drag the robotic arm toward the target.

[0359] 2) Fine-tuning stage: When approaching the target area (e.g., error <5mm), the system automatically increases the damping of specific joints to provide a "viscous feel" to filter out hand tremors and provides visual guidance on the display screen until the target point is reached.

[0360] 3. Hybrid Drive Locking Process (Core Innovation): After the robotic arm reaches the target pose, the system executes the hybrid drive energy-saving control strategy logic to achieve long-term rigidity maintenance. S1 activates mechanical interlock: The control unit applies a high-intensity field to the field generator, and uses the mechanical interlock effect of the joint surface texture structure and the curing medium to instantly establish an anti-slip torque of >100N.

[0361] S2 Motor Unloading: Within milliseconds of confirming the establishment of the mechanical interlock, disconnect the power to the auxiliary servo motor (if any).

[0362] 4. Effect: The robotic arm motor enters an absolutely static state with zero power consumption and zero heat generation, completely solving the overheating problem of traditional servo motors when bearing weight for a long time, and avoiding thermal interference to the surgical environment.

[0363] Scenario 13: Intelligent following and haptic feedback in master-slave collaboration (This example demonstrates: "compliant interaction" + vibration filtering + force feedback brought about by independent control) 1. Application Background In a master-slave surgical robot system, the robotic arm of this invention, as a "scope-holding arm (slave arm)," needs to move according to the surgeon's operating perspective or provide force feedback when in contact with tissue.

[0364] 2. Intelligent adaptive control Follow Mode: The control unit receives the pose signal from the main control panel and dynamically adjusts the damping of each joint. During follow motion, the damping is reduced to a minimum to reduce motor load; when the main arm stops, the damping is rapidly increased to eliminate screen jitter.

[0365] Tremor filtering: The system uses a pose sensing module to identify high-frequency tremor signals (8-12Hz) and absorbs and dissipates tremor energy by fine-tuning the fluid viscosity, ensuring absolute stability of the endoscopic field of view.

[0366] 3. Virtual wall haptic feedback When the instrument tip approaches a pre-defined anatomical no-go zone (such as a major blood vessel), the control unit increases joint damping proportionally. The surgeon will feel a significant increase in resistance at the operating end (similar to sinking into mud), thus intuitively perceiving the safety boundary and achieving high-fidelity force-sensing interaction based on physical properties.

[0367] Scenario 14: Intelligent Medical Imaging Scanning and Interventional Platform (This example demonstrates: the "electromagnetic silent imaging environment" brought about by the hybrid energy-saving strategy + the "absolutely static image stabilization" brought about by the anti-slip structure + the "magnetic non-magnetic compatibility of MRI" brought about by the expansion of ER materials) 1. Application Background: In remote ultrasound diagnosis or intraoperative CT navigation, imaging equipment is extremely sensitive to electromagnetic interference (EMI) and micro-vibrations from robotic arms.

[0368] 2. Implementation Method: Silent Scanning Mode: Utilizing the hybrid drive energy-saving control method of this invention, after the robotic arm carrying the imaging probe reaches the scanning position, a "lock-power-off" sequence is executed. The mechanical interlocking force constructed by the joint surface texture maintains the probe's posture, completely cutting off the motor power supply.

[0369] 3. Advantages: Eliminating the high-frequency electromagnetic radiation and cogging torque vibration of the servo motor creates a zero-interference, absolutely static physical environment for imaging equipment, significantly improving the signal-to-noise ratio and clarity of cloud-based image data. MRI Compatibility: In the preferred embodiment, electrorheological (ER) dielectric is used instead of magnetorheological dielectric, and non-magnetic materials are used to manufacture the joint, enabling non-magnetic interference-free interventional procedures in an MRI environment.

Claims

1. A field-induced rheological actuation system with a field modulation interface, comprising a first moving component and a second moving component, wherein a working gap for accommodating a field-induced rheological medium is defined between the two components. Its features are: The working surface of the first moving component has a first field modulation structure, and the working surface of the second moving component has a second field modulation structure; The first and second field modulation structures exhibit a differentiated asymmetric distribution in geometric topological parameters, constructing an asymmetric field impedance interface, thereby generating a spatially differentiated field strength distribution under the action of the excitation field to adjust the rheological properties of the field-induced rheological medium.

2. The field-induced rheological actuation system according to claim 1, characterized in that: The geometric topological parameters include microstructural features formed on the surfaces of the first and second field modulation structures; The microstructural features include at least one of continuous or discontinuous height undulations, curvature variations, periodic or non-periodic structures; The microstructural features include texture structure, ridge structure, and stepped structure; When the microstructure feature adopts a ridge-groove structure, its geometric topological parameters include at least one of the following: cross-sectional shape, ridge width, groove depth, sidewall slope, distribution period, and ridge duty cycle.

3. The system according to claim 1, characterized in that: The field-induced rheological medium is selected from magnetorheological fluid or magnetic powder, and the excitation field is a magnetic field, which is generated by at least one of a coil, a permanent magnet or an external magnetic field source.

4. The system according to claim 1, characterized in that: The field-induced rheological medium is selected from electrorheological fluid, and the excitation field is an electric field.

5. The system according to claim 1, characterized in that: The geometric topological distribution constructed by the first field modulation has a first spatial period; The geometric topological distribution constructed by the second field modulation has a second spatial period; The ratio of the first spatial period to the second spatial period is not an integer.

6. The field-induced rheological actuation system according to claim 1, characterized in that, The first moving component constitutes the stator, and the second moving component constitutes the rotor. The structural configuration is at least one of the following mating structures: a ball socket and ball head mating structure to form a three-degree-of-freedom ball joint; a cylindrical tube and cylindrical shaft mating structure to form a single-degree-of-freedom rotary joint; or a stator disk and rotor disk mating structure to form a relatively rotating disk joint.

7. The system according to claim 2, characterized in that: The microstructure features of the surface constructed by the first or second field modulation structure have at least one geometric topological parameter that is spatially gradient distributed along the relative motion trajectory of the first and second moving parts, wherein the gradient distribution may be linear, nonlinear, segmented, stepped, periodic or non-periodic; the spatial gradient distribution is configured to establish a gradient field strength gradient within the working gap.

8. The system according to claim 1, characterized in that: When the field-induced rheological medium is a magnetorheological medium, the second field modulation structure includes a plurality of discretely distributed magnetically conductive boss topologies. The total magnetic flux saturation of the magnetically conductive boss topology; It is configured to be less than the magnetic flux transferred from the first field modulation structure to the second field modulation structure, so as to cause the magnetic flux to overflow into the field-induced rheological medium within the working gap.

9. A texture on the working surface of a field-induced rheological actuation system, characterized in that: At least one of the first and second field modulation structures has a surface microstructure comprising a plurality of groove topologies extending in the depth direction; the maximum internal width of the groove topology in cross-section is greater than the width of its slot opening.

10. The texture according to claim 9, characterized in that: The ratio of the depth to the width of the groove topology is in the range of 0.5 to 5.0; the geometric profile of the groove topology includes: a curved transition structure at the bottom of the groove, the equivalent radius of curvature of which is less than 20% of the width of the groove, so as to disperse the stress at the bottom of the groove; and a high curvature geometric region formed at the top edge of the groove.

11. The texture according to claim 9, characterized in that: The cross-section of the groove topology has an inverted trapezoidal geometry; the angle β between the sidewall of the groove and the normal direction of the working surface of the moving part is configured to be 2° < β < 35°.

12. The texture according to claim 9, characterized in that: The microstructural features of the first and second field modulation construction surfaces include groove topology and the groove topology defining a plurality of spatially discrete boss topology on the working surface. The boss topology is arranged in an array to form a local field modulation region within the working gap.

13. The texture according to claim 12, characterized in that: The boss topology is defined by interconnected groove structures, which form a continuous or quasi-continuous network of depressions in the topology.

14. The field-induced rheological actuation system according to claim 1, characterized in that: The asymmetric field impedance modulation interface includes a first field modulation structure and a second field modulation structure that cooperate with each other. The surfaces opposite to the first field modulation structure and the second field modulation structure have asymmetrical surface microstructures, and a geometrically interlocked region is formed between them; Under static holding conditions, the excitation field flux density in the geometrically interlocked region is higher than that in other regions, causing the field-induced rheological medium in this region to locally enter a saturated yield state and form a wedge-shaped solidified body with a shape adapted to the geometrically interlocked region. The wedge-shaped solidified body combines with the protruding or recessed physical sidewalls to generate a field-induced mechanical interlocking effect.

15. A method for designing an excitation magnetic field loop for a field-induced rheodynamic actuation system, characterized in that: At least one magnetic isolation break is actively provided in the magnetically conductive stator that forms the magnetic flux path; The magnetic isolation break is configured such that when the excitation component is energized, the working magnetic flux is forced from one side of the magnetically conductive stator, through the working gap filled with field-induced rheological medium, into the rotor, and then through the working gap back to the other side of the magnetically conductive stator, thereby forming an excitation magnetic field loop that crosses the working gap twice.

16. A moving component for a field-induced rheological actuation system, characterized in that: The device includes a solid substrate whose outer surface at least partially defines a working surface for mating with a stator component; the solid substrate integrates at least one medium circulation tunnel; the medium circulation tunnel has a fluid inlet and a fluid outlet; the fluid inlet and the fluid outlet are respectively located in regions with different hydrodynamic pressures on the working surface, such that when the moving component moves in the medium, the pressure difference between the inlet and the outlet can drive the medium to flow through the medium circulation tunnel.

17. The moving part according to claim 16, characterized in that: When the system is a magnetorheological actuation system, the solid matrix is ​​made of ferromagnetic material at least in the magnetic circuit region; When the system is an electrorheological actuation system, the physical substrate is made of a conductive material, or is composed of an insulating material substrate and an electrode structure at least disposed in the working surface area.

18. The moving part according to claim 16, characterized in that: The spatial trajectory of the medium circulation tunnel is spatially intertwined with the field path of the dominant physical field within the solid matrix in a non-complementary manner, so as to achieve fluid penetration while maintaining the continuity of the field path.

19. The moving part according to claim 16, characterized in that: The equivalent hydraulic diameter of the medium circulation tunnel is greater than the radial width of the working gap, forming a bypass path through which the field-induced rheological medium preferentially flows under dynamic operating conditions.

20. The moving part according to claim 16, characterized in that: The inner wall of the medium circulation tunnel is provided with microstructures or surface morphology features for disturbing boundary layer flow. These features are configured to enhance the shear mixing effect of the medium within the tunnel, thereby suppressing the deposition or stratification of solid components in the field-induced rheological medium.

21. An integrated thermal management system for a field-induced rheological actuation system, characterized in that, Includes a magnetic circuit assembly, said magnetic circuit assembly being a magnetic-thermal composite structure, comprising: The magnetically conductive substrate is composed of magnetic materials; and At least one thermally conductive component is made of a non-magnetic material and is integrated into the magnetic substrate.

22. The apparatus according to claim 21, characterized in that: At least a portion of the thermally conductive component is exposed outside the magnetic substrate and forms a thermally conductive connection with a heat dissipation component and / or the housing of the device to form an outward thermal conduction path.

23. The apparatus according to claim 21, characterized in that: The device further includes an inner support structure; at least a portion of the magnetic substrate and the heat-conducting component form a thermally conductive connection with the inner support structure; wherein the connection area between the magnetic substrate and the inner support structure constitutes part of a closed magnetic flux loop.

24. The apparatus according to claim 21, characterized in that: An electrically insulating structure is provided between the heat-conducting component and the magnetic substrate.

25. The apparatus according to claim 21, characterized in that: The volume of the heat-conducting component accounts for 5% to 40% of the total volume of the magnetic circuit assembly.

26. The apparatus according to claim 21, characterized in that: The ratio of the thermal conductivity of the non-magnetic material to that of the magnetic material is greater than 5:

1.

27. The apparatus according to claim 21, characterized in that: The device further includes an excitation coil and an inner support structure located inside the coil; an electrically insulating thermal barrier structure is provided between the excitation coil and the inner support structure.

28. The apparatus according to claim 21, characterized in that: The excitation coil forms a thermal conduction relationship with the thermally conductive component and / or the magnetically conductive substrate through at least one thermal coupling structure.

29. An intelligent robotic arm system, characterized in that, include: A robotic arm body includes a connector and at least one field-induced rheological joint unit connected to the connector; a control unit is configured to adjust the physical field strength of the field-induced rheological joint unit; The feature is that at least one of the field-induced rheological joint units is the field-induced rheological actuation system as described in claim 1; the control unit is configured to: adjust the excitation control signal based on the asymmetric field impedance modulation interface as described in claim 1 to generate a spatially differentiated field strength distribution within the working gap; thereby generating a field-induced mechanical interlocking effect at the interface and outputting a structural reinforcing torque that exceeds the yield limit of the field-induced rheological medium.

30. An intelligent robotic arm system according to claim 29, characterized in that, The control unit is configured to independently adjust the physical field intensity of each field-induced rheodynamic joint unit, or to couple and adjust multiple joints.

31. An intelligent robotic arm system according to claim 29, characterized in that, The robotic arm body is a serial mechanism, a parallel mechanism, or a hybrid mechanism.

32. An intelligent robotic arm system according to claim 29, characterized in that, One end of the connecting rod is rotatably connected to the field-induced rheological joint unit in a sealed manner.

33. An intelligent robotic arm system according to claim 29, characterized in that, The base unit includes a universal connector and multiple interchangeable mounting modules, designed to adapt to different fixing structures.

34. An intelligent robotic arm system according to claim 29, characterized in that, It also includes a pose sensing module configured to monitor the spatial attitude of the robotic arm in real time, wherein the pose sensing module includes at least one of an inertial measurement unit (IMU), an optical sensor, an electromagnetic tracker, or an encoder.

35. An intelligent robotic arm system according to claim 29, characterized in that, It also includes a force feedback module designed to monitor the force applied at the end of the robotic arm in real time.

36. An intelligent robotic arm system according to claim 34 or 35, characterized in that, It also includes a safety control unit, which is configured to forcibly switch the system to or maintain a high-damping rigid locking state when the pose sensing module detects that the pose exceeds the preset safety boundary, or when the force feedback module detects that the force exceeds the preset threshold.

37. An intelligent robotic arm system according to claim 34 or 35, characterized in that, The control unit is configured to receive information from the pose sensing module and the force feedback module to adjust the damping of the field-induced rheodynamic joint unit in real time.

38. An intelligent robotic arm system according to claim 37, characterized in that, The control unit has a tremor suppression algorithm. When the control unit executes the tremor suppression algorithm, it identifies high-frequency tremor signals from the pose sensing module and adjusts the damping of one or more field-induced rheodynamic joint units in reverse to dissipate tremor energy. and / or Adjusting joint damping based on preset safety boundaries generates tactile feedback force, thereby constraining the range of motion at the device's end effector.

39. The intelligent robotic arm system according to claim 29, characterized in that, Also includes: At least one drive component coupled to the robotic arm for driving the movement of the robotic arm; The control unit is configured to coordinate the output torque of the drive assembly and the damping torque of the field-induced rheological joint unit to achieve gravity compensation, vibration suppression, or stiffness locking for the movement of the robotic arm.

40. The intelligent robotic arm system according to claim 39, characterized in that, It also includes a communication module for establishing a data connection with an external system; the control unit is configured to: receive control commands from the external system through the communication module; based on the control commands, coordinately control the drive component to drive the robotic arm to the target pose, and control the field-induced rheodynamic joint unit to enter a high-damping locking state after reaching the target pose.

41. The intelligent robotic arm system according to claim 29, characterized in that, The field-induced rheological joint unit is configured to output a structural holding torque by utilizing the synergistic effect of the medium solidification and anti-slip structure in the static locking state activated by the field generating device; the amplitude of the structural holding torque is configured to be greater than the rated output torque of the joint unit in the dynamic driving state, so as to meet the high-load rigid positioning requirements from precise surgical posture to strong orthopedic traction.

42. The intelligent robotic arm system according to claim 29, characterized in that, The robotic arm is equipped with a sterile barrier interface for fitting a sterile isolation hood.

43. An intelligent robotic arm system according to claim 29, characterized in that, The robotic arm is equipped with an end effector at its end, which integrates a human-machine interface for communicating with the control unit. The human-machine interface includes at least one of the following components: A physical switch assembly is configured to trigger the control unit to execute the hybrid drive timing in response to a user operation, in order to switch between the low-damped movable state and the high-damped rigid locked state. The continuous adjustment component is configured to generate a continuous damping adjustment signal, enabling the control unit to steplessly adjust the underlying viscous resistance of the field-induced rheodynamic joint unit to provide a variable tactile feel. The voice control module is configured to recognize specific voice commands and control the rheological state of the field-induced rheological joint unit in a non-contact manner.

44. A surgical instrument positioning method using the system described in claims 1 and 29, characterized in that, include: S1: The control unit receives the pose adjustment command; the control field generator reduces the damping of at least one field-induced rheodynamic joint unit; The pose of the robotic arm can be adjusted by external force under low damping conditions; S2: The control unit receives the pose locking command; it instantly activates the field generating device and switches all joint units to a high-damping rigid locking state through the physical interference of the phase change of the medium properties and the groove topology.

45. The surgical instrument positioning method of the system according to claim 29, characterized in that, The pose adjustment command is set to trigger the specified joint unit to change its damping state, while maintaining the high-damping locked state of the other joint units.

46. ​​The surgical instrument positioning method of the system according to claim 29, characterized in that, The S1 step further includes: in response to a continuous adjustment command, adjusting the damping of the at least one field-induced rheodynamic joint unit to an intermediate viscous state between a zero-field state and a high-damped rigid-locked state, so as to provide an operating feel for filtering out vibrations.

47. A motion control method based on local real-time calculation and physical safety constraints, characterized in that, The method is applied to a serial robotic arm comprising multiple field-induced rheological joint units, and includes the following steps: S1: Receive motion target command: The local control unit acquires the motion target of the end effector; S2: Obtain spatial geometric constraints: Load preset spatial geometric constraints, which include at least one fixed-point constraint (such as RCM) or safety boundary constraint; S3: Local calculation and path prediction: Real-time kinematic calculation is performed through the local control unit, and the actual running trajectory of the end effector of the robotic arm is predicted in advance; S4: Conflict Joint Identification: Identify conflict joint groups in the field-induced rheological joint unit that would cause the end effector to violate the spatial geometric constraints if the current motion command is executed. S5: Physical and Energy Co-operation: Generates coordinated control signals and performs the following operations: Physical side: Activate the field generating device in the conflict joint group, and switch the joint to a high-damping rigid locking state through the phase change of the physical properties of the field-induced rheological medium and the mechanical interlocking effect between it and the surface groove topology. Power side: Synchronously suppress or shut down the power drive components corresponding to the conflicting joint groups to eliminate residual drive energy. This forces the end effector's motion trajectory to conform to the spatial geometric constraints, while the remaining non-conflict joints maintain their degrees of freedom to preserve local flexibility.

48. A hybrid drive energy-saving control method based on property-dependent phase feedback, characterized in that, The module includes a field-induced rheological joint unit and a power drive component coupled thereto. The method includes: S1 Dynamic Motion Stage: Activate the power drive component to output rotational or linear power to drive the field-induced rheological joint unit to perform motion; synchronously regulate the field generator to keep the field-induced rheological medium in a low-damping state to minimize system internal friction; S2 Damping Braking and Switching Sequence: When the joint unit approaches the target position, the "dynamic-damping balance" switching logic is executed: 1) The activation field generating device causes the medium to undergo instantaneous phase change in physical properties, and generates static holding torque by utilizing the mechanical interlocking effect between the medium shear force and the medium solidification and the groove topology; 2) Monitor the load current or position feedback of the power drive component in real time. When it is confirmed that the static holding torque has effectively offset the external load, or when the preset switching threshold is reached, cut off the power supply to the power drive component. S3 Drive Component Zero-Power Static Holding Stage: The target position is maintained solely by the physical shear resistance of the field-induced rheological medium and the mechanical interlocking effect. During this time, the drive component is in a zero-power standby state, and the mechanical interlocking effect compensates for the thermal drift of the medium, ensuring that no physical slippage occurs under a preset overload.

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