Humanoid robot thigh, humanoid robot, and manufacturing method

Abstract

Disclosed in the present invention are a humanoid robot thigh, a humanoid robot, and a manufacturing method. The thigh is of an integrally-formed structure, and all components are integrally formed by means of a selective laser melting process without a mechanical connection joint. The thigh comprises a skeleton, skin, and a first equal-density lattice filled between the skeleton and the skin; the skeleton is in a configuration of "local housing thickening + second equal-density lattice"; the skin is a thin housing with equal thickness; the skeleton and the skin are combined into a whole; the first equal-density lattice is added between the skeleton and the skin; and the skeleton comprises a housing, a first reinforcing plate, a second reinforcing plate, and a second equal-density lattice with which the internal space of the skeleton is filled. According to the present invention, the problem of vibration of a plastic appearance part during robot movement due to mechanical connection is effectively avoided, and the assembly time of a leg part is saved. In addition, the configuration design is relatively simple, and the total weight of the leg part is effectively reduced while the rigidity meets the use requirement, thereby prolonging the service life of the thigh part.

Description

Humanoid robot thigh, humanoid robot, and manufacturing method Technical Field

[0001] The present invention belongs to the field of precision manufacturing of humanoid robots, and in particular relates to a humanoid robot thigh, a humanoid robot, and a manufacturing method. Background Art

[0002] Humanoid robots are a landmark achievement in bionic mechanisms. Their appearance and joint layout mimic the human body, resulting in similar joint flexibility and, in theory, the ability to perform a wide range of human movements. They have great potential for replacing humans in various heavy and monotonous tasks, as well as in disaster relief and rescue operations. Currently, driven by artificial intelligence, humanoid robots possess capabilities such as swarm computing and machine vision, enabling them to interact effectively with humans. Therefore, they have great potential for future development as companions for the elderly and children, and are a type of robot that many countries are eager to develop.

[0003] In order to meet the functional requirements of the robot in the above-mentioned application scenarios, the robot's structural components, especially the main load-bearing components of the lower limbs, such as the thighs, calves, and feet, should be lightweight and high-strength. Such characteristics reduce the rotational inertia of the structural components during movement, thereby improving the positional accuracy of the humanoid robot when performing complex gestures and other actions. At the same time, the robot's appearance must conform to human aesthetics, because a beautiful appearance can enhance human favorability and lay an emotional foundation for human-machine interaction. In addition, the robot's components need to be highly integrated. Currently, the robot's thigh components have a large number of parts, and the parts are mechanically connected. However, the connection parts are more prone to failure than the base body. Therefore, reducing the number of connection points can increase the service life of the parts and increase the robot's battery life.

[0004] Focusing on these functional requirements, the present invention, based on selective laser melting technology, designs a humanoid robot thigh with integrated "structure and appearance." The thigh is divided into a load-bearing portion and an appearance portion. The load-bearing portion is designed as a "partially thickened shell + constant density lattice" configuration, while the appearance portion is configured as a thin shell of constant thickness. An equal density lattice is arranged in the cavity between the load-bearing and appearance portions, and the load-bearing and appearance portions are composited into one piece. The thigh components are integrally formed using a selective laser melting process, without mechanical joints. This thigh is lightweight and strong, with an integrated appearance that meets human aesthetic requirements. It also reduces the number of connection points, thereby increasing the service life of the robot's lower limb components. Summary of the Invention

[0005] The purpose of the present invention is to address the deficiencies in the prior art and to provide a humanoid robot thigh, a humanoid robot, and a manufacturing method.

[0006] The objectives of the present invention are achieved through the following technical solutions: In a first aspect, an embodiment of the present invention provides a humanoid robot thigh, wherein the thigh is an integrally formed structure, wherein the thigh components are integrally formed by a selective laser melting process, and the thigh comprises:

[0007] A skeleton comprising a shell, a first reinforcing plate, a second reinforcing plate, and a second uniform density lattice, wherein two first reinforcing plates are symmetrically provided at the upper end of the shell, the second reinforcing plate is provided at the lower end of the shell, and the second uniform density lattice fills the remaining space after removing the shell, the first reinforcing plate, and the second reinforcing plate from the skeleton;

[0008] The skin has a second motor mounting portion, a hip motor cover and a second motor mounting slot at its upper end, the hip motor cover surrounds the second motor mounting portion, and the second motor mounting slot is arranged below the second motor mounting portion; a PCB board mounting slot and a PCB cover mounting portion are arranged on one side of the middle part of the skin, and a decorative plate mounting slot and a decorative plate mounting portion are arranged on the other side, and a second communication wire trough is arranged in the middle part of the skin; a second bearing mounting slot and a second bearing end cover fitting portion are arranged at the lower end of the skin; and

[0009] A first isodensity lattice is filled between the skeleton and the skin.

[0010] Furthermore, the material used for the thigh is aluminum magnesium scandium zirconium, and the process used for the thigh is laser metal 3D printing.

[0011] Furthermore, a motor mounting portion and a first motor mounting slot are provided at the upper end of the housing, and the first motor mounting slot is provided below the first motor mounting portion;

[0012] The middle part of the housing is provided with a weight-reducing groove, a first communication line groove, a motor power line groove and a slope portion, and the weight-reducing groove is located above the slope portion;

[0013] The lower end of the shell is provided with a first bearing installation groove and a first bearing end cover fitting portion.

[0014] Furthermore, the thickness of the shell is 2.1mm-2.5mm;

[0015] The thickness of the skin is 1 / 3 to 1 / 2 of the thickness of the shell.

[0016] Furthermore, the upper end of the first reinforcing plate is connected to the bottom groove surface of the first motor mounting groove, and the lower end of the first reinforcing plate is connected to the longitudinal wall surface of the shell.

[0017] Furthermore, the first reinforcing plate and the second reinforcing plate are both provided with powder leakage holes;

[0018] The powder leakage hole is elliptical, with its major axis parallel to the length direction of the corresponding first reinforcing plate or the second reinforcing plate, and the length of its minor axis is less than or equal to 1 / 2 of the width of the corresponding first reinforcing plate or the second reinforcing plate;

[0019] The diameter of the powder leakage hole is 3-4 mm.

[0020] Furthermore, the cell structure parameters of the first isodensity lattice and the second isodensity lattice are the same, wherein the cell structure parameters include cell side length, rod diameter and inclination angle;

[0021] The ratio of the rod diameter to the cell side length of the first and second equal-density lattices is 1 / 7 to 1 / 9, and the rod diameter is greater than or equal to 0.5 mm.

[0022] Furthermore, the interface area between the shell and the second isodensity lattice is reliably connected through over-contact of the second isodensity lattice, and the interface area between the shell, the skin and the first isodensity lattice is reliably connected through over-contact of the first isodensity lattice.

[0023] A second aspect of an embodiment of the present invention provides a humanoid robot, comprising:

[0024] Robot body; and

[0025] The aforementioned humanoid robot thighs.

[0026] A third aspect of an embodiment of the present invention provides a method for manufacturing the humanoid robot thigh, comprising the following steps:

[0027] S1. Extract the three gaits of the humanoid robot: landing, starting, and standing on two feet, and analyze the boundary condition characteristics and load values ​​of the humanoid robot's thigh under these three gaits;

[0028] S2, design an initial model of the humanoid robot thigh including industrial design elements;

[0029] S3. Set boundary condition characteristics and load values ​​on the initial model, perform topological calculations, and analyze material distribution characteristics;

[0030] S4. Identify the area where material needs to be removed after topological calculation on the initial model, and complete the removal of material in the area to form a skeleton;

[0031] S5. Perform shell extraction on the skeleton to form a skeleton shell, and locally thicken the shell;

[0032] S6. Fill the inner space after the skeleton is shelled with a second constant density lattice, and the shell and the second constant density lattice are composited by over-contact;

[0033] S7, extracting the shell from the initial model to form a skin;

[0034] S8, filling the space between the skin and the skeleton shell with a first isodensity lattice, and compounding the first isodensity lattice and the shell in an over-contact manner;

[0035] S9. Composite the skeleton, skin, and first-equal-density lattice in a unified coordinate system to form a lightweight, integrated humanoid robot thigh.

[0036] The beneficial effects of the present invention are that the thigh of the present invention is made of a material with higher strength than ordinary aluminum, and a topological design method is used in the design, so it has the effects of light weight and high strength, and is 50% lighter than a solid part. The strength meets the use requirements after simulation; the thigh of the present invention is an integrated molding structure, and the integrated appearance maintains the appearance contour formed by the industrial design to the greatest extent, which is closer to human aesthetic needs; compared with traditional machined structural parts + plastic shells, it can reduce the number of connection points, which helps to increase the service life of the thigh parts; the present invention effectively avoids the vibration problem of plastic appearance parts caused by mechanical connections when the robot moves, saves the assembly time of the leg parts, and at the same time the configuration design is relatively simple, which effectively reduces the total weight of the leg parts while the stiffness meets the use requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] FIG1 is a schematic diagram of the three-dimensional structure of the thigh of a humanoid robot according to the present invention;

[0038] FIG2 is a schematic diagram of the three-dimensional structure of the skeleton of the present invention;

[0039] FIG3 is a longitudinal cross-sectional view of the skeleton of the present invention;

[0040] FIG4 is a second longitudinal cross-sectional view of the skeleton of the present invention;

[0041] FIG5 is a longitudinal cross-sectional view of a second isodensity lattice filled in the framework of the present invention;

[0042] FIG6 is a longitudinal cross-sectional view of the skin according to the present invention.

[0043] In the figure, the skeleton 1, the housing 11, the first motor mounting portion 111, the first motor mounting slot 112, the weight reduction slot 113, the first communication line slot 114, the first bearing mounting slot 115, the first bearing end cover fitting portion 116, the motor power line slot 117, the slope portion 118, the first reinforcing plate 12, the second reinforcing plate 13, and the second uniform density lattice 14;

[0044] Skin 2, second motor mounting part 21, hip motor cover 22, second motor mounting slot 23, PCB board mounting slot 24, PCB cover mounting part 25, second bearing mounting slot 26, second bearing end cover fitting part 27, second communication wire slot 28, decorative plate mounting slot 29, decorative plate mounting part 30. DETAILED DESCRIPTION

[0045] Exemplary embodiments will be described in detail herein, examples of which are illustrated in the accompanying drawings. In the following description, when referring to the drawings, like numbers in different figures represent like or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all possible embodiments consistent with the present invention. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present invention, as detailed in the appended claims.

[0046] The terms used in this invention are for the purpose of describing specific embodiments only and are not intended to limit the invention. The singular forms "a," "the," and "the" used in this invention and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0047] It should be understood that although the terms "first," "second," "third," etc. may be used in the present invention to describe various information, such information should not be limited to these terms. These terms are merely used to distinguish information of the same type from one another. For example, first information may also be referred to as second information, and similarly, second information may also be referred to as first information, without departing from the scope of the present invention. Depending on the context, the term "if" as used herein may be interpreted as "when," "when," or "in response to determining."

[0048] The present invention will be described in detail below with reference to the accompanying drawings. Unless there is any conflict, the features of the following embodiments and implementations may be combined with each other.

[0049] Referring to Figure 1, the humanoid robot thigh of the present invention is an integrally molded structure. The thigh components are integrally formed using a selective laser melting process, without mechanical or welded joints. The thigh comprises a skeleton 1, skin 2, and a first isodensity lattice filling the space between the skeleton 1 and skin 2. The skeleton 1 and skin 2 are integrally molded using a selective laser melting process, without mechanical or welded joints. Skeleton 1 is the load-bearing portion of the humanoid robot thigh, and has a configuration of "locally thickened shell 11 + second isodensity lattice 14." Skin 2 is the exterior portion of the humanoid robot thigh, and has equal thickness. The first isodensity lattice is located within the cavity between the exterior and load-bearing portions, forming an integrally molded structure.

[0050] Preferably, the material used for the thigh is aluminum magnesium scandium zirconium, and the process used for the thigh is laser metal 3D printing.

[0051] It should be noted that, during the thigh model design stage, the skeleton 1 and skin 2 are first designed independently, and then the models of the skeleton 1 and skin 2 are compounded in the same coordinate system, and then the complex is integrally molded through a selective laser melting process. Therefore, the humanoid robot thigh described in the present invention is an integrally molded structure.

[0052] It should be understood that the selective laser melting process is a metal processing process that can be used to perform grooves, holes, and other processing on the composite thigh, which helps to increase the rigidity of the thigh structure and is also required for the routing of electrical wires and communication lines.

[0053] In this embodiment, the skeleton 1 includes a shell 11, a first reinforcing plate 12, a second reinforcing plate 13, and a second uniform density lattice 14, as shown in Figures 3 and 4. Two first reinforcing plates 12 are symmetrically arranged at the upper end of the shell 11, and the second reinforcing plate 13 is arranged at the lower end of the shell 11. The second uniform density lattice 14 fills the remaining space in the skeleton 1 after removing the shell 11, the first reinforcing plates 12, and the second reinforcing plates 13.

[0054] It should be understood that the skeleton 1 is a hollow structure, which is equivalent to the shell 11 on the outside. The internal structure includes a first reinforcing plate 12 and a second reinforcing plate 13 , and the internal hollow part is filled with the second equal-density lattice 14 .

[0055] Furthermore, the upper end of the housing 11 is provided with a first motor mounting portion 111 and a first motor mounting slot 112 for mounting a motor. The first motor mounting slot 112 is provided below the first motor mounting portion 111. The motor is mounted in the first motor mounting portion 111 and is locked by the first motor mounting slot 112 to prevent the motor from moving. The middle portion of the housing 11 is provided with a weight reduction slot 113, a first communication line slot 114, a motor power line slot 117, and a slope 118. The weight reduction slot 113 is located above the slope 118. The provision of the weight reduction slot 113 helps reduce the weight of the thigh and is conducive to lightweight design. The first communication line slot 114 can be used to accommodate communication lines, which can make the overall wiring of the thigh structure more regular. The motor power line slot 117 is used to accommodate the motor power line, which can make the overall wiring of the thigh structure more regular. The slope 118 can be used to transmit force. The lower end of the shell 11 is provided with a first bearing mounting groove 115 and a first bearing end cover fitting portion 116, wherein the first bearing mounting groove 115 is used to install the knee bearing. During installation, the knee bearing is installed into the first bearing mounting groove 115 so that the knee bearing fits with the first bearing end cover fitting portion 116 of the first bearing mounting groove 115. Then, in order to prevent the knee bearing from falling out of the first bearing mounting groove 115 after long-term use, it is fixed with a bearing cover, and the bearing cover is connected to the thigh with threads, as shown in Figure 2.

[0056] It should be understood that when the motor and bearing are assembled on the thigh, a machining allowance of 0.5mm-1.5mm should be reserved to ensure machining accuracy. The housing 11 is a continuous housing that includes the overall outline of the frame 1.

[0057] Furthermore, the thickness of the housing 11 is 2.1 mm to 2.5 mm. It should be understood that the thickness of the housing 11 is generally greater than or equal to 2.1 mm and less than or equal to 2.5 mm.

[0058] Furthermore, the housing 11 is partially thickened, and the thickened parts are the threaded hole wall, the bearing hole wall and the positioning pin hole wall, and the thickened thickness is twice the normal thickness.

[0059] Furthermore, the first motor mounting portion 111 is provided with screw holes evenly distributed in the axial direction. The four surfaces on the first motor mounting slot 112 that match the motor are machined with an upper deviation less than or equal to 0.05 mm and a lower deviation of 0 mm.

[0060] Furthermore, the length of the weight-reducing groove 113 is 1 / 4-1 / 3 of the length of the skeleton 1 , and the width is approximately 1 / 2 of the width of the shell 11 in this area.

[0061] Furthermore, the inclination angle of the slope portion 118 relative to the length of the thigh is between 45° and 60°, that is, the inclination angle of the slope portion 118 relative to the length of the thigh is greater than or equal to 45° and less than or equal to 60°. The radius of the fillet in the transition area between the slope portion 118 and the vertical surface of the frame 1 is greater than or equal to 5mm and less than or equal to 10mm, as shown in Figure 3.

[0062] Furthermore, the upper end of the first reinforcing plate 12 is connected to the bottom surface of the first motor mounting slot 112, and the lower end of the first reinforcing plate 12 is connected to the longitudinal wall of the housing 11, as shown in Figure 3. The lower end of the first reinforcing plate 12 reaches a position 1 / 3 to 2 / 3 of the length of the weight reduction slot 113.

[0063] Furthermore, a powder leakage hole 121 is provided on both the first reinforcing plate 12 and the second reinforcing plate 13. The powder leakage hole 121 is elliptical in shape, with its major axis parallel to the length direction of the corresponding first reinforcing plate 12 or second reinforcing plate 13, and its minor axis length being less than or equal to 1 / 2 of the width of the corresponding first reinforcing plate 12 or second reinforcing plate 13. That is, the powder leakage hole 121 provided on the first reinforcing plate 12 has its major axis parallel to the length direction of the first reinforcing plate 12, and its minor axis length being less than or equal to 1 / 2 of the width of the first reinforcing plate 12. The diameter of the powder leakage hole 121 is 3-4 mm. It should be noted that the location of the powder leakage hole 121 should be as concealed as possible.

[0064] Furthermore, the first isodensity lattice and the second isodensity lattice 14 have the same cell structure parameters, wherein the cell structure parameters include cell side length, rod diameter and inclination angle.

[0065] Furthermore, the cell of the second iso-density lattice 14 is a body-centered cubic structure. The cell type of the second iso-density lattice 14 can change the vertical side length on the basis of the body-centered cubic structure, and the floating range of the side length is 1 to 1.5 times the original side length.

[0066] Furthermore, the ratio of the rod diameter to the cell side length of the first and second iso-density lattices 14 is 1 / 7 to 1 / 9, and the rod diameter is greater than or equal to 0.5 mm. As shown in FIG5 , the cell side length of the second iso-density lattice 14 is 4 mm, and the rod diameter is 0.5 mm.

[0067] Furthermore, the second isodensity lattice 14 and the first isodensity lattice are oriented parallel to the length direction of the thigh.

[0068] In this embodiment, the skin 2 can be understood as a shell after the overall outline of the thigh is extracted. As shown in Figure 6, the upper end of the skin 2 is provided with a second motor mounting portion 21, a hip motor cover 22 and a second motor mounting slot 23. The hip motor cover 22 surrounds the second motor mounting portion 21. The second motor mounting slot 23 is provided below the second motor mounting portion 21. The motor is installed in the second motor mounting portion 21. At the same time, the motor is clamped by the second motor mounting slot 23 to prevent the motor from moving. The hip motor cover 22 surrounds the installed motor. A PCB board mounting groove 24 and a PCB cover mounting portion 25 are provided on one side of the middle part of the skin 2, and a decorative panel mounting groove 29 and a decorative panel mounting portion 30 are provided on the other side. A second communication line groove 28 is provided in the middle part of the skin 2, wherein the PCB board is installed in the PCB mounting groove 24, and then the PCB cover is installed in the PCB cover mounting portion 25, which can cover the PCB board and protect the PCB board installed on the inner thigh; a decorative panel mounting groove 29 and a decorative panel mounting portion 30 are provided on the outer side of the thigh, and the two are used together to install the decorative panel. During installation, the decorative panel is installed in the decorative panel mounting groove 29 so that the decorative panel fits the decorative panel mounting portion 30. The lower end of the skin 2 is provided with a second bearing mounting groove 26 and a second bearing end cover fitting portion 27 for installing the knee bearing. During installation, the knee bearing is installed into the second bearing mounting groove 26 so that the knee bearing fits with the second bearing end cover fitting portion 27 of the second bearing mounting groove 26. Then, in order to prevent the knee bearing from falling out of the second bearing mounting groove 26 after long-term use, it is fixed with a bearing cover, and the bearing cover is connected to the thigh with threads.

[0069] Furthermore, the contour of the skin 2 completely fits the contour of the thigh. The contour of the skin 2 is the contour of the thigh, and the appearance of the skin 2 is the appearance of the thigh, as shown in FIG1 .

[0070] Furthermore, the structural positions of the skin 2 and the skeleton 1 correspond, as shown in Figures 2 and 6. For example, the position of the first motor mounting slot 112 on the skeleton 1 corresponds to the position of the second motor mounting slot 23 on the skin 2, and the position of the weight reduction slot 113 on the skeleton 1 corresponds to the position of the PCB board mounting slot 24 and the PCB cover mounting portion 25 of the skin 2, and so on.

[0071] Furthermore, the thickness of the skin 2 is uniform across all parts, and is 1 / 3 to 1 / 2 the thickness of the shell 11. It should be understood that the skin 2 is a thin metal shell of uniform thickness, and its thickness is 1 / 3 to 1 / 2 the thickness of the shell 11. Once the thickness of the skin 2 is determined, the tolerance is generally no more than 0.2 mm.

[0072] Furthermore, the overlapping area between the skin 2 and the shell 11 is set according to the thickness of the shell 11.

[0073] Furthermore, the area where the overlapping area of ​​the skin 2 and the shell 11 transitions to the non-overlapping area is rounded, and the radius is greater than or equal to 0.5 mm, which can prevent the transition area from cracking during 3D printing.

[0074] Furthermore, the motor power line and the communication line have a smooth transition at the intersection of the skeleton 1 and the skin 2 without defects such as steps and protrusions.

[0075] Furthermore, the interface area between the shell 11 and the second isodensity lattice 14 is reliably connected through over-contact of the second isodensity lattice 14, and the interface area between the shell 11, the skin 2 and the first isodensity lattice is reliably connected through over-contact of the first isodensity lattice.

[0076] Furthermore, the motor power line slot 117 is arranged close to the back of the thigh and does not interfere with the PCB board mounting slot 24 and the weight reduction slot 113 on the inner side of the thigh.

[0077] It is worth mentioning that an embodiment of the present invention further provides a humanoid robot, which includes a robot body and the humanoid robot thigh described in any one of the above embodiments.

[0078] In addition, an embodiment of the present invention also provides a method for manufacturing a humanoid robot thigh.

[0079] The manufacturing method of the humanoid robot thigh of the present invention specifically comprises the following steps:

[0080] S1. Extract the three main gaits of humanoid robot movement: landing, starting, and standing on two feet, and analyze the boundary condition characteristics and load values ​​of the humanoid robot thigh under the three main gaits.

[0081] For example, through dynamic simulation, the force direction and magnitude of the thigh structure at the moment of landing and the torque of the knee joint motor can be measured.

[0082] S2. Design an initial model of the humanoid robot thigh that includes industrial design appearance elements.

[0083] Specifically, the initial model can be seen in FIG1 . The initial model is solid, and is subsequently divided into a skeleton 1 and a skin 2 . Operations such as shelling and filling with equal density lattices are all performed based on the initial model.

[0084] S3. Setting boundary condition characteristics and load values ​​on the initial model, performing topological calculations, and analyzing material distribution characteristics on the basis of ensuring the setting of the first communication wire duct 114 and the motor power wire duct 117.

[0085] Specifically, the lower end of the humanoid robot's thigh and the mounting surface of the bearing are set as a six-degree-of-freedom fixed constraint, which can effectively fix the lower end; at the moment when the humanoid robot's thigh contacts the ground when it is downward, the upper end of the thigh will be subjected to a large impact force, which is equivalent to a downward load value of 2400N. Therefore, a vertical downward load of 2400N is set at the center position of the first motor mounting part 111 at the upper end of the thigh, and a counterclockwise torque of 200Nm is set. The torque simulates a load borne by the humanoid robot's thigh when the motor rotates alone and the humanoid robot maintains a kicking posture and does not move. The load is presented in the form of torque. The maximum output torque of the motor in this embodiment is 200Nm, so a counterclockwise torque of 200Nm is set in this embodiment. Only after setting the boundary condition characteristics and load values ​​described above on the initial model can the topology calculation be performed. On the basis of retaining the first communication cable tray 114 and the motor power cable tray 117, the distribution characteristics of the material are analyzed. It can be found that the distribution characteristics such as the area with high stress and the area with low stress can be obtained. Then, the area with low stress can be removed. The high stress indicates that the area is subjected to high force and needs to be strengthened.

[0086] S4. Identify the area where material needs to be removed after topological calculation on the initial model, and complete the removal of material in the area to form a skeleton 1.

[0087] Specifically, topological software can be used to calculate the area where material needs to be removed, and a corresponding rendering will be generated, as shown in FIG2 . Then, the area where material needs to be removed is identified on the initial model, and the material in the area is removed to form a skeleton 1 .

[0088] S5. Perform shell extraction processing on the skeleton 1 to form a skeleton shell 11, and locally thicken the shell 11.

[0089] Specifically, after determining the thickness of the shell 11, the skeleton 1 is shelled according to the thickness to form the skeleton shell 11. For some special areas such as important connection parts or areas with relatively large load-bearing, such as threaded hole positions, motor mounting surface positions, and bearing fitting surface positions, the wall thickness must be controlled above 3 mm. The wall thickness is different from that of ordinary positions and requires additional thickening. Therefore, these special areas of the shell 11 need to be locally thickened.

[0090] S6. The second constant density lattice 14 is used to fill the inner space of the skeleton 1 after the shell is extracted, and the shell 11 and the second constant density lattice 14 are composited in an over-contact manner.

[0091] It should be understood that the over-contact mode can be understood as negative contact, that is, the second equal-density lattice 14 will grow into the shell, not only in the internal space after the skeleton 1 is shelled, but also in the over-boundary space.

[0092] S7. Shell the initial model to form skin 2.

[0093] Specifically, after the thickness of the skin 2 is determined, the initial model is subjected to shell extraction according to the thickness to form the skin 2.

[0094] S8. Fill the space between the skin 2 and the skeleton shell 11 with a first isodensity lattice, and the first isodensity lattice and the shell 11 are composited in an over-contact manner.

[0095] S9. Composite the skeleton 1, the skin 2, and the first isodensity lattice in a unified coordinate system to form a lightweight integrated humanoid robot thigh.

[0096] In summary, the working principle of the manufacturing method of the humanoid robot thigh specifically includes the following: the configuration of the load-bearing part in the present invention is first obtained through topological calculation of the material distribution characteristics under given working conditions, and then the configuration of the load-bearing part is reconstructed according to the material distribution characteristics. Therefore, such a design theoretically has the advantages of light weight and high strength. In order to further reduce weight, the load-bearing part is designed to be a "shell + lattice" configuration. The thickness of the shell 11 is greater than the thickness of the skin 2 of the appearance part. The shell 11 of the load-bearing part is the most important load-bearing component of the entire structure. The thickness of the shell 11 is increased in the area where stress concentration may occur. In order to increase the stiffness of the load-bearing part and at the same time eliminate the support remaining in the cavity during the 3D printing process, the cavity inside the load-bearing part is filled with a three-dimensional space lattice. The three-dimensional space lattice can specifically be an equal-density lattice. The filling of the equal-density lattice can increase the stiffness of the shell 11. The exterior uses a thin-walled skin 2, which is thinner than the load-bearing shell 11. To improve the dimensional accuracy of the exterior printing and avoid adding or removing supports in the internal dead space, the cavity between the skin 2 and the load-bearing shell 11 is also filled with a uniform density lattice. For the assembly surfaces of the structural components, given the low printing precision of the 3D printing process, sufficient margins are left in the assembly dimensions, and any excess is removed through machining to ensure lightweighting.

[0097] The characteristics of the present invention are: (1) the humanoid robot thigh is divided into a load-bearing part and an appearance part, and the two parts are combined into one, and the integrated molding is achieved through the metal 3D printing process; (2) the configuration of the load-bearing part is obtained by the topological design method, and the influence of the wiring of wires and communication lines inside the thigh on the structural stiffness is considered on the basis of the original initial model, and the reconstructed model is obtained by the subtraction method; (3) the load-bearing part is shelled into a locally thickened shell 11, and the internal cavity is filled with a second isodensity lattice 14; (4) in the part where the appearance part and the load-bearing part overlap, the thickness of the shell 11 is processed according to the thickness of the load-bearing part shell 11; (5) in the area where the appearance part and the load-bearing part overlap, the external contour of the structural part remains unchanged; (6) the first isodensity lattice is used to fill the space between the load-bearing part shell 11 and the appearance part skin 2, and the parameters of the first isodensity lattice in this area are the same as the parameters of the second isodensity lattice 14 inside the load-bearing part.

[0098] The above embodiments are intended only to illustrate the design concepts and features of the present invention. Their purpose is to enable those skilled in the art to understand the contents of the present invention and implement them accordingly. The scope of protection of the present invention is not limited to the above embodiments. Therefore, any equivalent changes or modifications made based on the principles and design concepts disclosed in the present invention are within the scope of protection of the present invention.

Claims

1. A humanoid robot thigh, characterized in that: The thigh is an integrally formed structure, and the components of the thigh are integrally formed by a selective laser melting process. The thigh includes: A skeleton (1) comprising a shell (11), a first reinforcing plate (12), a second reinforcing plate (13) and a second uniform density lattice (14), wherein two first reinforcing plates (12) are symmetrically arranged at the upper end of the shell (11), the second reinforcing plate (13) is arranged at the lower end of the shell (11), and the second uniform density lattice (14) fills the remaining space after the shell (11), the first reinforcing plate (12) and the second reinforcing plate (13) are removed from the skeleton (1); A skin (2), the upper end of which is provided with a second motor mounting portion (21), a hip motor cover (22) and a second motor mounting slot (23), the hip motor cover (22) surrounds the second motor mounting portion (21), and the second motor mounting slot (23) is arranged below the second motor mounting portion (21); a PCB board mounting slot (24) and a PCB cover mounting portion (25) are arranged on one side of the middle portion of the skin (2), and a decorative board mounting slot (29) and a decorative board mounting portion (30) are arranged on the other side, and a second communication line slot (28) is arranged in the middle portion of the skin (2); a second bearing mounting slot (26) and a second bearing end cover fitting portion (27) are arranged at the lower end of the skin (2); and A first isodense dot matrix is ​​filled between the skeleton (1) and the skin (2).

2. The humanoid robot thigh according to claim 1, characterized in that: The material used for the thigh is aluminum magnesium scandium zirconium, and the process used for the thigh is laser metal 3D printing.

3. The humanoid robot thigh according to claim 1, characterized in that: A motor mounting portion (111) and a first motor mounting slot (112) are provided at the upper end of the housing (11), and the first motor mounting slot (112) is provided below the first motor mounting portion (111); A weight-reducing groove (113), a first communication wire groove (114), a motor power wire groove (117) and a slope portion (118) are provided in the middle portion of the housing (11), and the weight-reducing groove (113) is located above the slope portion (118); The lower end of the housing (11) is provided with a first bearing installation groove (115) and a first bearing end cover fitting portion (116).

4. The humanoid robot thigh according to claim 1, characterized in that: The thickness of the shell (11) is 2.1 mm-2.5 mm; The thickness of the skin (2) is 1 / 3 to 1 / 2 of the thickness of the shell (11).

5. The humanoid robot thigh according to claim 1, characterized in that: The upper end of the first reinforcing plate (12) is connected to the bottom groove surface of the first motor installation groove (112), and the lower end of the first reinforcing plate (12) is connected to the longitudinal wall surface of the housing (11).

6. The humanoid robot thigh according to claim 1, characterized in that: The first reinforcing plate (12) and the second reinforcing plate (13) are both provided with powder leakage holes (121); The powder leakage hole (121) is elliptical, with its major axis being parallel to the length direction of the corresponding first reinforcing plate (12) or the second reinforcing plate (13), and the length of its minor axis being less than or equal to 1 / 2 of the width of the corresponding first reinforcing plate (12) or the second reinforcing plate (13); The powder leakage hole (121) has a diameter of 3-4 mm.

7. The humanoid robot thigh according to claim 1, characterized in that: The cell structure parameters of the first isodense lattice and the second isodense lattice (14) are the same, wherein the cell structure parameters include cell side length, rod diameter and inclination angle; The ratio of the rod diameter to the cell side length of the first isodense lattice and the second isodense lattice (14) is 1 / 7 to 1 / 9, and the rod diameter is greater than or equal to 0.5 mm.

8. The humanoid robot thigh according to claim 1, characterized in that: The interface area between the shell (11) and the second isodensity lattice (14) is reliably connected through over-contact of the second isodensity lattice (14), and the interface area between the shell (11), the skin (2) and the first isodensity lattice is reliably connected through over-contact of the first isodensity lattice.

9. A humanoid robot, characterized in that: include: Robot body; and The humanoid robot thigh according to any one of claims 1 to 8.

10. A method for manufacturing a humanoid robot thigh according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1. Extract the three gaits of the humanoid robot: landing, starting, and standing on both feet, and analyze the boundary condition characteristics and load values ​​of the humanoid robot's thigh under these three gaits; S2, an initial model of the humanoid robot thigh design including industrial design appearance elements; S3. Setting boundary condition characteristics and load values ​​on the initial model, performing topological calculations, and analyzing material distribution characteristics; S4, identifying the area where material needs to be removed after topological calculation on the initial model, and completing the removal of the material in the area to form a skeleton (1); S5, performing a shell extraction process on the skeleton (1) to form a skeleton shell (11), and locally thickening the shell (11); S6, using a second equal density lattice (14) to fill the internal space of the skeleton (1) after the shell is extracted, and the shell (11) and the second equal density lattice (14) are composited in an over-contact manner; S7, extracting the shell from the initial model to form a skin (2); S8, using a first isodense lattice to fill the space between the skin (2) and the skeleton shell (11), and the first isodense lattice and the shell (11) are composited in an over-contact manner; S9, compounding the skeleton (1), the skin (2) and the first isodensity lattice in a unified coordinate system to form a lightweight integrated humanoid robot thigh.

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