Axial-Flux Motor Joint Module for High Torque in Thin Form

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Solution Overview

Problem

Existing joint modules are bulky due to the use of iron materials, leading to increased weight and energy wastage, which hinders their application in space-constrained environments.

Innovation Solution

Incorporation of an axial magnetic flux motor with a lightweight metal and PEEK material housing, along with a harmonic reducer and dual encoder, to create a compact, high-torque, and lightweight joint module.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If iron materials are used for housing and components, then electromagnetic shielding effect is improved, but weight increases

Engineering Contradiction:

Improveelectromagnetic shielding effectVSAvoidjoint module weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses aluminum alloy for the housing instead of traditional iron materials, combining lightweight properties with electromagnetic shielding capability. The aluminum alloy housing integrates both structural support and electromagnetic shielding functions, reducing weight while maintaining shielding effectiveness against external magnetic fields and motor leakage fields.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies localized electromagnetic shielding measures rather than using heavy iron materials throughout. The aluminum alloy housing provides distributed shielding, and specific components like the encoder magnetic ring are protected through strategic positioning and design, achieving effective shielding with reduced overall weight.

Inventive Principle:

Principle #3Local quality

2Device complexity

If traditional radial magnetic flux motor is used, then motor structure is simple, but axial length increases and torque density decreases

Engineering Contradiction:

Improvemotor structure complexityVSAvoidaxial length

Core Design Contradiction:

Device complexityVSLength of moving object

Solution Approach 1:

The patent inverts the traditional radial magnetic flux motor design by adopting an axial magnetic flux motor configuration. In the axial magnetic flux motor, the magnetic flux flows axially between the stator and rotor, allowing the motor to achieve high torque density in a compact axial space, thereby reducing the overall axial length of the joint module while maintaining structural feasibility.

Inventive Principle:

Principle #13The other way round (Inversion)

3Device complexity

If traditional radial magnetic flux motor is used, then motor design is conventional, but torque output relative to volume is lower

Engineering Contradiction:

Improvemotor design conventionalnessVSAvoidtorque output

Core Design Contradiction:

Device complexityVSPower

Solution Approach 1:

The patent adopts axial magnetic flux motor design where the magnetic flux path is arranged axially rather than radially. This configuration allows for higher torque density because the magnetic flux directly links the stator and rotor across the axial gap, enabling more efficient torque generation within the same volume, thus improving power output without significantly increasing design complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the fundamental magnetic flux path parameter from radial to axial direction. This parameter change enables the motor to achieve higher torque density by optimizing the magnetic circuit configuration, where the axial flux path allows for more effective utilization of magnetic material and better torque generation per unit volume.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution results in a high-torque, high-energy density, and lightweight joint module that efficiently utilizes power output, reducing the axial length and enhancing torque-to-weight ratio.

Implementation Method 1

an axial magnetic flux motor is incorporated in a power component

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 2

the gear reducer component is provided with a harmonic reducer

Methodology Applied

Scientific EffectMechanical transmission: Gear

Data Source

PatentUS12483082B1Thin motor joint module

Publication Date: 2025.11.25 SHENZHEN KOMO INNOVATION ROBOTICS TECHNOLOGY CO LTD

AI summary

A thin motor joint module is provided, which includes a power component, a gear reducer component, and an output component, the power component, the gear reducer component, and the output component are all provided in a housing. The power component is provided with an axial magnetic flux motor, the gear reducer component is provided with a harmonic reducer, and the housing is composed of lightweight metal materials and PEEK materials. The advantage of the present disclosure is that the axial magnetic flux motor is provided in the power component. Compared with traditional radial magnetic flux motors, the axial magnetic flux motor is flatter and outputs a larger torque, which can reduce an axial length of the joint module and ensure a larger output torque. The housing is made of lightweight metal materials and PEEK materials, thus forming a high torque, high energy density, and lightweight joint module.