Collaborative Robot Joint Module with Integrated Multi-Turn Encoder
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Solution Overview
Problem
The high cost and complexity of encoder calibration in collaborative robot arms, coupled with high failure rates and the need for specialized equipment and engineers, hinder market competitiveness and production efficiency.
Innovation Solution
A joint module for collaborative robot arms utilizing a multi-turn absolute encoder integrated with a base, bearing, rotating shaft, and circuit board, allowing for individual calibration before assembly and easy replacement or disassembly, reducing the need for recalibration and specialized equipment during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual single-turn absolute encoders are used on motor output shaft and reducer output shaft, then security functions are improved, but production cost increases
Solution Approach 1:
The patent merges the functions of two separate single-turn absolute encoders into a single multi-turn absolute encoder. The multi-turn absolute encoder integrates the encoding disk, bearing, rotating shaft, and circuit board into one unified component that provides both single-turn and multi-turn positioning capabilities, thereby reducing component count and production cost while maintaining the required security functions.
Solution Approach 2:
The multi-turn absolute encoder serves multiple functions: it provides absolute positioning information for both the motor shaft and reducer shaft, enables collision detection, monitors encoder faults, and offers multi-turn revolution counting. This multi-functional design replaces the need for separate encoders and calibration systems, reducing overall system cost and complexity.
2Reliability
If dual single-turn absolute encoders are used, then security functions are improved, but calibration complexity increases
Solution Approach 1:
The multi-turn absolute encoder is pre-calibrated during manufacturing to provide accurate absolute positioning information without requiring field calibration. The encoder includes pre-configured parameters and initialization routines that automatically establish the reference position, eliminating the need for complex calibration procedures during installation or maintenance.
Solution Approach 2:
The encoder system performs self-initialization and self-calibration through automated routines executed by the control board. The multi-turn absolute encoder automatically detects its reference position and configures its parameters without requiring external calibration equipment or specialized engineers, thereby simplifying the deployment and maintenance process.
3Ease of manufacture
If multi-turn absolute encoder is used, then production cost is reduced, but encoder failure impact increases
Solution Approach 1:
The system implements redundancy and fault detection mechanisms to cushion against encoder failures. The control board continuously monitors the multi-turn absolute encoder for anomalies and can detect encoder faults before they lead to system failure. Additionally, the system maintains operational safety by having backup detection methods and by designing the control logic to handle encoder failures gracefully.
4Productivity
If integrated multi-turn absolute encoder design is used, then assembly efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The integrated encoder design segments the encoder into modular components (encoding disk, bearing, rotating shaft, circuit board) that are precision-manufactured and pre-assembled as a unit. This modular segmentation allows for precise manufacturing of individual components in controlled environments, then facilitates easy integration into the robot joint without requiring high-precision field assembly.
Data Source
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AI summary
The present disclosure provides a collaborative robot arm and a joint module (11). The joint module includes a housing (111), a driving assembly (112), and a multi-turn absolute encoder. The joint module detects the angular position of the output shaft (1121) and records a number of rotating revolutions of the output shaft only by means of the multi-turn absolute encoder. The multi-turn absolute encoder includes a base (1153), a bearing (11551), a rotating shaft (1154), an encoding disk (1151A), and a circuit board (1157), the encoding disk is rotatably connected with the base by the rotating shaft and the bearing, the circuit board is fixedly connected with the base, and the reading head (1152A) on the circuit board detects the angular position of the output shaft cooperatively with the encoding disk, making the multi-turn absolute encoder be an integrated structure. The base and the rotating shaft are detachably connected with the housing and the output shaft respectively.