Modular Rotational Actuator with Integrated Torque Sensing
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Solution Overview
Problem
Prior art prosthetic and robotic limbs lack the power density, portability, and ergonomic design of human arms, with inefficient electromechanical drives, bulky connections, and limited degrees of freedom, and fail to provide integral torque and position sensing for modular and weather-tight connections.
Innovation Solution
A modular rotational electric actuator with integrated control electronics, a friction planetary gear assembly, cycloidal gear stage, and a resilient joint connector that allows quick connection and disconnection of limb segments, incorporating torque and position sensors for precise control and load measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electromechanical devices are used to drive robotic limbs, then the limbs can achieve basic movement functions, but the devices become bulky, heavy, and inefficient, reducing power density
Solution Approach 1:
The patent combines the motor, gear train, control electronics, and sensors into a single integrated actuator module. This merging of previously separate components into one compact unit achieves high power density while minimizing weight, directly resolving the contradiction between power output and weight.
Solution Approach 2:
The patent employs a nested arrangement where the gear train is positioned within the motor housing, and control electronics are integrated within the same compact space. This nesting of components maximizes space utilization and achieves high power density without increasing weight proportionally.
2Reliability
If custom bolted and screwed mechanical connections are used for each joint, then the connections can be mechanically secure, but the electrical interconnections require complex wiring harnesses and bulky connectors
Solution Approach 1:
The patent merges mechanical connections and electrical interconnections into a single integrated connector. This unified connector provides both mechanical support and electrical pathways simultaneously, eliminating the need for separate wiring harnesses and reducing device complexity while maintaining connection reliability.
Solution Approach 2:
The connector is designed to serve multiple functions: mechanical support, electrical power transmission, and data communication. This multi-functional universal connector works across all joint modules, simplifying the overall system architecture and reducing wiring complexity.
3Adaptability or versatility
If prosthetic arms are designed with basic three-way movement (elbow bend, wrist rotation, hand clamp), then the design is simple, but the degrees of freedom are limited compared to human arms
Solution Approach 1:
The patent divides the prosthetic arm into multiple modular joint segments, each with its own actuator and connector. This segmentation allows each module to be independently controlled, enabling complex multi-degree-of-freedom movement while keeping individual module complexity manageable through standardization.
Solution Approach 2:
The patent employs dynamic control of multiple joint modules with independent actuators, allowing real-time adjustment of degrees of freedom based on task requirements. This dynamic capability enables the prosthetic to adapt between simple and complex movement patterns without requiring permanently complex mechanical structures.
4Measurement precision
If conventional prosthetics lack integral torque and position sensing, then the design is simpler, but the ability to sense loads and stresses in the limb is insufficient
Solution Approach 1:
The patent integrates torque sensors and position sensors directly within each actuator module, combining sensing functions with actuation. This integration achieves precise measurement of torque and position while minimizing additional complexity by sharing the actuator housing and control electronics.
Solution Approach 2:
The integrated sensors provide real-time feedback on torque and position to the control system, enabling precise control and monitoring of each joint. This feedback mechanism enhances measurement precision and allows the prosthetic to adapt to load conditions dynamically.
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 provides a compact, lightweight, high-torque actuator with improved degrees of freedom, reduced power requirements, and enhanced ergonomics, enabling robust and precise control of prosthetic or robotic limbs with integrated torque and position sensing.
Implementation Method 1
The resilient member elastically couples the joint connector to a portion of the output housing
Implementation Method 2
a first gear train and motor assembly which includes at least one friction planetary gear assembly and a motor
Data Source
AI summary
A modular rotational electric actuator includes an output housing and internal drive components that include integrated control electronics, a torque sensor, and a portion of a joint assembly. The joint assembly includes a joint connector coupled to the internal drive components, including integrated control electronics, e.g., by a resilient member. The resilient member elastically couples the joint connector to a portion of the output housing, the joint connector including a portion that extends outward therefrom.