Reducer Torque Sensing Structure for Closed-Loop Accuracy
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Solution Overview
Problem
Existing reducers and servo motors in open-loop applications suffer from reduced accuracy due to temperature effects and complex design mechanisms when additional encoders are added for closed-loop feedback control, leading to increased costs and routing issues.
Innovation Solution
A reducer with a torque sensing structure and flexible components that utilize encoders for closed-loop feedback control, incorporating a flexible body and arms to measure torsional deformation for improved accuracy, with encoders placed between the reducer and motor to minimize complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an encoder is added at the output end of the reducer for closed-loop feedback control, then control accuracy is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent merges the encoder module with the output shaft assembly by integrating the encoder disk directly onto the output shaft and positioning the encoder reader on the housing. This integration eliminates separate encoder mounting mechanisms and simplifies the overall structure while maintaining closed-loop feedback functionality. The encoder components are combined with existing structural elements rather than being added as separate assemblies.
2Measurement precision
If an encoder is added at the output end of the reducer for closed-loop feedback control, then control accuracy is improved, but cost increases significantly
Solution Approach 1:
The output shaft assembly serves multiple functions: it transmits mechanical power, provides mounting for the encoder disk, and acts as a reference element for the encoder measurement system. The housing serves dual purposes as both structural support and mounting surface for the encoder reader. This multi-functionality reduces the need for additional specialized components, thereby lowering manufacturing costs.
3Measurement precision
If an encoder is added at the output end of the reducer for closed-loop feedback control, then control accuracy is improved, but circuitry and routing become difficult issues
Solution Approach 1:
The encoder reading function is extracted as a separate modular component (encoder reader) that can be independently positioned and wired. The encoder disk is extracted as a separate element that can be mounted on the output shaft without interfering with other components. This modular extraction simplifies circuit routing by allowing independent wiring paths for each encoder component rather than requiring complex integrated wiring.
4Measurement precision
If a direct drive system is used to eliminate reducer loss and backlash, then efficiency and precision are improved, but motor size and cost increase for high torque applications
Solution Approach 1:
The patent implements closed-loop feedback control by measuring the actual output position with the encoder and comparing it with the commanded position. The control system uses this feedback information to compensate for reducer backlash and precision errors, allowing the use of a smaller motor with reducer while achieving precision comparable to or better than a direct-drive system. The feedback mechanism enables software-based compensation that replaces the need for oversized motors.
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
Enhances control accuracy by calculating output torque through torsional deformation measurement, reducing design complexity and costs while maintaining space efficiency.
Implementation Method 1
The flexible component includes a flexible body and at least two flexible arms, wherein the flexible body is axially arranged on the output end, the at least two flexible arms are perpendicular to the axial direction, and extended outwardly from the flexible body, and the at least two flexible arms are allowed to deform under force and make the flexible body to form a shifted position difference
Data Source
AI summary
A reducer with a torque sensing structure and a flexible component thereof are disclosed. The flexible component is axially arranged on an output plate of a rotating mechanical device such as a reducer, and includes a flexible body and at least two flexible arms. The flexible body is axially arranged on the output plate. The at least two flexible arms are extended outwardly from the flexible body perpendicular to the axial direction. When the reducer outputs torque through the output plate, the at least two flexible arms are deformed by force, causing the flexible body to form a shifted position difference. By comparing the shifted position difference and a rotational position of the output plate, an output torque value can be calculated to realize the application of the torque sensor.