Drive unit for robotic manipulators

Abstract

In one form there is disclosed an internally balanced involute-type speed reducer; the reducer comprising a stator stage, an input stage, an output stage, and a plurality of gear sets in mesh. In a further form there is disclosed an actuator assembly for a robot; said actuator assembly comprising a stator core located within an outer housing and subtended by inner and outer mounting hubs; said hub supporting a drive train and bearings within the actuator assembly. In a further form there is disclosed a transducer system operable in conjunction with the reducer or actuator assembly.

Claims

1. An internally balanced involute-type speed reducer; the reducer comprising a stator stage, an input stage, an output stage, and a plurality of gear sets in mesh, the reducer further comprising: a stator ring gear including a row of many gear teeth fixedly connected to a stator core by a direct coupling, and a rotor providing input torque rotatably connected to the stator core about a central axis and inclusive of an offset crank with offset axis parallel to the central axis and offset by a distance of the crank offset, and an offset crank fixedly connected to the rotor, the crank rotatably connected to a compound pinion; the crank offset sized to position the compound pinion teeth in mesh on one side with the ring gears; the rotor rotating with gears in mesh between the stator ring gear and pinion teeth; whereby the compound pinion precesses round the stator ring gear; a counterweight fixedly connected to the rotor and located in a void between an external gears and the ring gears and 180 degrees out of phase with the offset crank of the rotor, and the compound pinion including two rows of many gear teeth laid out in rows that mesh with ring gear and output gear where their pitch circles intersect at only one point per mesh; the compound pinion being rotatably connected to the rotor about the offset) crank axis, and an output ring gear coaxial to the stator and comprising: a plurality of gear teeth distributed evenly about the central axis and in constant mesh with the gears of the compound pinion; whereby precession of the compound pinion around the stator ring gear induces rotation of the output ring gear about the central axis; the reducer gear ratio set by difference between the reduction ratio of the compound pinion and stator ring gear and the reduction ratio of the pinion gears and output ring gear; the output rotation direction set depending on whether the ratio of stator ring gear teeth to pinion teeth is greater or less than that between the output ring gear teeth and the compound pinion teeth, wherein an actuator assembly further includes a hollow center extending through the stator core from end to end; and wherein the two rows of gear teeth of the compound pinion are merged into a single set of many gear teeth laid out in a single row, with teeth extending radially outwards and evenly distributed around the peripheral circumference of the compound pinion and in mesh with both the stator ring gear and the output ring gear.

2. The actuator assembly including the speed reducer of claim 1, further including, an electric motor with motor stator windings fixedly connected to the stator core and motor rotor fixedly connected to the rotor, and a plurality of permanent magnets fixedly connected to the motor rotor and evenly spaced around the periphery of the stator.

3. The actuator assembly of claim 2, further including an outer housing and inner and outer mounting hubs constituting, an outer hollow housing having outer hub rings fixedly connected at each end, and inner mounting hubs fixedly connected to each end of the stator core and rotatably connected with the outer mounting hubs.

4. The actuator assembly of claim 1, wherein a spring element replaces the direct coupling, the spring element elastically connects the stator ring gear the stator core.

5. The actuator assembly of claim 4, wherein the stator ring gear is rotatably connected to the outer housing by a bearing about the central axis to ensure gears of the compound pinion and stator ring gear mesh without misalignment despite the stator ring gear being elastically connected to the stator core.

6. The speed reducer of claim 1, wherein, the two rows of gear teeth of the compound pinion comprise a primary row and an output row that extend from the outer pinion surface and project outwards; and the stator ring gear meshes with the pinion primary row of teeth; the stator ring gear teeth extending from the inner surface of the stator ring gear and projecting inwards, and an output ring gear meshing with the teeth of the output row of the compound pinion; the teeth of the ring gear extending from the inner surface of the stator ring gear and projecting inwards.

7. The speed reducer of claim 6, wherein compound pinion primary and output stages are helical gears of opposing hands with helical gear teeth in mesh with pinion teeth of the correct hand to mesh.

8. The speed reducer of claim 6, wherein the stator ring gear teeth and compound pinion teeth have a cycloid profile and an internal counterbalance is fixedly connected to the rotor and is located within the inner circumference of the compound pinion.

9. The actuator assembly of claim 1, wherein an electronic controller, sensors and cable looms are included.

10. The actuator assembly of claim 9, wherein the sensors include a position sensing transducer signalling relative and absolute angular displacement of the outer housing relative to the stator core.

11. The actuator assembly of claim 10, wherein the actuator assembly is a robot actuator assembly.

12. The actuator assembly of claim 9, wherein the controller is situated in the void between the motor and the inner and outer mounting hubs at the upstream end of the device and is fixedly connected to the stator core.

13. The actuator assembly of claim 1, wherein the inner and outer mounting hubs have a plurality of tapped holes positioned at regular intervals around their axis.

14. The actuator assembly of claim 13, wherein hole geometry is the same for corresponding inner and outer mounting hubs at each end of the device.

15. The actuator assembly of claim 13, further including a plurality of tapped mounting holes on the outer housing.

16. The actuator assembly of claim 13, wherein the bearings that rotatably connect the inner and outer hubs are cone bearings.

17. The actuator assembly of claim 13, wherein the bearings that rotatably connect the inner and outer hubs are deep groove ball bearings.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Embodiments of the present invention will now be described with reference to the accompanying drawings wherein:

(2) FIG. 1 is a perspective view of a first preferred embodiment of a robot muscle actuator

(3) FIG. 2 is a sectioned 3D view of the robot muscle actuator of FIG. 1.

(4) FIG. 3 is a sectioned view showing internal details of components comprising the robot muscle actuator of FIG. 1.

(5) FIG. 4 is a front view of the robot muscle actuator of

(6) FIG. 1 viewed from the downstream side.

(7) FIG. 5 is the back view of the robot muscle actuator from FIG. 1 viewed from the upstream side.

(8) FIG. 6 is an exploded view of the robot muscle actuator of FIG. 1 showing components and subassemblies comprising the embodiment.

(9) FIG. 7 is a logical symbolic sectional view of an embodiment of the actuator.

(10) FIG. 8 is a simplified block schematic sectional view provided as a summary of components of an example of an embodiment and their interrelationship;

(11) FIG. 9 is a logical symbolic view of one embodiment of the speed reducer gears component of an embodiment.

(12) FIG. 10 on the left is a view of the precession drive subassembly as viewed from the downstream side and on the right is the same subassembly as viewed from the upstream side; FIG. 10 illustrates a Balanced involute-type speed reducer (Precession drive) assembly as viewed from the downstream on the left and upstream sides on the right;

(13) FIG. 11 on the left shows the precession drive subassembly viewed from the downstream side and on the right shows a section view C-C of the subassembly shown on the left to reveal the part geometry, inter-relatedness and organization.

(14) FIG. 12 is an exploded view of the precession drive subassembly to more clearly show the geometry of individual parts from which it is comprised.

(15) FIG. 13 is a simplified sketch showing 4 embodiments of the Precession drive

(16) FIG. 14 is a front view on the left and section view C-C on the right of an embodiment of the external pinion compound involute speed reducer.

(17) FIG. 15 is an isometric view of the external pinion compound involute speed reducer of FIG. 14.

(18) FIG. 16 is a front view on the left and section view C-C on the right of an embodiment of the hybrid compound involute type speed reducer.

(19) FIG. 17 is a 3D view of the hybrid compound involute type speed reducer of FIG. 16.

(20) FIG. 18 Front and section view A-A of an embodiment of an inline compound cycloidal reducer

(21) FIG. 19 3D view of an inline compound cycloidal reducer of FIG. 18.

(22) FIG. 20 is a 3D view showing an embodiment of the balanced cycloid type speed reducer compound pinion, bearing retainer and offset crank.

(23) FIG. 21 is a front view on the left and section view A-A on the right showing external and internal details of the balanced cycloid reducer reduction assembly of FIG. 20.

(24) FIG. 22 top view shows an embodiment of the actuator configured to include a spring element which connects the stator ring gear to the stator core thus providing a spring in series with the transmission hence allowing the device to operate as a series elastic actuator;

(25) FIG. 22 bottom view shows an embodiment of the actuator configured with a direct coupling which connects the stator ring gear to the stator core thus providing a rigid transmission

(26) FIG. 23 shows a 3D exploded view of the actuator assembly spring element of FIG. 22.

(27) FIG. 24 is a 3D exploded view showing the stator, outer housing, end mounting hubs, optional hub nut and bearings only. In this embodiment there is no drive train components hence this can be used as a freewheeling wheel hub mount.

(28) FIG. 25 is an exploded view of the actuator configured for direct 1:1 drive with the speed reducer replaced with direct a drive coupling and series elastic element for compliance.

(29) FIG. 26 is a view an application of the robot muscle actuator of FIG. 1 showing how it can be integrated with a control horn, pushrods, clevises and a base mounting plate for operation as a classic radio controlled servo system.

(30) FIG. 27 on the left is a top view and on the right an end view showing an application of the robot muscle actuator of FIG. 1 implemented as a dual tendon capstan drive. FIG. 27 right hand view illustrates a Robot muscle implemented as a dual tendon capstan drive.

(31) FIG. 28 is a 3D view showing an application of the robot muscle actuator of FIG. 1 implemented as a dual tendon capstan drive.

(32) FIG. 29 is a view of three robot muscle actuators from FIG. 1 augmented with additional parts as listed for operation as a three degree of freedom robotic arm elbow configured in such a way that the input and output limbs can fully fold back on themselves.

(33) FIG. 30 on the left is the is a view of the robotic arm elbow of FIG. 29 and on the right is sectioned view A-A of the robotic arm elbow of FIG. 29 showing the outer housing, cone bearings, stator and mounting hubs of the robotic muscle actuator of FIG. 1.

(34) FIG. 31 is a view of three robot muscle actuators of FIG. 1 augmented with additional parts as listed for operation as a three degree of freedom robotic arm elbow configured in such a way that the central axis of each degree of actuation freedom intersects in the joint at a single point for all ranges of motion of all axes.

(35) FIG. 32 on the left is a view of an application of the robot muscle actuator from FIG. 1 augmented with additional parts as listed for operation as powered wheel hub motor. FIG. 32 on the right is a view of the same robot muscle actuator on the left included here for additional clarity.

(36) FIG. 33 is a view of an application of a robot muscle actuator as embodied in FIG. 1 implemented as the powered driving actuator hub of a robotic track drive assembly and also a robot muscle actuator assembly configured without motor, controller and drive train for operation as the second passive hub of the same robotic track drive assembly.

(37) FIG. 34 is a section view of a direct drive electric motor actuator embodiment of a robot actuator;

(38) FIG. 35 is a 3D section view of a direct drive robot actuator of FIG. 34 configured with an electric motor actuator with series elastic spring element.

(39) FIG. 36 shows section views of further embodiments of the actuator illustrated in FIG. 3 through the same section profile.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

First Embodiment

(40) A first embodiment of a robot muscle actuator 64 with precession drive 23 of the present invention is illustrated in FIG. 1 to FIG. 6.

(41) FIG. 1 is a view of a first preferred embodiment of a robot muscle actuator; FIG. 1 more specifically is a 3D view of an electric motor actuator with precession drive transmission supporting stiff servo or series elastic actuator embodiments of a robot muscle actuator and optional controller. A Vernier scale is included on the outer and inner hubs for accurate manual reading of actuator displacement;

(42) FIG. 2 is a sectioned 3D view of the robot muscle actuator showing outer housing 10, hollow stator core, mounting hubs and hub bearings only. Drive train has been omitted for clarity. FIG. 2 illustrates a Section View showing Outer housing, hollow stator core, mounting hubs and hub bearings only. Drive train has been omitted for clarity; FIG. 2 drive train components have been omitted in this configuration to show this novel actuator bearing and hub mounting configuration which is optimised for low weight, high rigidity, high versatility, hollow, scalable and adjustable housings for joints, hubs and actuators. This is the simplest embodiment which can be used as an unpowered joint or wheel hub;

(43) FIG. 3 is a sectioned view showing internal details of components comprising the robot muscle actuator of FIG. 1; FIG. 3 illustrates a Robot muscle actuator front view as seen from the downstream end on the left and shown as section B-B on the right; FIG. 3 features include speed reducer, offset crank counter balance 26, hollow central stator shaft, stator ring gear 25, series elastic spring element 33, controller circuit board 11 and other components comprising this embodiment;

(44) FIG. 4 is the front view of robot muscle actuator from FIG. 1 viewed from the downstream side; FIG. 4 illustrates a Robot muscle actuator front view as seen from the downstream end on the left and shown as section B-B on the right;

(45) FIG. 5 is the back view of robot muscle actuator from FIG. 1 viewed from the upstream side; FIG. 5 illustrates a Robot muscle actuator back view as seen from the upstream end;

(46) FIG. 6 is an exploded view of the robot muscle actuator of FIG. 1 showing components and subassemblies comprising the invention; FIG. 6 illustrates an Exploded view of robot muscle actuator;

(47) The robot muscle actuator 64 is cylindrical in shape and in most but not necessarily all cases may have a hollow centre providing a channel for cabling, hoses and the routing of other connectors to pass through the device from end to end as required. The device may have an external 12 and internal 42 coaxial hub at each end.

(48) The robot muscle actuator 64 shown in FIG. 2 includes an inner hollow stator core 41 passing axially through the centre of the device supporting on bearings at each end an outer housing 10 which is actuated for rotational motion by an internal drive train. The drive train includes an electric motor 14 which drives a speed reducer transmission 23. The speed reducer is fixedly connected to the stator via a direct coupling 62 or a spring element 33 which places the spring element or direct coupling in series with the drive train. The precession drive output drives the outer housing 10 in rotation, torque or positioning.

(49) The bearings at each end of the device can be pre-loaded to prevent any play, flex, backlash or misalignment from occurring in the device even under high static, dynamic and impact triaxle loading. The stator inner mounting hub 43 at the downstream end of the stator is fixedly connected to the stator core in such a way that torque is transferred between the stator core and the stator hub whilst also allowing the stator hub to pre-load the hub bearing. The device has identical stator inner and outer housing outer mounting hubs at both ends of the device which are populated with mounting holes. Placement of these holes has been optimized for maximum diameter to provide the highest possible mounting rigidity and load bearing capacity and also for versatile mounting options for incorporating the device into a machine.

(50) Beyond this the outer housing 10 which rotates with the output mounting hubs 12 and 48 also has a wide variety of mounting options via the hub surface itself and via the variety of mounting holes provided.

(51) The robot muscle actuator prime mover is an electric motor 14 with the motor stator 22 fixedly connected to the stator core and upstream inner hub 41. The motor stator 22 is surrounded by a motor rotor 21 including magnets commonly known as an outrunner motor. The motor rotor 21 is rotatably connected by bearings to the stator core 41 and fixedly connected to rotor with offset crank 26. The hollow stator 41, bearings 34 and offset crank 26 can be seen in FIG. 3 section view. Rotor bearings 30 and 31 support the rotors motion about the central axes.

(52) The balanced compound speed reducer comprises a stator ring gear 25, a rotor with offset crank 26, a compound pinion 28 and an output ring gear 24 and bearings 30, 31 and 29, the improvement being the addition of a counterbalance mass fixedly connected to the rotor 26 which axially and radially balances the rotating components to avoid vibration. The actuator can provide very low backlash with high efficiency and performance at a low cost.

(53) The rotor 26 has an eccentric crank feature for affixing a bearing which gives the bearing the same eccentricity about the rotors central axis as can be seen in left view on FIG. 11. A compound pinion 28 is rotatably connected to the pinion bearing 29 which gives the compound pinion the same eccentricity about the rotors central axes as the pinion bearing 29 and offset crank. This eccentricity is set such that the teeth of the compound pinion 28 form a mesh on one side with the teeth on the stator ring gear 25 and output ring gear 24 and do not mesh on the opposite side. The mesh between the stator ring gear teeth and the compound pinion teeth is the stator mesh and the mesh between the output ring gear 24 and the compound pinion 28 is the output mesh.

(54) Torque from the motor rotor 21 provides the input to the speed reducer causing the rotor with offset crank 26 to rotate about the central axis.

(55) As the rotor with offset crank 26 rotates the stator mesh causes the compound pinion 28 to precess around the stator ring gear 25. As the stator ring gear 25 is fixedly connected to the stator core 41 the compound pinion 28 will process and rotate in the opposite direction of rotor motion with a velocity ratio dictated by the stator mesh ratio which is the ration of teeth of the stator ring gear 25 to the number of teeth in mesh with this gear on the compound pinion 28. Compound pinion rotation drives the output ring gear 24 with relative ratio of the output mesh given by the ration of teeth on this compound pinion and the teeth on the output ring gear 24.

(56) The final speed reducer reduction ratio or rotor speed to output ring gear speed is given by the difference between ration of stator mesh to the ratio of the output mesh.

(57) So the key to setting the final speed reducer output is careful selection teeth numbers in the stator and output meshes.

(58) Set as similar as possible stator and output mesh ratios to produce high reduction ratios and set as different as possibly stator and output mesh ratios for low reduction ratios. Furthermore the direction of output motion at the output ring gear 24 is determined in sense by which of the stator mesh or output mesh has the larger ration. For transmissions with higher reduction at the stator mesh than at the output mesh, the resultant motion at the secondary output ring gear is in the same as the direction of motor rotor rotation. Example teeth counts and the resulting output ratio can be seen in TABLE. 2.

(59) Note that to avoid gear interference of gear teeth with involute profiles and with pressure angle of 14.5 degrees, the difference in tooth numbers between the ring gear and pinion should not be less than 15. For teeth with involute gear profiles and with pressure angle of 20 degree the difference in tooth numbers should not be less than 12 to avoid tooth interference. This is not the case with cycloid gear profiles as they effectively have significant addendum modifications.

(60) The device is easily configured to be either a standard rigid servo actuator or a series elastic actuator based on the which connector element is used fixedly connect reducers stator ring gear 25 to the stator core 41. If the direct coupling 62 is included the device will be a rigid servo and if the spring element 33 is used the device will be a series elastic actuator. This means that actuators configured as rigid servos and others configured as series elastic actuators can easily be combined together into the same machine as required without having to manage varying control requirements currently offered when mixing and matching a range of actuators.

(61) For actuators that include the spring element 33 a stator bearing is also included so the stator ring gear 25 is supported to remain rotatably connected to the outer housing 10 and to maintain the mesh alignment of pinion teeth and the stator ring gear despite the stator ring gear being elastically connected to the stator core 10. The stator ring gear bearing 101 allows the stator ring gear 25 to be axially displaced relative to the stator core 41 as the spring element 33 is loaded and unloaded by the load which enables spring operation whilst maintaining correct alignment and centre distance between the stator ring gear and the compound pinion 28.

(62) The low moving part count and simplicity of the device means that machine builders can afford to have one, tens or hundreds of actuators of all sizes all operating under the same automation architecture and control system for an order of magnitude less cost than existing devices.

(63) The inclusion of a series elastic element means the robot can fall or sustain an impact load without being damaged. So robots using it are robust and not as susceptible to expensive damage and repairs which are common in operating under demanding conditions of use and interaction with the real world and people.

(64) The device has a hollow channel axially right through the device which allows for cables, shafts, fluid lines etc. to be routed through the device from end to end which allows ease of creation of complex multi degree of freedom limb devices with multiple actuators. Furthermore this hollow channel allows multiple actuators to be connected to power and control signals and also have these cables, shafts and hoses protected within this hollow central channel instead of having to hang freely outside the limb where they can get pinched, snagged or damaged.

(65) A smaller channel has been created in the inner hub at the upstream end which allows control lines to exit the device through the stator hub or to exit radially into the stators central hollow cavity. This provides cable routing options whilst preventing any cable fouling with components mounted to the stator hub.

(66) The device includes an absolute position sensing transducer which provides joint position feedback during operation. The absolute position sensor can sense the actuator's position after start up without the need for calibration activities such as are needed in systems with increments shaft encoders.

(67) This transducer system includes a novel absolute position sensing method which utilizes dual channel potentiometers that are wrapped around the periphery of the controller board. A passive element for each channel is mounted on the outer housing and each is in contact with one channel which in turn provides two channels of continuous absolute position sensing. An algorithm is used to combine the signals from each channel to calculate the absolute actuator position through the full 360 degree motion range despite each individual channel having deadband and nonlinear responses during some angles of feedback.

(68) The Precession drive 23 may be geometrically unbalanced and hence susceptible to vibration issues if this issue was not solved by the novel provision in this invention for compensation via a counterbalance element incorporated in the offset crank 26. This counterbalance elements positioned diametrically opposite to the crank offset. For the involute type speed reducer this counterbalance is positioned radially and axially in the void that occurs due to the crank offset in between the outer ring gears 24 and 25 and the compound pinion 28 periphery as seen on the left in FIG. 11 and in section C-C on the right. The geometry of this offset counter balance mass is designed such that the resulting position the centroid of the entire precessing rotor mass including the offset crank part, the orbiting deep groove bearing, the circlip 32 and the compound pinion 28 is at the centre of rotation of the rotor 21 and axially central to the offset mass of these listed parts. The positioning of this counter balance mass in the void between the compound pinion 28 and the ring gears 24 and 25 is novel and maximizes transmission compactness.

(69) In the case of the compound cycloid type reducer this counterbalance mass is incorporated into the rotor 26 and is again opposite the crank offset to balance the device. These counterbalances prevent vibration during motion in all directions giving low noise high part life and prevents interference with other devices in contact with this one.

(70) Three Additional embodiments of the compound speed reducer have been invented which are novel the first has been named an external pinion precession drive, the second has been named a hybrid precession drive and the third being named the inline precession drive. Note that although each embodiment shows involute tooth profiles, cycloidal tooth profiles can be substituted and operation as described is still valid.

(71) FIG. 7 is alogical symbolic sectional view of an embodiment of the actuator. In this logical view key elements are shown including symbols to represent relationships between them. Symbols used are not uncommon when depicting planetary and speed reducer configurations; FIG. 7 illustrates a Logical symbolic sectional view of actuator; FIG. 7 parts are represented by their bounding box or simplified sectional shape for clarity;

(72) FIG. 8 is a simplified sectional view provided as a summary of items and an example of their layout; FIG. 8 illustrates a Simplified View;

(73) FIG. 9 is a logical symbolic view of one embodiment of the speed reducer gears in mesh outlining terminology; FIG. 9 illustrates a Logical symbolic view of speed reducer gears in mesh outlining terminology; FIG. 9 circles represent the pitch circle of gears in mesh;

(74) FIG. 10 on the left is a view of the precession drive subassembly as viewed from the downstream side and on the right is the same subassembly as viewed from the upstream side; FIG. 10 illustrates a Balanced involute-type speed reducer (Precession drive) assembly as viewed from the downstream on the left and upstream sides on the right;

(75) FIG. 11 on the left shows the precession drive subassembly viewed from the downstream side and on the right shows a section view C-C of the subassembly shown on the left to reveal the part geometry, inter-relatedness and organization. The counterbalance mass that balances the eccentricity caused by the offset crank is labelled and sits between the pinion and ring gears; FIG. 11 illustrates a Front and section C-C view of balanced compound involute-type speed reducer;

(76) FIG. 12 is an exploded view of the precession drive subassembly to more clearly show the geometry of individual parts from which it is comprised; FIG. 12 illustrates an Exploded view of the balanced involute type speed reducer (precession drive) subassembly;

(77) FIG. 13 is a simplified sketch showing four novel embodiments of the Precession drive presented here. View a) shows the standard configuration in which pinion gear pitch circles are internal to the pitch circles of the ring gears. View b) shows the external pinion configuration in which pinion gear pitch circles are external to the pitch circles of the ring gears. View c) shows the hybrid pinion configuration in which one pinion gear pitch circle is inside a ring gear and the other pinion gear pitch circle is outside a ring gear. View d) shows the inline pinion configuration of FIG. 19 in which both pinion gear pitch circles are internal to their corresponding ring gear pitch circles however one pinion gear pitch circle is located axially inline and radially within the other pinion gear pitch circle.

(78) FIG. 13 is a simplified sketch showing 3 variations of speed reducer assembly. The top view shows the standard configuration in which the pinion pitch circle is internal to the stator pitch circle and output ring gears, the middle view shows a configuration wherein the pinion pitch circle is external to the stator and output ring gear pitch circle and the bottom view shows a configuration wherein the pinion pitch circle is in between the stator ring gear and the output ring gear pitch circles; FIG. 13 illustrates Three variations showing embodiments of the precession drive and its versatility in function with the first FIG. 13A at the top showing the embodiment of FIG. 1, the second in the middle FIG. 13B showing the precession drive configured such that the pinion orbits an internal primary and secondary the ring gear and the third FIG. 13C at the bottom showing a pinion set to precess in mesh with the primary ring gear external to it and the secondary ring gear internal to it;

Second Embodiment

(79) A second embodiment of a balanced compound involute type speed reducer named here as an external pinion precession drive the present invention is illustrated in FIG. 14 and FIG. 15.

(80) FIG. 14 is a front view on the left and section view C-C on the right of the external pinion compound involute speed reducer. In this configuration the pinion is external to the stator and output ring gears. A void is indicated which allows the offset crank mass eccentricity to balance the pinion mass eccentricity so the assembly is balanced; FIG. 14 illustrates a Front and section view C-C of external pinion precession drive subassembly;

(81) FIG. 15 is an isometric view of the external pinion compound involute speed reducer; FIG. 15 illustrates an Isometric view of the external pinion compound involute speed reducer;

(82) In this embodiment the rotor with offset crank 52 is radially external to the compound pinion 53, stator ring gear 54 and output ring gear 55. A bearing is fixedly connected to the rotor with an eccentricity. The compound pinion 53 is fixedly mounted to the inner bearing half and hence also is eccentric to the rotation axis of the rotor 52. The eccentricity holds the teeth of the compound pinion in mesh with those of the stator ring gear 54 and output ring gear 55 on one side and the teeth out of mesh on the opposite side. As the rotor rotates the compound pinion 53 precesses around the periphery of the stator ring gear 54 causing it to rotate in the opposite direction to rotor motion. The precessing and rotating compound pinion hence drives the output ring gear in which it is also in mesh on one side. This embodiment is in essence an involute type speed reducer turned inside out. A counterbalance void can be included into the rotor as shown-in FIG. 14 to balance the transmissions rotating parts radially and axially to reduce vibrations whilst in operation. The external pinion precession drive can be incorporated into the robot muscle actuator as required to suit system requirements.

Third Embodiment

(83) A third embodiment of a the compound involute type speed reducer named here a hybrid precession drive of the present invention is novel and is illustrated in FIG. 16 and FIG. 17.

(84) FIG. 16 is a front view on the left and section view C-C on the right of the hybrid compound involute type speed reducer. In this configuration the pinion is between the stator ring gear and the output ring gear; FIG. 16 illustrates a Front and section view C-C of hybrid compound involute type speed reducer (hybrid precession) subassembly. Ring gears and pinion are all in the same plane; FIG. 16 ring gears and pinion are all in the same plane;

(85) FIG. 17 is a 3D view of the hybrid compound involute type speed reducer. Counterbalance is part of the offset crank as indicated and is positioned between outer, output ring gear and the inner stator ring gear to balance the eccentricity of the precessing pinion; FIG. 17 illustrates a 3D view of the hybrid compound involute type speed reducer;

(86) In this embodiment the compound pinion 58 is positioned radially internal to the output ring gear 59 and radially external to the stator ring gear 60. The compound pinion has the primary row of teeth on its inner surface jutting inwards and has the secondary row of teeth on its outer surface jutting outwards. A rotor with offset crank 57 is rotatably connected via a pinion bearing 61 to the compound pinion 58. The pinion bearing 61 allows the compound pinion to rotate freely about an access eccentric to the rotor axis. This eccentricity holds the primary compound pinion inner teeth in mesh with the teeth of the stator ring gear 60 on one side and holds the teeth out of mesh on the opposite side. The eccentricity also holds the secondary compound pinion teeth on the pinions outer surface in mesh with the teeth on the output ring gear 59 on one side and holds them out of mesh on the opposite side. As the rotor rotates about its axis the compound pinion is caused to precess around the periphery of the stator ring gear 60 and rotate in the direction of rotor rotation. Pinion rotation causes the output ring gear 59 to rotate in the direction of rotor rotation with ratio set by the primary and secondary gear meshes. The hybrid precession drive can be incorporated into the robot muscle actuator as required to suit system requirements.

Fourth Embodiment

(87) A fourth embodiment of the compound speed reducer is the inline compound cycloidal type speed reducer named here an inline precession drive of the present invention which is novel and is illustrated in FIG. 18 and FIG. 19.

(88) FIG. 18 front and section view A-A of an inline compound cycloidal reducer, the improvement being that the surfaces that teeth protrude from have been placed radially inline to reduce the axial size of the transmission. FIG. 18 illustrates a Front and section view A-A of an inline compound cycloidal reducer;

(89) FIG. 19 3D view of an inline compound cycloidal reducer. FIG. 19 illustrates a 3D view of an inline compound cycloidal reducer;

(90) In this embodiment the compound pinion 108 has been folded so that the surfaces that teeth protrude from have been placed radially inline to reduce the axial size of the transmission. All components function as they do in the compound precession drive.

(91) The gear teeth profiles applicable for the compound speed reducer include but is not limited to involute profiles but can operate with cycloidal, saw tooth and helical gear profiles. For involute type speed reducers optimal gear tooth design for constant velocity, quiet, high torque and power transmission with zero tooth interference is achieved by using involute tooth profiles and obeying internal gear design practices such as utilizing 12 extra teeth on external gears 24 and 25 compared with the meshing pinion gears 28 for a 20 degrees pressure angle profile. And for meshes with a 14-½ degree pressure angle there will be 15 extra teeth on external gears 24 and 25 compared with the meshing pinion gears 28 to avoid gear interference.

(92) The precession drive 23 incorporates ball, roller, journal or cone bearings depending on scale, application and load conditions.

(93) Embodiments of the invention can be manufactured in a range of sizes based on system requirements or the engineering ‘preferred size’ scaling sequencing to best provide actuator in sizes to suit automation applications from sub miniature to heavy industrial automation servo drives. Hence actuators may vary from 12 mm in diameter and depth or smaller up to 200 mm in diameter or larger depending on demand. There is no limit to the size this device can be scaled up to and it is not unreasonable to expect devices in the order of several meters in diameter and some meters in depth.

(94) FIG. 20 is a 3D view showing the balanced cycloid type speed reducer compound pinion, bearing retainer and offset crank. The cycloid tooth profile provides for a high reduction high torque transmission option for the robot actuator. The bearing retainer 95 is eccentric to balance the eccentricity of the compound pinion 96; FIG. 20 illustrates a balanced compound Cycloid reducer assembly; FIG. 20 ring gears are omitted for clarity;

(95) FIG. 21 is a front view on the left and section view A-A on the right showing external and internal details of the balanced cycloid reducer reduction assembly including the compound pinion, offset crank, bearing retainer and pinion bearing; FIG. 21 illustrates a balanced compound cycloid reducer assembly front and sectional views;

(96) FIG. 22 top view shows the actuator configured to include spring element 33 which connects the stator ring gear to the stator core thus providing a spring in series with the transmission hence allowing the device to operate as a series elastic actuator;

(97) FIG. 22 bottom view shows the actuator configured with a direct coupling 62 which connects the stator ring gear to the stator core thus providing a rigid transmission; FIG. 22 illustrates Modular components are swappable to suit actuator requirements. Top view shows spring element 33 for series elastic operation and bottom view shows direct coupling 62 for operation as a stiff servo;

(98) FIG. 23 shows a 3D exploded view of the actuator assembly spring element; FIG. 23 illustrates a Robot muscle actuator with series elastic spring element;

(99) FIG. 24 is a 3D exploded view showing the stator, outer housing, end mounting hubs, optional hub nut and bearings only. In this embodiment there is no drive train components hence this can be used as a freewheeling wheel hub mount; FIG. 24 illustrates a Stator, outer housing, end mounting hubs and bearings only;

(100) FIG. 25 is an exploded view of the actuator configured for direct 1:1 drive with the speed reducer replaced with direct a drive coupling and series elastic element for compliance; FIG. 25 illustrates a Direct 1:1 drive with precession drive replaced with direct drive coupling and series elastic element for compliance;

(101) FIG. 26 is a view of the robot muscle actuator of FIG. 1 showing how it can be integrated with a control horn, pushrods, clevises and a base mounting plate for operation as a classic radio controlled servo system; FIG. 26 illustrates a Robot Muscle Actuator fitted with pushrods, clevis rod ends and control horn implemented as a classic radio control servo system;

(102) FIG. 27 on the left is a top view and on the right an end view showing the robot muscle actuator of FIG. 1 implemented as a dual tendon capstan drive. The robot muscle actuator is the master system which drives the remote slave system control horn via an antagonistic cable tendon and clevis rod end pair. The robot muscle inner hub is mated to ground giving actuated output at the robot muscle outer hub and outer housing. The outer housing provides a constant radius driving drum around which both tendon cables are wrapped and which are wound on one side and wound off the other side as the robot muscle outer hub rotates on its axis to draw in and let out cable and hence the rod ends drive the control horn slave system in synchronicity as a slave to the robot muscle master system excitation. The tendons are terminated with cable crimps at the robot muscle actuator end in this example and mate with stepped holes that passes through the capstans rim hub rims. The capstan rim mates with the robot muscle outer hub via bolts into the threaded holes provided at the periphery of the outer housing and outer hub. The excitation torque is hence transferred to cable tension in a distributed fashion blended between static friction between the cable and outer housing and also between the cable termination crimp and the capstan rim hub, the proportions or torque transferred of each depending on the number of turns of cable that wrap the outer housing; FIG. 27 illustrates a Robot muscle implemented as a dual tendon capstan drive;

(103) FIG. 28 is a 3D view showing the robot muscle actuator of FIG. 1 implemented as a dual tendon capstan drive; FIG. 28 illustrates a Robot muscle implemented as a dual tendon capstan drive;

(104) FIG. 29 is a view of three robot muscle actuators from FIG. 1 augmented with additional parts as listed for operation as a three degree of freedom robotic arm elbow configured in such a way that the input and output limbs can fully fold back on themselves; FIG. 29 illustrates Three degree of freedom actuator elbow joint fully collapsable on it's self configuration;

(105) FIG. 30 on the left is the is a view of the robotic arm elbow of FIG. 29 and on the right is sectioned view A-A of the robotic arm elbow of FIG. 29 showing the outer housing, cone bearings, stator and mounting hubs of the robotic muscle actuator of FIG. 1 to show internal details including the device's capability for continuous routing of cables throughout the robotic elbow assembly via the series of adjoining passages made from the stator's hollow centre and hollow limb elbow components; FIG. 30 illustrates a Robot Muscle Actuator elbow section view showing open central passage throughout device for cable routing. Drive train omitted for clarity. Bearings, mounting hubs, example loom and outer housing only are shown in this view; FIG. 30 bearings, mounting hubs, example loom and outer housing only are shown in this view;

(106) FIG. 31 is a view of three robot muscle actuators from FIG. 1 augmented with additional parts as listed for operation as a three degree of freedom robotic arm elbow configured in such a way that the central axis of each degree of actuation freedom intersects in the joint at a single point for all ranges of motion of all axes; FIG. 31 illustrates a Single, double or triple degree of freedom actuator joint; FIG. 31 note that similar configurations can be constructed with two or one robot actuator and degree of freedom if that is the requirement;

(107) FIG. 32 on the left is a view of the robot muscle actuator from FIG. 1 augmented with additional parts as listed for operation as powered wheel hub motor and on the right is a view of the same robot muscle actuator on the left included here for additional clarity; FIG. 32 illustrates an Electric Vehicle wheel hub drive;

(108) FIG. 33 is a view of a robot muscle actuator as embodied in FIG. 1 implemented as the powered driving actuator hub of a robotic track drive assembly and also a robot muscle actuator assembly configured without motor, controller and drive train for operation as the second passive hub of the same robotic track drive assembly; FIG. 33 illustrates a Track hub drive actuator configuration;

(109) FIG. 34 is a section view of a direct drive electric motor actuator embodiment of a robot actuator;

(110) FIG. 35 is a 3D section view of a direct drive robot actuator configured with an electric motor actuator with series elastic spring element 33 and optional controller board. This actuator can also be configured without the control board;

(111) Note that the hybrid involute precession drive reduction ratios do not necessarily conform to those represented in TABLE. 2.

(112) Other embodiments of this invention as shown in FIG. 36 are realized by removing drive train features whilst maintaining the design of the hollow spool shaped stator, the outer housing 10, the mounting hubs 12 and 41 at each end and the arrangement of bearings 37 and 34 that support rotation of the outer housing around the inner stator spool.

(113) FIG. 36 shows the fully featured drive train including the motor, speed reducer and spring element. FIG. 36c shows an embodiment without the spring element hence this operates as a stiff servo. FIG. 36b shows an embodiment further excluding the speed reducer and re-introducing the spring element which operates as a direct drive actuator without a speed reducer that can do force sensing and has impact resilience due to the inclusion of the spring element. FIG. 36a shows an embodiment including only the motor drive train element which operates as direct drive motor. A further embodiment not shown here includes no drive train elements and thus operates as a freewheeling joint with inner spool like stator, an outer housing supported on bearings and including the mounting hubs at each end.

(114) FIG. 36 shows some possible actuator embodiment variations: Top view a) is a section view of actuator configured as a direct drive electric motor with hollow centre, inner and outer mounting hubs, an outer housing, cone bearings, a stator with looming and a motor rotor fixedly attached to the outer housing. View b) is a sectional view of the actuator of a) further incorporating a series elastic spring element connecting the rotor to the outer housing 10 and outer mounting hubs. A bearing rotatably connects the motor rotor to the outer housing to ensure true rotational alignment during operation and whilst under load. View C) shows a sectional view of the actuator of b) further incorporating a speed reducer. View d) is a sectional view of the actuator shown in view c) further incorporating a spring element which elastically connects the speed reducer stator ring gear to the stator core 41;

(115) Further embodiments beyond these are configured by including or excluding the controller with the embodiments listed above. Hence position sensing can be added to the freewheeling embodiment, a controller can be added to the direct drive embodiment etc.

(116) Vernier

(117) A further aspect of embodiments of this invention can be seen in FIG. 1 and is the inclusion of a vernier inner and outer circular scales marked on the outer mounting and inner mounting hubs of the actuator to add the facility of visually reading the precise angular displacement of the actuator independently of the electronic position sensing systems. This enables manual calibration and joint displacement measurements to be made without having to rely on the devices instrumentation. It can also aid in the calibration of the devices electronic position sensing systems.

INDUSTRIAL APPLICABILITY

(118) Embodiments of the present invention provide a robot muscle series elastic actuator incorporating novel and standard speed reducers provides an ideal bearing, actuator and control system solution for robot joints, track and wheel drives, artificial digits and limbs, puppet automation, electric vehicle locomotion and automation devices creating movement, torque, power, positioning and environmental awareness for systems capable of great work.

(119) A versatile robot muscle series elastic actuator extends the capabilities of existing robot joint actuators through its novel design to include operation as a self-contained geared wheel hub motor solution for robot track and wheel drives and also for electric vehicles in general.

(120) The cylindrically modular device with hollow centre, high rigidity bearings and highly versatile symmetric mounting hubs provides a simple, economical, homogeneous and versatile automation solution.

(121) Novel speed reducers are presented that provide simple, economical, high torque density, low backlash and balanced transmissions ideal as standalone transmission solutions as well as being ideal for incorporating into the robot muscle series elastic actuator presented here.

(122) The modular device is optionally hollow, with high rigidity bearings and highly versatile, double ended mounting hubs provides a simple, light weight, economical, homogeneous and versatile automation solution.

(123) A double ended actuator is presented which can function as a wheel axle and bearing assembly or as an actuated joint that is modular, scalable and configurable and that can incorporate freewheeling variations and direct drive variations. These actuator embodiments can include novel or standard speed reducer options which provides an ideal bearing, actuator and control system solution for robot joints, track and wheel drives, artificial digits and limbs, puppet automation, heavy equipment, electric vehicle locomotion and automation devices creating movement, torque, power, positioning and environmental awareness for systems capable of great work.

(124) In one form access to both stator and output mounting hubs is available at both ends of the device via optimally placed mounting hubs and integrated hub bearings resulting in a high rigidity self-contained joint or rotatable hub with low weight construction that allows infinitely rotatable output across the entire outer housing. Furthermore the improvement provides for novel freewheeling, direct drive, geared or even series elastic operation of the actuators presented here.

(125) The above describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention.

(126) Part Numbering List

(127) TABLE-US-00003 TABLE 1 ITEM NO. DESCRIPTION 10 Outside housing; outer housing 11 Controller circuit board; controller circuit board 12 Outer hub downstream (outer mounting hub); outer hub downstream; outer hub; outer mounting hub; Outer hub 13 Cable loom; cable loom 14 DC motor assembly 15 DC motor hollow shaft axle 16 DC motor, motor mount 17 DC motor stator base 18 DC motor ball bearing race 19 DC motor ball bearing race 20 DC motor front hub and dish 21 DC motor rotor bell periphery magnet cover; Motor rotor 22 DC motor stator windings; Motor stator windings 23 Precession drive assembly (Assem1); Speed Reducer drive assembly; Precession drive assembly 24 Ring gear (Secondary or output ring gear) (upstream) Output ring gear; output gear; Output ring gear pitch circle 25 Ring gear (Primary or stator ring gear) (downstream); Stator ring gear; stator ring gear (primary); Stator Ring gear pitch circle 26 Offset crank; offset crank; Offset crank counter balance; Rotor with offset crank; counter balance; Offset crank axis; Central rotor axis .sup. 26A Offset crank axis 27 Bearing retainer (crank half downstream); Bearing retainer 28 Compound pinion; compound pinion; primary gears; secondary gears; Compound pinion primary set of teeth pitch circle .sup. 28A Compound pinion secondary set of teeth pitch circle 29 Pinion bearing (Ball bearing race (44 × 35 × 5)); Pinion bearing 30 Ball bearing race (27 × 20 × 4) (motor and crank bearing upstream); Ball bearing race 31 Ball bearing race (27 × 20 × 4)(motor and crank bearing downstream); Bearing; Ball bearing race; Ball bearing 32 Pinion bearing circlip retainer; Circlip 33 Series elastic actuator spring element; Series elastic spring element; S.E.A spring; spring element; Spring element 34 Cone bearing balls and retainer assembly (Downstream); Outer hub bearing; Cone bearings and retainer assembly; Hub bearing 35 Cone bearing ball retainer downstream 36 Cone bearing balls downstream 37 Cone bearing balls and retainer assembly (upstream); Inner mounting hub bearing; Hub bearing 38 Cone bearing ball retainer upstream 39 Cone bearing balls upstream 40 Stator Assembly 41 Hollow stator core; inner mounting hub 41A; Upstream inner mounting hub; hollow stator core; Hollow stator, upstream inner hub; stator core .sup. 41A Hollow stator core 42 Hub nut (Inner hub retaining nut); hub nut 43 Cone bearing inner hub (Stator hub downstream); Downstream inner mounting hub; cone bearing inner hub with Vernier scale; cone bearing inner hub; Inner hub; Linner mounting hub; Inner mounting hub 44 Absolute potentiometer assembly; Absolute P.O.T. assembly 45 Absolute potentiometer slip ring 46 Absolute Potentiometer brushes 47 Potentiometer tracks absolute potentiometer assembly 48 Outer hub upstream; outer mounting hub 49 Bolt 50 Bolt 51 Precession drive assembly (external crank configuration) 52 Rotor with offset crank (external crank configuration); Rotor with offset crank (external crank config); Offset crank (external crank config); Counter balance void 53 Compound pinion (external crank configuration); Compound pinion; Compound pinion (external crank config) 54 Ring gear primary (external crank configuration); Stator ring gear; Stator ring gear (external crank config) 55 Output ring gear (Ring gear secondary)(external crank configuration); Output ring gear 56 Precession drive assembly (Hybrid configuration) 57 Offset crank (Hybrid configuration); Offset crank (Hybrid configuration); Rotor with offset crank (hybrid config); Crank counterbalance 58 Compound pinion (Hybrid configuration); Compound pinion 59 Outer ring gear(Hybrid configuration) Output ring gear; Output ring gear; Output ring gear (hybrid config) 60 Inner ring gear (Hybrid configuration) stator ring gear; Stator ring gear 61 Pinion bearing; Pinion bearing 62 Direct coupling; Direct coupling 63 Classic radio control servo system assembly 64 Robot muscle actuator assembly; Robot muscle actuator assembly .sup. 64A Robot muscle actuator assembly # 1; Robot Muscle # 1 .sup. 64B Robot muscle actuator assembly # 2; Robot Muscle # 2 .sup. 64C Robot muscle actuator assembly # 3; Robot Muscle # 3 65 Servo control horn; Servo control horn 66 Clevis rod end; Clevis rod end 67 Push rod; Push rod 68 Slave control horn; Slave control horn 69 Dual tendon capstan drive assembly 70 Capstan rim hub; Capstan rim hub 71 Tendon; Tendon 73 (68) Slave control horn 73 (66) Clevis rod end 74 Tendon end crimp; Tendon end crimp 75 Fully collapsible joint assembly 76 Limb tube; Limb tube 77 Spherical elbow joiner 78 Triple degree of freedom actuator joint assembly 79 Outer flange hub elbow; Outer flange hub elbow 80 Inner flange hub elbow; Inner flange hub elbow 81 Inner flange hub adapter; Inner flange hub adapter 82 Outer flange hub adapter; Outer flange hub adapter 83 Electric Vehicle wheel hub drive assembly 84 Wheel rim; Wheel rim 85 Spoke; Spoke 86 Spoke flange adapter; Spoke flange adapter 87 Track hub drive actuator configuration 88 Track; Track 89 Secondary (passive) actuator, bearing only assembly; Secondary (passive) actuator, bearing only assembly 90 91 Cycloidal reducer assembly 92 Ring gear (Secondary or output ring gear) (upstream) 93 Ring gear (Primary or stator ring gear) (downstream) 94 Offset crank; Offset crank 95 Bearing retainer (crank half downstream); Bearing retainer and counterbalance 96 Compound pinion; Compound pinion 97 Pinion bearing (Ball bearing race (44 × 35 × 5)); Pinion bearing 98 Bearing race (motor and crank bearing upstream) 99 Bearing race (motor and crank bearing downstream) 100  Pinion bearing circlip retainer 101  Stator ring gear bearing (Supports SEA configuration); Stator ring gear bearing 102  Intentionally left blank 103  Inline reducer assembly 104  Output ring gear (Secondary mesh); Output ring gear 105  Stator ring gear (Primary mesh; Stator ring gear) 106  Rotor with offset crank; Rotor; Rotor Offset crank; Rotor with offset crank 107  Bearing retainer (crank half downstream) 108  Compound pinion; Compound pinion; Compound pinion (inline) 109  Pinion bearing (Ball bearing race 110  Bearing race (motor and crank bearing upstream) 111  Bearing race (motor and crank bearing downstream) 112  Pinion bearing circlip retainer 113  Upstream end of housing assembly; upstream side 114  Downstream end of housing assembly; downstream side 115  Direct drive motor 116  Motor rotor bearing 117  Direct drive motor with S.E.A & controller 118  Motor drive, speed reducer SEA & controller 119  Motor drive, speed reducer, rigid actuator & controller 120  Motor rotor bearing 121  Standard internal pinion 122  Offset crank centre 123  Motor centre 124  External pinion 125  Hybrid pinion 126  Inline pinion 127  Bearing 128  Bearing 129  Crank offset

(128) TABLE-US-00004 TABLE 2 shows a selection of teeth combinations, stator and output mesh ratios and final reducer output ratios with direction. Note detail has been lost for some numbers as they have been truncated to 2, 3 or 4 decimal places in this table. Stator gear teeth 12 20 25 100 199 79 100 Pinion primary teeth 11 19 24 84 183 78 99 Stator ratio 0.0909 0.0526 0.0417 0.1905 0.0874 0.0128 0.0101 Pinion secondary Output output teeth gear teeth ratio Resultant speed reducer ratios 12 13 0.0833 −143.0 35.3 26.0 −10.1 −264.3 15.4 14.8 20 21 0.0500 −25.7 −399.0 126.0 −7.5 −28.1 28.2 26.3 20 26 0.3000 6.2 5.3 5.0 11.9 6.1 4.5 4.5 25 26 0.0400 −20.4 −82.3 −624.0 −6.9 −21.9 38.3 34.8 82 98 0.1951 11.5 8.4 7.8 257.2 11.1 6.6 6.5 27 28 0.0370 −19.3 −66.5 −224.0 −6.8 −20.6 42.8 38.5 184 200 0.0870 −275.0 31.7 24.0 −10.5 −2287.5 14.7 14.1 79 80 0.0127 −12.9 −25.3 −34.9 −5.7 −13.5 −6240.0 396.0 98 99 0.0102 −12.5 −23.8 −32.1 −5.6 −13.1 −386.1 9801.0