阅读说明：本技术 轻质高承载减速器、减速器齿轮及其仿骨构造生成方法 (Light high-bearing speed reducer, speed reducer gear and bone-imitating structure generation method thereof ) 是由 黄强 范徐笑 黄日成 黄高 廖静平 余张国 刘兴中 左昱昱 于 2020-06-15 设计创作，主要内容包括：本发明提供一种轻质高承载减速器、减速器齿轮及其仿骨构造生成方法。所述减速器齿轮包括：外轮廓层和被所述外轮廓层包覆的网状多孔基层,所述外轮廓层包括安装面层、齿面层和连接面层,所述连接面层连接在所述安装面层和齿面层之间并与所述安装面层和齿面层一起构成完整齿轮外轮廓；所述安装面层、齿面层和连接面层为密实构造；所述网状多孔基层位于所述外轮廓层形成的腔体内,所述网状多孔基层内具有呈多孔网架结构的纤维小梁。本发明实施例的减速器齿轮克服了减速器不能同时满足机器人要求的轻质、高承载耐冲击、高精度高效率传动三方面要求的难题,在传动关键元器件,尤其是减速器方面为机器人实现超动态运动提供了更大的优势。(The invention provides a light high-bearing speed reducer, a speed reducer gear and a bone-like structure generation method thereof. The speed reducer gear includes: the outer contour layer comprises an installation surface layer, a tooth surface layer and a connecting surface layer, and the connecting surface layer is connected between the installation surface layer and the tooth surface layer and forms a complete gear outer contour together with the installation surface layer and the tooth surface layer; the mounting surface layer, the tooth surface layer and the connecting surface layer are of compact structures; the reticular porous base layer is positioned in the cavity formed by the outer contour layer, and a fiber trabecula in a porous grid structure is arranged in the reticular porous base layer. The reducer gear of the embodiment of the invention overcomes the difficulty that the reducer can not meet the requirements of light weight, high bearing impact resistance, high precision and high efficiency transmission of a robot at the same time, and provides greater advantages for realizing ultra-dynamic motion of the robot in the aspects of transmission key components, particularly the reducer.)

1. A reduction gear for a robot, characterized in that the reduction gear comprises: the outer contour layer comprises an installation surface layer, a tooth surface layer and a connecting surface layer, and the connecting surface layer is connected between the installation surface layer and the tooth surface layer and forms a complete gear outer contour together with the installation surface layer and the tooth surface layer;

the mounting surface layer, the tooth surface layer and the connecting surface layer are of compact structures;

the reticular porous base layer is positioned in the cavity formed by the outer contour layer, and a fiber trabecula in a porous grid structure is arranged in the reticular porous base layer.

2. The speed reducer gear according to claim 1, wherein the thickness of each fiber trabecula along each point on the axis thereof and the spatial arrangement and connection relationship of each fiber trabecula are determined according to a spatial stress curve generated by a load spectrum of an ideal working condition of the gear.

3. A reducer gear according to claim 1,

the reticular porous base layer is provided with porous cavities between beams, wherein the porous cavities are separated by the fiber trabeculae and are communicated with each other, and at least part of the porous cavities are filled with a tough soft material.

4. A reducer gear according to any one of claims 1 to 3, wherein the mounting surface is a supporting fixed connecting surface of the gear in the reducer, and the tooth surface layer is an acting surface for transmitting rotary motion and torque by mutual engagement between the reducer gears; the thicknesses of different local point parts of the installation surface layer and the tooth surface layer are determined according to the bearing capacity and the torque load of the ideal working condition of the gear.

5. A reducer gear according to any one of claims 1 to 3, wherein the mounting surface is configured in the form of a circular hole, a splined hole, a rectangular keyed hole or a regular polygonal hole fitted to an axial hole; the structural form of the tooth surface layer is an involute tooth form or a cycloid tooth form.

6. The retarder gear of claim 2, wherein the mesh-like porous base layer is formed by printing a mesh-like porous base layer structure using 3D printing, the mesh-like porous base layer structure being constructed by:

converting the comprehensive load spectrum of the coating surface of the reticular porous base layer coated by the mounting surface layer and the tooth surface layer according to the comprehensive load spectrum of the force and the torque of different local point positions of the mounting surface layer and the tooth surface layer;

taking the comprehensive load spectrum of the cladding surface as a load boundary condition of the optimized design of the reticular porous base layer, taking light weight as an optimization target on the premise of ensuring the force and moment transmission supporting strength, and obtaining a spatial stress spectrum of the reticular porous base layer by a finite element topological structure optimization method;

the method comprises the steps of designing material distribution corresponding to each space point in the reticular porous base layer based on a space stress spectrum of the reticular porous base layer, distributing the material in each space point in the reticular porous base layer to form fiber trabeculae, determining the thickness of each section of the fiber trabeculae along the axial line and the spatial arrangement and connection of each section of the fiber trabeculae based on the space points distributed with the material, and forming a porous cavity between beams by each space point which is not distributed with the material in the reticular porous base layer.

7. A reducer gear according to any one of claims 1 to 3,

the mounting surface layer, the tooth surface layer and the connecting surface layer are made of self-fluxing alloy powder or wire through a melt coating or melt deposition process and a contour finishing process;

the reticular porous base layer is made of self-fluxing alloy powder or wire materials by a 3D printing process.

8. The reducer gear according to claim 7, wherein the material used for the mounting surface layer and the tooth surface layer is FeCSIB alloy powder which comprises the following components in percentage by mass: 4.0% of C, 2.0% of Si, 1.0% of Cr, 0.7% of Mn, 0.25% of Mo, less than or equal to 0.2% of Cu, less than or equal to 0.035% of S, less than or equal to 0% of P, and 035%;

the material used by the fiber trabecula of the reticular porous base layer is Ti₆AlV₄And (3) alloying powder.

9. A reducer gear according to claim 3,

the soft material filled in the porous cavity of the reticular porous base layer is made of AlMg powder or thermosetting plastic powder, wherein the AlMg powder comprises the following elements in percentage by mass: 93% of Al and 7.0% of Mg; the thermosetting plastic powder contains the following element components in percentage by mass: epoxy is 48%, PU is 35%, PF is 17%.

10. A decelerator for robots, comprising a decelerator gear for robots according to any one of claims 1 to 9.

11. A generation method for obtaining a reducer gear for robots according to any one of claims 1 to 9, comprising the steps of:

designing based on the requirement of the gear alternating dynamic load using working condition as an initial condition to obtain the thickness of each position of the tooth surface layer and the mounting surface layer, thereby obtaining the design space of the reticular porous base layer;

acquiring a comprehensive load spectrum of the coated surface of the reticular porous base layer based on the comprehensive load of the tooth surface layer and the mounting surface;

determining optimal design initial parameters of the reticular porous base layer, wherein the optimal design initial parameters comprise: processing capability parameters of the used 3D printing equipment; material performance parameters of the reticulated porous base layer; and a safety factor;

3D finite element meshing is carried out on the design space of the reticular porous base layer;

carrying out layered numbering on 3D finite element grids divided from the design space of the reticular porous base layer;

carrying out in-layer two-dimensional coordinate numbering on the 3D finite element grids on the trunk axis based on the layering numbering, and calculating the shortest transmission path from each 3D finite element grid of the first layer containing the most 3D finite element numbers to the last layer containing the least 3D finite element numbers, so that the numbered 3D finite element grids of each layer are contained in all the shortest transmission paths for at least 1 time, and taking the shortest transmission paths as the trunk axes of the grids in which the fiber trabeculae are grown and arranged;

carrying out in-layer two-dimensional coordinate numbering on the 3D finite element grids on the non-trunk axis, and obtaining a spatial stress spectrum of a design space of the mesh porous base layer consisting of periodic full stress spectrums of all the 3D finite element grids according to the comprehensive load spectrum of the coated surface of the mesh porous base layer and the trunk axis of the grids;

according to the spatial stress spectrum of the design space of the reticular porous base layer, growing a main fiber trabecula which meets the requirements of the supporting strength and toughness of the reticular porous base layer in the space of the reticular porous base layer;

growing and supplementing branch type fiber trabeculae;

obtaining a 3D printing model of the reticular porous base layer based on all the generated fiber trabeculae;

manufacturing a mesh-shaped porous base layer by using a 3D printing mode;

and manufacturing an outer contour layer by using a laser melting coating or melting deposition process, wherein the outer contour layer comprises a tooth surface layer, a mounting surface layer and a connecting surface layer, and covers the reticular porous base layer.

Technical Field

The invention relates to the field of bionic robots, in particular to a light high-bearing speed reducer, a speed reducer gear and a bone-imitating structure generation method thereof.

Background

At present, speed reducers for robots (particularly bionic robots) meet the use requirements of three aspects of light weight, high bearing impact resistance, high precision and high efficiency transmission at home and abroad. The prior art mainly comprises 3 types of speed reducers with different structural principles: although the harmonic speed reducer has the advantage of light weight, the harmonic speed reducer has serious defects in the aspects of impact resistance, high-efficiency transmission and the like; although the cycloid speed reducer (such as an RV speed reducer) has impact resistance and high transmission precision, the self weight of the cycloid speed reducer is the same as that of the cycloid speed reducer and too heavy; the planetary gear reducer has outstanding advantages in high-precision and high-efficiency transmission, is superior to a cycloid reducer in light weight characteristic but inferior to a harmonic reducer, and is superior to the harmonic reducer in high-bearing impact resistance but inferior to the cycloid reducer.

Disclosure of Invention

In view of the above, embodiments of the present invention provide a reducer gear, a reducer for a robot, and a method for generating a reducer gear, so as to obviate or mitigate one or more of the disadvantages of the related art.

The technical scheme of the invention is as follows:

a decelerator gear for a robot, the decelerator gear comprising: the outer contour layer comprises an installation surface layer, a tooth surface layer and a connecting surface layer, and the connecting surface layer is connected between the installation surface layer and the tooth surface layer and forms a complete gear outer contour together with the installation surface layer and the tooth surface layer; the mounting surface layer, the tooth surface layer and the connecting surface layer are of compact structures; the reticular porous base layer is positioned in the cavity formed by the outer contour layer, and a fiber trabecula in a porous grid structure is arranged in the reticular porous base layer.

In some embodiments, the thickness of each fiber trabecula along each point on the axis and the spatial arrangement connection relationship of each fiber trabecula are determined according to the space stress curve generated by the ideal condition load spectrum of the gear machine.

In some embodiments, the fiber trabeculae of the reticular porous base layer are separated into beam-to-beam porous cavities which are communicated with each other, and at least part of the porous cavities are filled with the tough soft material.

In some embodiments, the installation surface layer is a supporting and fixing connection surface of the gear in the speed reducer, and the tooth surface layer is an action surface for transmitting rotary motion and torque by mutual meshing between gears of the speed reducer; the thicknesses of different local point parts of the installation surface layer and the tooth surface layer are determined according to the bearing capacity and the torque load of the ideal working condition of the gear.

In some embodiments, the installation surface layer is in the form of a round hole, a spline hole, a rectangular spline hole or a regular polygon hole matched with the shaft hole; the structural form of the tooth surface layer is an involute tooth form or a cycloid tooth form.

In some embodiments, the reticulated porous base layer is formed from a reticulated porous base layer structure printed using 3D printing, constructed using the following steps:

converting the comprehensive load spectrum of the coating surface of the reticular porous base layer coated by the mounting surface layer and the tooth surface layer according to the comprehensive load spectrum of the force and the torque of different local point positions of the mounting surface layer and the tooth surface layer;

taking the comprehensive load spectrum of the cladding surface as a load boundary condition of the optimized design of the reticular porous base layer, taking light weight as an optimization target on the premise of ensuring the force and moment transmission supporting strength, and obtaining a spatial stress spectrum of the reticular porous base layer by a finite element topological structure optimization method;

the method comprises the steps of designing material distribution corresponding to each space point in the reticular porous base layer based on a space stress spectrum of the reticular porous base layer, distributing the material in each space point in the reticular porous base layer to form fiber trabeculae, determining the thickness of each section of the fiber trabeculae along the axial line and the spatial arrangement and connection of each section of the fiber trabeculae based on the space points distributed with the material, and forming a porous cavity between beams by each space point which is not distributed with the material in the reticular porous base layer.

In some embodiments, the mounting face, tooth face and connection face are made using self-fluxing alloy powders or wires by a melt coating or melt deposition process and a contour finishing process; the reticular porous base layer is made of self-fluxing alloy powder or wire materials by a 3D printing process.

In some embodiments, the material used for the mounting surface layer and the tooth surface layer is FeCSIB alloy powder which comprises the following components in percentage by mass: 4.0% of C, 2.0% of Si, 1.0% of Cr, 0.7% of Mn, 0.25% of Mo, less than or equal to 0.2% of Cu, less than or equal to 0.035% of S and less than or equal to 0.035% of P.

In some embodiments, the material used for the fiber trabeculae of the reticulated porous substrate is Ti₆AlV₄And (3) alloying powder.

In some embodiments, the soft body material filled in the porous cavities of the mesh-like porous base layer is AlMg powder or thermosetting plastic powder, wherein the AlMg powder comprises the following components in percentage by mass: 93% of Al and 7.0% of Mg; the thermosetting plastic powder contains the following element components in percentage by mass: epoxy is 48%, PU is 35%, PF is 17%.

A decelerator for a robot includes the decelerator gear for a robot.

A generation method for obtaining the speed reducer gear for the robot comprises the following steps:

designing based on the requirement of the gear alternating dynamic load using working condition as an initial condition to obtain the thickness of each position of the tooth surface layer and the mounting surface layer, thereby obtaining the design space of the reticular porous base layer;

acquiring a comprehensive load spectrum of the coated surface of the reticular porous base layer based on the comprehensive load of the tooth surface layer and the mounting surface;

determining optimal design initial parameters of the reticular porous base layer, wherein the optimal design initial parameters comprise: processing capability parameters of the used 3D printing equipment; material performance parameters of the reticulated porous base layer; and a safety factor;

3D finite element meshing is carried out on the design space of the reticular porous base layer;

carrying out layered numbering on 3D finite element grids divided from the design space of the reticular porous base layer;

carrying out in-layer two-dimensional coordinate numbering on the 3D finite element grids on the trunk axis based on the layering numbering, and calculating the shortest transmission path from each 3D finite element grid of the first layer containing the most 3D finite element numbers to the last layer containing the least 3D finite element numbers, so that the numbered 3D finite element grids of each layer are contained in all the shortest transmission paths for at least 1 time, and taking the shortest transmission paths as the trunk axes of the grids in which the fiber trabeculae are grown and arranged;

carrying out in-layer two-dimensional coordinate numbering on the 3D finite element grids on the non-trunk axis, and obtaining a spatial stress spectrum of a design space of the mesh porous base layer consisting of periodic full stress spectrums of all the 3D finite element grids according to the comprehensive load spectrum of the coated surface of the mesh porous base layer and the trunk axis of the grids;

according to the spatial stress spectrum of the design space of the reticular porous base layer, growing a main fiber trabecula which meets the requirements of the supporting strength and toughness of the reticular porous base layer in the space of the reticular porous base layer;

growing and supplementing branch type fiber trabeculae;

obtaining a 3D printing model of the reticular porous base layer based on all the generated fiber trabeculae;

manufacturing a mesh-shaped porous base layer by using a 3D printing mode;

and manufacturing an outer contour layer by using a laser melting coating or melting deposition process, wherein the outer contour layer comprises a tooth surface layer, a mounting surface layer and a connecting surface layer, and covers the reticular porous base layer.

According to the reducer gear, the reducer for the robot and the generation method of the reducer gear of the embodiment of the invention, the obtained beneficial effects at least comprise that:

the reducer gear of the embodiment of the invention overcomes the difficulty that the reducer can not meet the requirements of a robot (especially a bionic robot) on three aspects of light weight, high bearing impact resistance, high precision and high efficiency transmission, and provides greater advantages for realizing ultra-dynamic motion of the robot in the aspects of transmission key components, especially the reducer.

Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

It will be appreciated by those skilled in the art that the objects and advantages that can be achieved with the present invention are not limited to the specific details set forth above, and that these and other objects that can be achieved with the present invention will be more clearly understood from the detailed description that follows.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. For purposes of illustrating and describing some portions of the present invention, corresponding parts of the drawings may be exaggerated, i.e., may be larger, relative to other components in an exemplary apparatus actually manufactured according to the present invention. In the drawings:

fig. 1 is a structural diagram of a bone section for supporting and bearing the body of a general higher mammal in the prior art.

Fig. 2 is a schematic structural view of a bone structure bionic gear in an embodiment of the invention.

Fig. 3 is a schematic flow chart illustrating an optimized design method of a bone structure bionic gear according to an embodiment of the present invention.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the following embodiments and accompanying drawings. The exemplary embodiments and descriptions of the present invention are provided to explain the present invention, but not to limit the present invention.

It should be noted that, in order to avoid obscuring the present invention with unnecessary details, only the structures and/or processing steps closely related to the scheme according to the present invention are shown in the drawings, and other details not so relevant to the present invention are omitted.

It should be emphasized that the term "comprises/comprising" when used herein, is taken to specify the presence of stated features, elements, steps or components, but does not preclude the presence or addition of one or more other features, elements, steps or components.

It is also noted herein that the term "coupled," if not specifically stated, may refer herein to not only a direct connection, but also an indirect connection in which an intermediate is present.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the drawings, the same reference numerals denote the same or similar parts, or the same or similar steps.

The embodiment of the invention aims at the key part of the optimization target of light weight and high bearing impact resistance of the planetary gear type speed reducer, namely the gear (mainly comprising 3 types of sun gear, planet gear, inner gear ring and the like), and carries out bone structure bionic design and manufacture, so that the gear of the speed reducer is light like a biological skeleton and has the same ratio and high bearing impact resistance, thereby effectively improving the characteristics of the whole light weight and high bearing impact resistance of the speed reducer, and the bionic robot using the speed reducer has greater advantages in the aspect of realizing ultra-dynamic motion.

The embodiment of the invention provides a reducer gear, a reducer for a robot and a generation method of the reducer gear, which are used for overcoming the difficult problems that the reducer cannot meet the requirements of the robot (especially a bionic robot) on three aspects of light weight, high bearing impact resistance, high precision and high efficiency.

According to an aspect of the present invention, the speed reducer gear for a robot (hereinafter, also referred to as a bone structure bionic gear, a bionic gear or a gear) according to an embodiment of the present invention may be in the form of an internal gear or an external gear, as shown in fig. 2, the speed reducer gear includes an outer contour layer and a mesh-shaped porous base layer 30 coated by the outer contour layer, that is, the mesh-shaped porous base layer 30 is located at a middle position of the outer contour layer.

The outer contour layer comprises a mounting surface layer 20, a tooth surface layer 10 and a connecting surface layer, wherein the connecting surface layer is connected between the mounting surface layer 20 and the tooth surface layer 10 and forms a complete gear outer contour together with the mounting surface layer 20 and the tooth surface layer 10. In one embodiment, the connecting surface layer is disposed on both sides of the mesh-like porous substrate 30, and may be in a ring-shaped configuration, so as to combine the installation surface layer 20 and the tooth surface layer 10 to enclose the mesh-like porous substrate 30.

Wherein the mounting face layer 20 and the tooth face layer 10 are both of a dense construction. The reticular porous base layer 30 is positioned in a cavity formed by the outer contour layer, and a fiber trabecula 31 in a porous grid structure is arranged in the reticular porous base layer 30. These fiber beams 31 connect the facing circumferential surfaces of the mounting surface layer 20 and the tooth surface layer 10, and realize a lightweight design of the gear on the premise of satisfying the requirements for the support strength and toughness of the gear.

In some embodiments, the connection relationship between the thickness of each fiber beam 31 along each point on the axis and the spatial arrangement of each fiber beam 31 is determined according to the spatial stress curve generated by the ideal working load spectrum of the gear.

The bone structure bionic gear has the advantages of taking account of the supporting strength and toughness of an internal matrix, the surface contact strength and toughness, light weight and the like.

As shown in fig. 1 and 2, the mounting surface layer 20 and the tooth surface layer 10 according to the embodiment of the present invention are outer layer structures of a bone structure bionic gear, which imitate cortical bone 2 and outer cartilage distributed on the outer peripheral surface of a bone in a bone structure of a higher mammal, and have excellent high contact strength and contact toughness.

The mesh-shaped porous base layer 30 of the embodiment of the invention is an intermediate structure of a bone structure bionic gear, and is coated by an outer layer structure formed by the mounting surface layer 20 and the tooth surface layer 10. The bionic high-grade mammal bone structure is characterized in that spongy bone 1 which is wrapped by dense bone 2, connected by a large number of trabeculae to form a porous grid structure, regularly arranged according to a stress curve and has non-uniform anisotropy is adopted. The reticular porous base layer 30 is composed of a large number of fiber beams 31, the thickness of each section of the fiber beams 31 along the axial line and the spatial arrangement and connection relationship of each section of the fiber beams 31 are determined according to a spatial stress curve generated by the load spectrum of the actual working condition of the gear, and the reticular porous base layer 30 has excellent high supporting strength and supporting toughness.

In some embodiments, the plurality of fibrous trabeculae 31 of the mesh-like porous substrate 30 define a plurality of fine inter-beam porous cavities 32 that are interconnected, at least some of the porous cavities being filled with a soft, malleable material. The multi-hole cavity 32 between the beams can be filled with high-toughness soft materials according to the requirements of the working conditions. The bone marrow 3 is filled in a porous cavity of a spongy part of bones and has the functions of filling, supporting and enhancing in the bionic bone structure of higher mammals. The soft material is preferably high-toughness soft material to enhance the supporting strength and toughness of the region.

In some embodiments, the mounting surface layer 20 is a supporting and fixing connection surface of the gear in the reducer, and the tooth surface layer 10 is an action surface for transmitting rotary motion and torque by mutual meshing between gears of the reducer; when the gear is designed, according to the actual working condition of the gear, the thickness of different local point positions of the mounting surface layer 20 and the tooth surface layer 10 is determined according to the bearing capacity and the torque load of the ideal working condition of the gear, so that the requirements of high contact strength and contact toughness of the gear on different local point positions of the mounting surface layer 20 and the tooth surface layer 10 are met.

In some embodiments, the mounting surface layer 20 may be configured in a variety of ways according to the actual design and installation requirements, including but not limited to: the shaft hole is matched with a circular hole, a spline hole, a rectangular key hole, a regular polygon hole and the like. The structural form of the tooth surface layer 10 can be various forms according to the actual design of the meshing requirement of the planetary reducer gear, and the structural form comprises but is not limited to involute tooth form, cycloid tooth form and the like.

In some embodiments, the mesh-like porous base layer 30 is the primary medium of internal force and torque transfer for gears coated with the mounting-face layer 20 and the tooth-face layer 10; the mesh-shaped porous base layer 30 is formed by printing a mesh-shaped porous base layer structure using a 3D printing method, which is constructed by the following steps:

converting the comprehensive load spectrum of the coating surface of the reticular porous base layer 30 coated by the mounting surface layer 20 and the tooth surface layer 10 according to the comprehensive load spectrum of the force and the torque of different local point parts of the mounting surface layer 20 and the tooth surface layer 10;

taking the comprehensive load spectrum of the cladding surface as a load boundary condition of the optimized design of the reticular porous base layer 30, taking light weight as an optimization target on the premise of ensuring the force and moment transmission supporting strength, and obtaining a spatial stress spectrum of the reticular porous base layer 30 by topological structure optimization methods such as finite elements and the like;

the material distribution design corresponding to each space point in the reticular porous base layer 30 is carried out by the space stress spectrum of the reticular porous base layer 30, each space point distributed with the material in the reticular porous base layer 30 forms a large number of fiber beams 31, the thickness of each section of the fiber beams 31 along each point on the axial line is determined by the space points distributed with the material, the space arrangement connection of each section of the fiber beams 31 is determined, and each space point without the distributed material in the reticular porous base layer 30 forms a beam-to-beam porous cavity 32.

In some embodiments, the beam-to-beam porous cavity 32 may be partially or completely filled with a soft, high-toughness material, depending on the actual operating conditions. Specifically, according to the actual working condition requirement, according to the spatial stress spectrum of the reticular porous base layer 30, the soft material is distributed at the high stress points corresponding to the porous cavities 32 between the beams, and the high stress points of the porous cavities 32 between the beams distributed with the soft material form the complete filling high-toughness soft body.

In some embodiments, the two side faces of the bone structure bionic gear are provided with connecting surface layers which seal and compact the reticular porous base layer 30, and the connecting surface layers are made of the same material as the mounting surface layer 20 and the tooth surface layer 10. Furthermore, the connecting facing layer may be formed in the same manufacturing process as the mounting facing layer 20 and the tooth facing layer 10, such as laser melt coating, fused deposition, and other advanced additive manufacturing processes.

In some embodiments, the thicknesses of the parts of the tooth surface layer 10 and the mounting surface layer 20 should be optimally designed (which can be realized by using a finite element algorithm commonly used at present) according to the requirement of the alternating dynamic load use condition as an initial condition, but the thicknesses cannot be too thick, and the excessive thicknesses have the following defects: firstly, the weight of the gear is increased; ② the surface is too hard and brittle and easy to be peeled off by surface fatigue. The thickness of each portion of the tooth surface layer 10 and the mounting surface layer 20 cannot be too thin, and too thin cannot provide sufficient surface contact strength, and causes surface plastic deformation and damage in operation.

The materials and processing techniques of the tooth surface layer 10 and the mounting surface layer 20 described in the present invention are key factors for the tooth surface layer 10 and the mounting surface layer 20 to meet performance requirements.

In some embodiments, the material selected for the tooth surface layer 10 and the mounting surface layer 20 simulates cortical bone, and has various physical properties, such as compact structure, high hardness, suitability for advanced additive manufacturing processes such as laser melt coating and fused deposition, and high surface contact strength and contact toughness. The selection of specific material grades or components of the tooth surface layer 10 and the mounting surface layer 20 needs to be combined with optimization design to comprehensively balance the performance requirements of actual working conditions of the gear on the surface hardness, wear resistance, corrosion resistance, high-temperature oxidation resistance, creep resistance and the like of the gear, and meanwhile, the factors such as the material combination degree with the reticular porous base layer fiber trabecula 31 need to be considered.

According to another aspect of the present invention, there is also provided a method for manufacturing a bone structure bionic gear, which can be based on a 3D printing model of the bone structure bionic gear obtained by the optimal design method described below, including:

firstly, manufacturing a reticular porous base layer 30 by using an additive manufacturing process mode;

manufacturing a tooth surface layer and an installation surface layer by using a laser melting coating or melting deposition process on the basis of the reticular porous base layer 30, and cladding the surfaces of the tooth surface layer and the installation surface layer;

and finally, carrying out gear grinding or high-speed gear hobbing finish machining on the surface layer of the gear, and carrying out internal circle grinding or high-speed milling finish machining on the surface layer of the gear to obtain the bone structure bionic gear required by design and use.

The high-speed milling is realized by adopting high feeding speed and small cutting parameters, and the rotating speed of a main shaft of the high-speed milling is generally 15000 r/min-40000 r/min and can reach 100000r/min at most. The high-speed milling precision is generally 10-speed milling or higher, and the surface roughness Ra is generally less than 1 mu.

The gear using occasion can adopt self-prepared FeSiB alloy powder (for example, the mass fraction of a small amount of element components is C about 4.0%, Si about 2.0%, Cr about 1.0%, Mn about 0.7%, Mo about 0.25%, Cu less than or equal to 0.2%, S less than or equal to 0.035%, P less than or equal to 0, 035%), and a small amount of CaF is added₂(e.g., 3g CaF)₂1kg of FeSiB complexThe alloy is used as a tooth surface layer and a mounting surface layer material, the cladding layer is suitable for 1-3 mm in thickness (the cladding thickness is required to be reserved for the machining removal amount of grinding finish machining to be 0.3-0.5 mm), the power requirement of laser melting coating equipment is 2.0-2.5 kW, the focusing light spot is 3-4 mm, the scanning speed is 0.1-0.5 m/min, and argon protection is performed in the whole process. The surface hardness HRC 52-65 and the surface waviness W of the tooth surface can be obtained_z≤16μm。

After the tooth surface layer 10 and the mounting surface layer 20 of the embodiment of the invention are subjected to additive manufacturing processes such as cladding and the like, the contour dimension precision and the surface finish degree generally cannot directly meet the design and use requirements, and further finish machining is required. The surface layer 10 of the gear needs to be subjected to finish machining through gear grinding or high-speed gear hobbing, and the surface layer 20 of the gear needs to be subjected to finish machining through internal grinding or high-speed milling and the like, so that the tooth-direction precision, the mounting surface size, the form and position precision and the surface finish of the gear finally reach the design and use requirements.

The mesh-shaped porous base layer 30 formed by a large number of fiber small beams 31 and the optimization design of the possibly filled soft bodies in the porous cavities 32 between the beams are important components of the optimization process of the light weight, high bearing and impact resistance optimization design method of the gear, and simultaneously, the optimization process of the support strength and the toughness is ensured.

In some embodiments, the material selected for the fiber trabeculae 32 of the mesh-like porous base layer 30 is selected to simulate cancellous bone, and has various physical properties, such as light weight, small specific gravity, high tensile strength and yield strength, suitability for advanced additive manufacturing processes such as metal 3D printing, and self-fluxing alloy powder or wire with high support strength and support toughness of the mesh-like porous structure. The selection of specific material grades or components needs to be combined with optimization design to comprehensively balance the performance requirements of the actual working conditions of the gear on bearing, impact resistance, creep resistance and the like of each point part of the gear matrix, and meanwhile, the factors such as the degree of combination with cladding materials of a tooth surface layer and a mounting surface layer need to be considered. For example, the gear application of the invention can adopt Ti6AlV4 alloy powder as a 3D printing material of the reticular porous base layer fiber trabecula.

The porous cavity 32 between the beams may be filled with soft material selected to simulate cancellous bone marrow 3, and should have excellent material properties, and may be light weight, small specific gravity, moderate elastic modulus, excellent support toughness, plastic deformation resistance, excellent fire resistance, and suitable for performing multi-material 3D printing with metal 3D printing material and other advanced additive manufacturing processes, and metal or non-metal powder or wire with high support strength and support toughness of multi-continuous granular structure. The selection of specific material grade or component is determined by combining the optimization design result. For example, the gear using occasion of the invention can adopt self-matched AlMg powder (mass fraction: Al & lt & gt 93 percent, Mg & lt & gt 7.0 percent) or self-matched thermosetting plastic powder (mass fraction: Epoxy & lt & gt 48 percent, PU & lt & gt 35 percent, PF & lt & gt 17 percent) as a filling soft 3D printing material for multi-material 3D printing together with the metal 3D printing material.

According to still another aspect of the present invention, there is also provided a decelerator for a robot including the aforementioned decelerator gear for a robot, which has advantages of supporting strength and toughness, surface contact strength and toughness, and light weight, etc. due to the adoption of the bionic gear of a bone structure.

According to other aspects of the present invention, in order to obtain the fibrous trabeculae 31 of the mesh-shaped porous base layer 30 of the 3D printing process and the soft space entities possibly filled in the porous cavities 32 between the trabeculae, the present invention further provides a generation method for obtaining the reducer gear for the robot, so as to perform an optimized design on the reducer gear for the robot, as shown in fig. 3, specifically comprising the following steps:

the method comprises the following steps: the thickness of each part of the tooth surface layer 10 and the mounting surface layer 20 is obtained after optimization design is carried out based on the requirement of the alternating dynamic load using working condition as an initial condition, a coated surface structure of the peripheral outline of the meshed porous base layer 30 is obtained, and an optimization space (or called a design space) of the meshed porous base layer 30 and comprehensive loads of each point part on the coated surface of the peripheral outline of the meshed porous base layer 30, which are transmitted from the tooth surface layer 10 and the mounting surface layer 20, namely a comprehensive load spectrum of the coated surface of the meshed porous base layer 30 can be obtained. The method is characterized in that the design is carried out based on the requirement of the use working condition of the alternating dynamic load of the gear as the initial condition to obtain the thickness of each part of the tooth surface layer and the mounting surface layer, obtain the thickness of the reticular porous base layer and calculate the comprehensive load of the tooth surface layer and the mounting surface by adopting a common finite element algorithm in the prior art. The alternating dynamic load refers to the load effect that the size and the direction of the gear are changed periodically along with time in the working process.

determining initial parameters required by the optimized design, such as the minimum entity thickness (0.2-0.5 mm can be taken out of the invention), the minimum detail size (0.15 mm can be taken out of the invention), the maximum entity inclination angle (printing placement state, included angle between entity inclined plane and vertical plane, 55 degrees can be taken out of the invention) and the like related to the capability of the 3D printing equipment, and the elastic modulus, Poisson ratio and the maximum variation of cross section area (the maximum variation of the 3D printing metal material and the 3D printing soft material) (the2.3mm can be taken out, etc.) and safety factor (1.2 can be taken out according to the actual working condition of the gear).

Step three: and 3D finite element meshing is carried out on the optimized space of the reticular porous base layer 30, and the selected 3D finite element type order and the mesh fineness are mainly determined by estimating the preset minimum diameter of the fiber trabeculae 31.

the 3D finite element grids partitioned from the optimized space of the reticular porous base layer 30 are numbered in a layered mode, namely, the 3D finite element grids tightly attached to the tooth surface layer in the optimized space of the reticular porous base layer form an initial layer, which is temporarily marked as S_i1 layer; the 3D finite element mesh clinging to the installation surface layer forms a termination layer, temporarily recorded as S_t1 layer. Then, the hierarchy numbers are respectively opposite and synchronized from the initial layer and the end layer, i.e., S is closely attached_iThe 3D finite element mesh of 1 layer forms the next layer inside, temporarily recorded as S_i2 layers; i.e. clinging to S_tThe 3D finite element mesh of 1 layer forms the next layer inside, temporarily recorded as S_t2 layers. And layering the 3D finite element grids in the opposite direction until the 3D finite element grids completely meet, wherein all the 3D finite element grids are layered and numbered. Let n layers total, at this time, compare S_i1 layer and S_tNumber of 3D finite element grids contained in each of 1 layer (generally, external gear, S)_iNumber of 1 layer 3D finite element grids > S_tNumber of 3D finite element mesh of 1 layer, the inner gear is reversed), all layers are numbered again in the multi-direction. S_i1 layer and S_tLayer 1, containing a large number of 3D finite element meshes, denoted S again₁The 3D finite element mesh contained is small in number and is recorded as S again_nAll adjacent layers in the middle are numbered adjacently.

fifthly, numbering the two-dimensional coordinates in the layer of the 3D finite element grid on the trunk axis in a mode of S₁The layer is used as the numbering basis of the two-dimensional coordinates in the layer; with S_nThe layers serve as the basis for spatially expanded projection. S₁The two-dimensional coordinate system of the in-layer foundation serial number generally takes an axial direction as an x-axis forward direction, radially expands a four-finger ring into a y-axis forward direction according to the x-axis forward direction of a thumb of a right hand, and the determination mode of the position of an origin is to ensure that S is₁Two-dimensional coordinate numbering (S) of intra-layer adjacent 3D finite element meshes₁and x and y are both adjacent positive integers (i.e. x and y are equal to Z)⁺) The two-dimensional coordinate numbers of the adjacent 3D finite element meshes in the rest layers are positive integers because the number of the 3D finite element meshes in each layer is changed, but may not be adjacent. From S₁Layer to S_nSpatially spread projection of layers and from S₁Layer to S_nAnd layer-by-layer numbering of in-layer two-dimensional coordinates of the 3D finite element grid. First, for S₁Each 3D finite element mesh of a layer can be calculated to S separately_nShortest transfer path of layer (i.e. S)₁S can be found for each 3D finite element mesh of the layer_nThe transfer path with the least number of neighboring 3D finite element meshes that a certain 3D finite element mesh of a layer passes through). Removal of S₁And counting the times of the 3D finite element meshes of all the layers passing through the transmission path and the upper layer source end 3D finite element meshes passing through the transmission path. For numbering to S in a given order_kA 3D finite element mesh for a layer (1 < k ≦ n), the number of propagation paths traversed and the source-side 3D finite element mesh being: a is₁Secondary to 3D finite element mesh (S)_k-1，x_a1，y_a1)、a₂Secondary to 3D finite element mesh (S)_k-1，x_a2，y_a2)、…、a_mSecondary to 3D finite element mesh (S)_k-1，x_am，y_am) Setting the 3D finite element mesh (S)_k，x_t，y_t) And then: x is the number of_tIs a positive integer x_a1、x_a2、…、x_amIs closest toNumber of (a), y_tIs a positive integer y_a1、y_a2、…、y_amIs closest to

The number of (2). To this end, all the numbered 3D FEM meshes of each layer are included at least 1 time in the slave S₁Layer by layer 3D finite element mesh to S_nAll the shortest transmission paths of the layer are the main axes of the grids of the fiber trabecula growth arrangement of the reticular porous base layer.

numbering the 3D finite element grids on the non-main axis by using the inner two-dimensional coordinate, namely, in each layer, using each 3D finite element grid numbered on the main axis as a local original point on the layer, using the positive direction of the x axis and the positive direction of the y axis determined by the inner two-dimensional coordinate as the positive direction of the numbering, in the same layer, using each local original point as the center of a concentric circle for synchronous diffusion, numbering according to the sequence, until all the unnumbered 3D finite element grids on the non-main axis of each layer are numbered, and numbering into (S)_k，x_a，y_a) S of (. alpha.,. beta.)_k3D finite element mesh on layer non-trunk axis, representing 3D finite element mesh (S) on the trunk axis of the layer_k，x_a，y_a) the projection distance on the x-axis of the two-dimensional coordinates in the layer is alpha, the projection distance on the y-axis of the two-dimensional coordinates in the layer is beta (alpha, beta belongs to Z, alpha, beta is not equal to 0), and (S)_k，x_a，y_a) in the distance between the 3D finite element mesh on the (α, beta) non-trunk axis and the 3D finite element mesh on all trunk axes of the layer, and (S)_k，x_a，y_a) the shortest distance between the 3D finite element meshes on the trunk axis is | + | β |, which means that the paths | α | + | β |, of the two are adjacentThe 3D finite element meshes of (1) can be reached with each other.

step (c) calculating spatial stress spectrum of the netted porous base layer space by dividing one period of the comprehensive load spectrum of the netted porous base layer cladding surface into S_iExternal force load spectrum and S on layer 1_tAnd the support load spectrum on the 1 layer has equal average amplitude and opposite phase. Then, the external force load spectrum is set at S_iDecomposing to each 3D finite element mesh on 1 layer, and enabling the support load spectrum to be in S_tdecomposing to each 3D finite element mesh on layer 1, determining transfer function for each single mesh transfer path according to mesh trunk axis generated in step (v), and S₁And calculating the periodic single-path stress spectrum of each 3D finite element grid in one period of each 3D finite element grid on each single-grid transmission path according to the numbering sequence of each 3D finite element grid on the layer, and if a plurality of transmission paths pass through the same 3D finite element grid, overlapping the periodic single-path stress spectrum of each transmission path on the 3D finite element grid to finally obtain the periodic full stress spectrum of the 3D finite element grid, wherein the periodic full stress spectrum of the whole 3D finite element grid forms a space stress curve of the mesh-shaped porous base layer, namely the space stress spectrum.

carrying the 3D finite element grids on the non-main axis from near to far according to the minimum carrying principle at the basic center of each 3D finite element grid on the main axis of each layer according to the space stress spectrum of the reticular porous base layer, and carrying the 3D finite element grids (S) in each direction_k，x_t，y_t) The periodic full stress spectrum is determined by combining initial parameters such as elastic modulus and Poisson ratio related to the performance of the printing material so as to meet the requirement R (S) on the supporting strength and toughness of the reticular porous base layer_k，x_t，y_t). If R (S) is not satisfied_k，x_t，y_t) returning to the step III, adjusting initial parameters, dividing the 3D finite element meshes again, and recording the number T of return iterations_⑧When T is_⑧> set number of times T_⑧sAnd estimating and judging the subsequent filling of the cavity softwarewhen the supporting strength can be supplemented to meet the requirements, the iteration is not returned to the step ③, and the optimal solution OS of the supporting strength and the toughness requirements in each iteration calculation is obtained_⑧(S_k，x_t，y_t) and ninthly, entering the step.

Generally, the larger the stress amplitude in a certain direction of the periodic full stress spectrum of a certain 3D finite element mesh on the trunk axis is, the more non-trunk axis 3D finite element meshes are carried along the direction. If the stress amplitudes of the periodic full stress spectrum of a certain 3D finite element mesh on the trunk axis in all directions are zero, no trunk fiber trabecula grows in the transmission path passing through the 3D finite element mesh (in this case, the S of the transmission path of the 3D finite element mesh_iThe initial mesh on layer 1 does not share the external force load).

correcting a main fiber trabecula, and growing and supplementing branch fiber trabeculae on the basis of the main fiber trabeculae, wherein the main fiber trabeculae generated by the primary resolving in the step (R) do not meet the requirements of the minimum entity thickness, the minimum detail size, the maximum entity inclination angle, the maximum variation of cross-sectional area, safety coefficient and the like of the initial parameter requirement of the optimized design generally, therefore, a non-main axis 3D grid of a carried finite element needs to be increased, decreased and corrected in each direction layer by layer, if a certain main fiber trabecula local part can not meet the requirements of shape and support strength toughness simultaneously only by correction, a 3D finite element grid (S) near the main fiber trabecula local part is needed_j，x_a，y_a) (α, beta) growth supplements the branching type fiber trabecula to simultaneously meet the shape requirement and the supporting strength toughness requirement R (S) of the locally relevant fiber trabecula_j，x_a，y_a)(α，β)。

if the step (v) is to solve the OS with the optimum solution_⑧(S_k，x_t，y_t) The form relaxation requirement enters the step, and the step only needs to simultaneously meet the shape requirement and the optimal solution OS of the locally relevant fiber trabecula_⑧(S_k，x_t，y_t) The requirements of (1). The supplement branch type fiber trabecula should meet the shortest supplement path and the requirement of initial parameters. If the main type fiber trabecula is modified and the growth is supplementedThe full branch type fiber trabecula can not meet the shape requirement and the supporting strength toughness requirement R (S)_k，x_t，y_t) Or an optimal solution OS_⑧(S_k，x_t，y_t) And R (S)_j，x_a，y_a) (α, β) is required, then the procedure returns to the step (b), the initial parameters are adjusted, the main-trunk type fiber trabecula is regrown, and the number of times of return iteration T is recorded_⑨When T is_⑨> set number of times T_⑨sestimating and judging that the supporting strength can be supplemented by filling the cavity soft body subsequently to meet the requirements, then no returning to the step (iteration), and taking the optimum solution of supporting strength and toughness requirements in every iteration calculation to make it enter into the step (R).

Step (r): and generating all fiber trabecula 3D entities, and checking the sealing property and the flow shape property of the 3D printing model. And if the 3D entity model formed by all the fiber trabeculae cannot meet the requirements of the 3D printing process on the closure and the flow property, returning to the step ninthly to correct.

Step (ii) ofif any one or both of the step (r) and the step (nini) have the condition that the next step is carried out according to the optimal relaxation-solving requirement, the porous cavities among the beams are required to be filled with soft bodies to supplement the supporting strength and toughness of the reticular porous base layer_⑧(S_k，x_t，y_t) Then with R (S)_k，x_t，y_t)-OS_⑧(S_k，x_t，y_t) For 3D finite element mesh (S)_k，x_t，y_t) carrying the 3D finite element grid in the porous cavity space between the adjacent beams in the same way as the step (⑨) and the step (ninthly) to form a soft body filling solid 3D model, if OS exists_⑨(S_j，x_a，y_a) (α, β), the soft-filled solid 3D model is formed in the same manner.

Step (ii) ofAnd (3) completing the specific optimization design of the fiber trabeculae of the reticular porous base layer and the soft body entity possibly filled in the porous cavity between the beams to obtain a final 3D printing model of the whole fiber trabeculae entity or a 3D printing model of the soft body entity and the porous cavity between the beams.

The optimization process, the shortest transmission path and the least hanging principle ensure that the weight of the whole fiber trabecula 31 entity and the possibly filled soft body is the lightest on the premise of meeting the supporting strength and the supporting toughness of the reticular porous base layer 30.

And finally, obtaining a 3D printing model of the reticular porous base layer based on all the generated fiber trabeculae, manufacturing the reticular porous base layer by using a 3D printing mode, and manufacturing an outer contour layer by using a laser melting coating or melting deposition process, wherein the outer contour layer comprises a tooth surface layer, an installation surface layer and a connecting surface layer and covers the reticular porous base layer.

By the gear design and manufacturing method, the minimum modulus of the processed gear is 3-4 times of the minimum processing thickness of the fiber trabecula of the reticular porous base layer. The fiber trabecula of the reticular porous base layer is generally printed and processed by metal 3D, and the minimum processing thickness of the existing metal 3D printing process can reach 0.2mm, so the minimum modulus of the process capable of processing the gear is 0.6-0.8 mm.

The reducer gear, the reducer for the robot and the generation method of the reducer gear are also suitable for other structural parts, such as bevel gears, belt wheels, chain wheels, transmission shafts and the like.

According to other aspects of the invention, the bionic robot comprises the speed reducer for the robot, and the speed reducer can be in the forms of a harmonic speed reducer, a cycloid speed reducer, a planetary gear speed reducer and the like. The gear of the speed reducer adopts a bone structure bionic gear.

The reducer gear and the reducer for the robot in the embodiment of the invention overcome the problem that the reducer cannot meet the requirements of the robot (especially a bionic robot) on light weight, high bearing impact resistance, high precision and high efficiency, and provide greater advantages for realizing ultra-dynamic motion of the robot in the aspects of driving key components, especially the reducer.

Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments in the present invention.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes may be made to the embodiment of the present invention by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.