Development of A High-Torque-Density Double-Stator Vernier Machine System for Industrial Robots

Driven by the objectives and demands for the robust development of industrial robots in Guangdong Province, this project proposes to research high torque density dual-stator vernier motors and their integrated fault detection and fault-tolerant control technologies for industrial robot servo systems. Compared to existing commercial servo motors, the proposed dual-stator vernier motor, through the vernier motor topology, dual-stator structure, and Halbach array arrangement of permanent magnets, will significantly enhance torque density, thereby enabling direct drive of industrial robots. This solution eliminates the need for precision reducers that are typically paired with traditional permanent magnet synchronous servo motors, reducing reliance on foreign precision reducers and lowering production costs. It also eliminates noise generated by mechanical reduction devices, improving robot performance.

Furthermore, the project will conduct detailed electromagnetic structure analysis and multi-physics modeling optimization of the proposed high torque density dual-stator vernier motor to ensure its normal operation under rated conditions. Based on the characteristics of the inner and outer stators of this dual-stator vernier motor, the project innovatively proposes an inner-outer dual winding series structure and explores fault detection methods based on machine learning to enhance the ability to identify stator winding faults. Subsequently, the project plans to study fault-tolerant control algorithms based on the dual winding series structure, allowing the robot to maintain good performance in the event of faults and thereby reducing losses from large-scale production halts while ensuring reliability and cost-effectiveness.

In summary, this project aims to research high torque density dual-stator vernier motors and their fault-tolerant control solutions for industrial robots in manufacturing scenarios. This technological approach is of great significance to improving the product quality and production efficiency of industrial robots in China, contributing to the strategic goal of “Intelligent Manufacturing 2025.”