A Modular and High-Precision Motion Control System With an Integrated Motor

This paper describes the design and control of an integrated direct-drive joint suitable for applications that require a high-precision motion control system. The joint integrates a direct-drive synchronous motor with axial air gap, a torque sensor, and a high-resolution position sensor. The key design aspects of the integrated joint, like the motor´s armature, cooling system, motor housing, bearing arrangement, sensors, and power electronics are detailed. We also present a number of advanced implementations in motor torque control, optimal joint torque sensory feedback, and motion control using positive joint torque feedback. Experimental results illustrate an outstanding performance regarding thermal response, torque ripple, reference trajectory tracking, torque disturbance rejection, and joint stiffness.