Torque protection for strain wave drives

1. A torque-limiting actuator assembly comprising

a housing;

a motor affixed to the housing; the motor having a shaft that rotates at a first velocity;

a transmission coupled to the housing and the motor, the transmission comprising an input member, an intermediate member, and an output member, the members rotatable around a common axis;

the input member coupled to the shaft and configured to engage the intermediate member; the intermediate member configured to also engage the output member and cause it to rotate at a second velocity slower than the first velocity; and

a slip clutch including one or more clutch pads, wherein the intermediate member is held stationary by a slip clutch,

wherein the intermediate member comprises a body having a flange engaged by the slip clutch, and

wherein the intermediate member is held stationary by the one or more clutch pads up to a torque limit and configured to slip against the one or more clutch pads when torque exceeds the torque limit.

2. The torque-limiting actuator assembly of claim 1 , wherein the intermediate member is configured to slip against the one or more clutch pads when the output member experiences torque greater than the torque limit.

3. The torque-limiting actuator assembly of claim 1 , wherein the slip clutch comprises a first clutch pad engaged with a first side of the flange and a second clutch pad engaged with a second side of the flange, whereby the clutch pads releasably hold the intermediate member in a fixed position.

4. The torque-limiting actuator assembly of claim 3 , wherein the clutch pads frictionally hold the intermediate member in the fixed position.

5. The torque-limiting actuator assembly of claim 3 , wherein the slip clutch allows the intermediate member to rotate when the torque applied to it by the output member exceeds a torque limit.

6. The torque-limiting actuator assembly of claim 3 , wherein the first clutch pad is coupled to the housing.

7. The torque-limiting actuator assembly of claim 3 , further comprising a spring washer coupled to the housing, the spring washer configured to cause the second clutch pad to engage the second side of the flange.

8. The torque-limiting actuator assembly of claim 1 , wherein the transmission is a strain wave drive the input member is a wave generator, the intermediate member is a flexspline, and the output member is a circular spline.

9. A robot having at least one limb, the robot comprising:

a motor disposed on the robot, the motor having a drive shaft and being configured to move the at least one limb of the robot;

a transmission comprising an input member rotatably coupled to the drive shaft, an intermediate member held stationary by one or more clutch pads biased against a flange of the intermediate member up to a torque limit, and an output member rotatably engaged with the intermediate member, whereby rotation of the input member by the drive shaft causes rotation of the output member at a slower speed;

wherein the intermediate member is configured to slip against the one or more clutch pads when torque from the output member exceeds the torque limit;

wherein the output member is coupled to the at least one limb of the robot.

10. The robot of claim 9 , wherein the intermediate member comprises a body having a flange, the flange having a first side and a second side, wherein both sides are engaged by the one or more clutch pads.

11. The robot of claim 9 , wherein the one or more clutch pads comprises at least one clutch pad having a first side and a second side, the first side frictionally engaged with the intermediate member and the second side fixedly disposed on a housing.

12. The robot of claim 9 , wherein the one or more clutch pads comprises a first clutch pad mechanically biased against the flange of the intermediate member, wherein the first clutch pad frictionally engages the intermediate member and causes the intermediate member to frictionally engage a second clutch pad, whereby the intermediate member is immobilized until the torque limit is exceeded.

13. The robot of claim 9 , wherein the transmission is a strain wave drive the input member is a wave generator, the intermediate member is a flexspline, and the output member is a circular spline.

14. A method of protecting an actuator assembly from damage, the method comprising

providing an actuator having a housing, a motor disposed within the housing and having a drive shaft that rotates at an input speed, and a transmission assembly disposed within the housing, the transmission assembly comprising an input member, an intermediate member, and an output member; the input member rotatably coupled with the drive shaft whereby rotation of the input member at the input speed interacts with the intermediate member to cause the output member to rotate at a reduced speed compared to the drive shaft speed, the output member configured to provide torque up to a torque limit;

holding the intermediate member stationary by one or more clutch pads biased against a flange of the intermediate member so long as the torque on the output member is below the torque limit;

permitting the intermediate member to slip against the one or more clutch pads when the torque on the output member exceeds the torque limit.

15. The method of claim 14 , wherein the transmission assembly is a strain wave drive.

16. The method of claim 14 , wherein the output member is fixedly attached to a workpiece.

17. The method of claim 16 , wherein the workpiece is a limb of a robot.