Actuator Sensor Fusion for Precise High-Speed Load Positioning
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Solution Overview
Problem
Existing actuator systems, such as those used in lifting columns and mobile X-ray systems, face challenges in achieving high precision and speed during load movement, as they require significant force to overcome inertia, limiting user control and precision, especially when handling heavy loads.
Innovation Solution
A sensor system comprising a force sensor and an acceleration sensor, coupled with a processing device, is used to detect and control the actuator's movement by determining the total force and acceleration, allowing for precise and intuitive load positioning without the need for special control devices, by calculating the force exerted by the user and adjusting the motor drive accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If motor-driven actuators are used to move heavy loads, then the precision of positioning can be improved, but the speed of movement is limited by the control response time
Solution Approach 1:
The system performs preliminary actions by predicting the user's intended movement direction and preparing the motor drive in advance. The processing device calculates the direction of movement based on force sensor and acceleration sensor data before the user completes the positioning action, allowing the motor to be pre-positioned for the upcoming movement, thus achieving both high speed and high precision.
Solution Approach 2:
The system implements continuous feedback by constantly monitoring force sensor and acceleration sensor data to detect user input and movement state. This real-time feedback loop allows the processing device to adjust motor drive commands dynamically, maintaining precise control while enabling rapid response to user intentions, thereby resolving the contradiction between positioning precision and movement speed.
2Ease of operation
If counterweights or spring systems are used to assist movement, then the effective weight experienced by the user is reduced, but the inertia of the load remains unchanged
Solution Approach 1:
The system replaces traditional mechanical assistance systems (counterweights, springs) with an intelligent control system that uses sensors and motor drive. The force sensor and acceleration sensor detect user input and movement state, and the processing device calculates appropriate motor assistance to counteract both weight and inertia forces dynamically, providing ease of operation while handling the full inertia of the load through active control rather than passive mechanical means.
Solution Approach 2:
The system dynamically changes motor drive parameters based on real-time sensor data. By continuously adjusting motor torque and speed commands according to detected force and acceleration, the system adapts to varying load conditions and user intentions, effectively compensating for inertia forces during acceleration and deceleration phases while maintaining ease of operation throughout the movement range.
3Speed
If rapid movements are executed to overcome inertia, then the movement speed is improved, but the force required from the user increases
Solution Approach 1:
The acceleration sensor provides real-time feedback on the actuator part's acceleration state, which the processing device uses to calculate the inertia force. When rapid movement is detected or anticipated, the system automatically increases motor torque output to counteract the inertia force, allowing high-speed movement without requiring proportional increases in user force. The continuous feedback loop ensures the motor provides exactly the right amount of assistance during acceleration phases.
Solution Approach 2:
The system performs preliminary action by detecting user intent through the force sensor before rapid movement begins. The processing device predicts the required acceleration and pre-adjusts the motor drive parameters to provide necessary torque for the upcoming rapid movement. This preliminary preparation allows the user to initiate rapid movements with minimal force, as the motor is already positioned to provide the required acceleration assistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables precise and rapid positioning of heavy loads with reduced user effort, as the system assists movement by controlling the actuator based on detected forces and accelerations, allowing for intuitive operation without the need for special grips or contact points.
Implementation Method 1
a force sensor (2) which is designed to detect a total force (Fl) acting on an actuator part (3)
Implementation Method 2
an acceleration sensor (4) which is designed to detect an acceleration (a) of the actuator part (3)
Data Source
AI summary
In a sensor system for an actuator, in particular a lifting column, a force sensor is configured to detect a total force acting on an actuator part. An acceleration sensor is configured to detect an acceleration of the actuator part. Accordingly, the sensor system has a processing device, which is configured to control a drive of the actuator for moving the actuator part on a basis of the detected total force and the detected acceleration.