Concave-Convex Strain-Generating Structure for Six-Axis Force/Torque Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current six-axis force/torque sensors face challenges in productivity and yield rate due to manual mounting of strain gauges and the use of silicon-based semiconductor materials, leading to low production efficiency and poor product adaptation.
Innovation Solution
A strain-generating structure with a concave-convex design where strain gauges are parallel to a datum plane, allowing for machine-assisted surface mounting, and featuring stress distribution optimization through concave-convex structures to enhance strain detection performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual mounting of strain gauges is used, then measurement precision can be ensured, but productivity and manufacturing efficiency deteriorate
Solution Approach 1:
The strain gauge mounting positions are pre-designed with concave-convex structures on the strain body surface before assembly. The concave portions serve as pre-formed mounting cavities that guide and position the strain gauges automatically during assembly, eliminating the need for manual positioning while ensuring accurate strain detection at optimized locations.
Solution Approach 2:
The concave-convex structure on the strain body automatically guides the strain gauge positioning during assembly. The convex portions protrude to precisely locate the strain gauge positions, and the concave portions receive the strain gauges, enabling self-aligned mounting without manual intervention while maintaining measurement precision.
2Measurement precision
If silicon-based semiconductor materials are used, then measurement precision is improved, but ease of manufacture and adaptability deteriorate
Solution Approach 1:
The patent changes the material parameter from silicon-based semiconductor to elastomeric material for the strain body. This material substitution maintains the ability to generate measurable strain while dramatically improving manufacturability, enabling cost-effective mass production and better adaptation to different application scenarios without sacrificing strain detection capability.
Solution Approach 2:
The patent employs composite material construction by combining elastomeric material for the strain body with strain gauges made from conventional resistive materials. This composite approach leverages the advantages of both material types: the elastomeric material provides mechanical flexibility and ease of manufacture, while the strain gauges provide precise electrical strain measurement.
3Measurement precision
If concave-convex structure is added to optimize strain distribution, then measurement precision improves, but device complexity increases
Solution Approach 1:
The concave-convex structure is applied locally at specific positions on the strain body where strain gauges need to be mounted. Only the mounting surfaces feature these structural modifications, while the rest of the strain body maintains its simple elastomeric form. This localized application optimizes strain distribution at critical points without making the entire device complex.
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
Improves production efficiency and yield rate while ensuring accurate force and torque detection by optimizing strain distribution and reducing manual labor in sensor assembly.
Implementation Method 1
the six-axis force/torque sensor mainly builds a Wheatstone bridge using the resistance change effect after the deformation of a resistance strain gauge
Data Source
AI summary
Disclosed is a strain-generating structure and a force sensor. The strain-generating structure comprises at least one strain body configured to generate strain under an external force. A surface of the at least one strain body is provided with at least one concave-convex structure. The at least one concave-convex structure is provided with a concave portion and a convex portion adjacent to the concave portion. The convex portion of the at least one concave-convex structure is provided with at least one strain gauge. The at least one strain gauge is configured to sense the strain. The strain-generating structure has a datum plane perpendicular to an axis of the strain-generating structure. Each of the at least one strain gauge is disposed parallel to the datum plane. The strain-generating structure attaches the strain gauges to a plane that facilitates operation of the machine and considers the detection performance of a six-axis force/torque sensor.