Crankshaft Load Cell Structure for Accurate Radial Force Sensing
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Solution Overview
Problem
Current load cell designs for determining radial forces on crankshafts lack efficient measurement and support mechanisms, particularly in gear housings, leading to inaccurate force calculations and potential damage to strain sensors.
Innovation Solution
A load cell with a cylindrical receiving sleeve and fastening ring, featuring measuring areas with strain sensors and axial support areas, designed to absorb radial and axial forces, respectively, and connected via connection areas to ensure controlled deformation and precise force measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain sensors are attached to measuring areas to detect radial forces, then measurement precision is improved, but the strain sensors are vulnerable to damage from axial forces
Solution Approach 1:
The load cell is segmented into distinct functional areas: measuring areas with measuring tabs for radial force detection, and axial support areas with support tabs for axial force bearing. This segmentation allows strain sensors to be placed only where radial forces occur, protecting them from axial force damage while maintaining measurement precision.
Solution Approach 2:
The axial support areas act as intermediaries that bear and redirect axial forces away from the measuring areas. The support tabs with strain sensors detect axial forces separately, preventing these forces from damaging the radial force measuring sensors while maintaining overall structural integrity.
2Ease of manufacture
If the load cell structure is simplified for ease of manufacture, then manufacturing precision may be compromised, affecting measurement accuracy
Solution Approach 1:
The load cell merges multiple functions into a single integrated structure: the receiving sleeve, measuring areas, axial support areas, and fastening ring are formed as one piece. This merging simplifies manufacturing compared to assembling multiple separate components while maintaining the precise geometric relationships needed for accurate force measurement.
Solution Approach 2:
The design uses parameter optimization in the tab geometries and slot dimensions to achieve both manufacturability and precision. The measuring tabs and support tabs are designed with specific dimensional parameters that allow standard manufacturing processes to produce the required precision without complex machining operations.
3Ease of operation
If measuring tabs are designed with large angular range to improve deformability, then the defined direction of radial force measurement is compromised
Solution Approach 1:
The measuring tabs exhibit local quality differentiation: they have reduced thickness in specific regions to enhance deformability where needed, while maintaining adequate thickness and structural rigidity in other regions to preserve the defined direction of force measurement. This localized variation in geometric properties optimizes both deformability and measurement precision.
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
The design enables accurate measurement of radial forces, allowing for the calculation of torque on a crankshaft, while protecting strain sensors and providing stable support, thus enhancing the reliability and durability of force measurement systems.
Implementation Method 1
measuring areas which are intended to absorb radial forces of the receiving sleeve, which are transmitted from the ring of the bearing to the measuring areas. Strain sensors are attached to at least two of the measuring areas
Implementation Method 2
The load cell has axial support areas which are provided on the fastening ring for axially supporting the outer ring or ring of the bearing or for absorbing axial forces
Data Source
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AI summary
A load cell for determining a radial force on a crankshaft, comprising a mounting sleeve for receiving a bearing ring and a mounting ring for securing the load cell in a gearbox housing. Axial support areas are provided on the mounting ring for axial support of the outer ring of the first bearing. Furthermore, measuring areas are provided for recording radial forces on the mounting sleeve, connecting the mounting sleeve to the mounting ring. Strain gauges are attached to at least two of the measuring areas.