Deformable Body for Force Torque Sensor Using Segmented Hinges
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Solution Overview
Problem
Force/torque sensors are expensive due to complex structures requiring high-cost 3D machining and bonding processes, limiting their widespread application in robots, especially for multi-axis reactivity and torque sensing.
Innovation Solution
A deformable body with a substrate, disc, and hinges that allows for simple machining and multi-axis reactivity, featuring a substrate with a hole and a disc connected by hinges, enabling efficient use of inner space and customizable structures, reducing manufacturing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex 3D machining and wire-cut machining are used for deformable bodies, then multi-axis reactivity and torque sensing performance are improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The deformable body is segmented into multiple functional parts: a substrate, a disc, and multiple hinges connecting them. This segmentation allows each part to be manufactured using simple 2D machining processes rather than complex 3D machining, while the assembled structure achieves the required multi-axis reactivity and torque sensing performance through the coordinated deformation of these segmented components.
2Measurement precision
If bonding strain gages is performed for resistance type sensors, then force/torque sensing capability is improved, but manufacturing process complexity and supply price increase
Solution Approach 1:
The patent replaces the resistance type sensing mechanism (which requires bonding strain gages) with a capacitive sensing mechanism. The deformable body's structural deformation under force/torque directly changes the capacitance between fixed and movable electrodes, eliminating the need for complex strain gage bonding processes while maintaining force/torque sensing capability.
3Ease of manufacture
If capacitive sensors are used instead of resistance type sensors, then manufacturing process is simplified, but measurement precision and rigidity decrease
Solution Approach 1:
The patent introduces a disc component with curved surfaces that forms part of the capacitive sensing structure. The curved geometry of the disc and its interaction with the hinges creates a rigid yet deformable structure that maintains high rigidity while enabling precise capacitive measurement, thus resolving the trade-off between manufacturing simplicity and measurement precision.
4Ease of manufacture
If simple machining is used for deformable bodies, then manufacturing cost decreases, but achieving multi-axis reactivity becomes difficult
Solution Approach 1:
The patent employs asymmetric hinge designs with different dimensions and orientations to achieve multi-axis reactivity from a structure manufactured using simple 2D machining. The asymmetric geometry of the hinges allows the deformable body to exhibit different deformation characteristics along different axes, enabling multi-axis force and torque sensing without requiring complex 3D machining processes.
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 solution enables the production of cost-effective, high-performance force/torque sensors with simplified manufacturing, allowing for easy customization and efficient multi-axis reactivity, while maintaining high performance and thinness.
Implementation Method 1
a plurality of hinges protruding from a side surface of the disc and connecting the disc and the substrate
Data Source
AI summary
A deformable body for a force/torque sensor which may be attached to robots formed with multiple axes and multiple joints includes a substrate in which a hole is formed, a disc disposed above the hole, and a plurality of hinges protruding from a side surface of the disc and connecting the disc and the substrate.