Flexible Circuit Load Cell Assembly with Folded Hinges
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Solution Overview
Problem
The existing methods for attaching strain gauges to robotic fingers are time-consuming, laborious, and prone to damage due to the manual alignment and soldering of free-standing wires, which complicates the assembly and operation of robotic fingers used for measuring loads or strains.
Innovation Solution
A method involving a flexible circuit body with hinges, where strain gauges are attached to a strip and folded using jigs to align and secure them, eliminating the need for free-standing wires and simplifying the assembly process by integrating the gauges and support structures into a modular load cell assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If strain gauges are individually attached to the strain element with hand alignment, then the strain gauges can be precisely positioned, but the assembly process becomes time-consuming and tedious
Solution Approach 1:
The strain gauges are pre-attached to the flexible circuit body in a factory setting with precise positioning, eliminating the need for time-consuming hand alignment during robotic finger assembly. The flexible circuit body serves as a pre-assembled unit that integrates multiple strain gauges in their correct positions before being installed on the robotic finger.
Solution Approach 2:
Multiple strain gauges are merged onto a single flexible circuit body, transforming individual attachment operations into a single unit installation. This consolidation reduces the number of discrete assembly steps and improves productivity while maintaining precise positioning through the pre-assembled nature of the flexible circuit body.
2Reliability
If free-standing wires are soldered to each strain gauge, then electrical connections can be established, but the process becomes time-consuming and laborious with increased risk of wire damage
Solution Approach 1:
Multiple electrical connections are merged into integrated circuits printed directly on the flexible circuit body, eliminating the need for individual wire soldering to each strain gauge. This integration maintains reliable electrical connections while dramatically reducing assembly time and eliminating the laborious wire handling process.
Solution Approach 2:
The mechanical wire soldering process is replaced with printed circuit board technology, where electrical connections are created through conductive traces printed on the flexible circuit body. This substitution eliminates the time-consuming and error-prone soldering operation while maintaining reliable electrical connectivity.
3Adaptability or versatility
If multiple strain gauges are attached to sides of the strain element, then comprehensive strain measurement is achieved, but the assembly complexity increases significantly
Solution Approach 1:
Multiple strain gauges intended for different measurement locations are merged onto a single flexible circuit body that can be conformally attached to the strain element surface. This approach maintains comprehensive measurement capability while reducing assembly complexity by treating multiple gauges as a single integrated component rather than separate attachment operations.
Solution Approach 2:
The flexible circuit body can be dynamically conformed to the strain element surface, allowing the same flexible circuit body design to accommodate multiple strain gauge positions and configurations. This dynamic adaptability enables comprehensive strain measurement while simplifying assembly, as the flexible circuit body can be attached in various orientations and positions as needed.
Data Source
AI summary
A method of manufacturing a load cell assembly and methods of folding a circuit device are disclosed. A flexible circuit body including a strip having at least one hinge is provided, with the strip being in a first position or an unfolded position. A plurality of strain gauges are attached to the strip, with the hinge disposed between the strain gauges. A jig is provided and the strip of the flexible circuit body is folded along the hinge utilizing the jig to define a second position or folded position of the strip.