Six-Axis Force Sensor Strain Structure for Automated Gauge Mounting
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Solution Overview
Problem
The industrialization of six-dimensional force sensors is hindered by low productivity and yield rates due to the manual mounting of strain gauges on multiple surfaces and the use of silicon-based semiconductor materials, which are difficult to process, leading to high production costs and limited civilian applications.
Innovation Solution
A strain-generating structure with strain gauges parallel to a datum plane and concave-convex structures on the strain body, allowing machine-assisted mounting and differential stress distribution for efficient strain detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are manually mounted on multiple surfaces of the strain body, then the sensor can detect force accurately, but the production difficulty increases and productivity decreases
Solution Approach 1:
The patent repositions all strain gauges to be mounted on a single surface (the first surface) of the strain body rather than distributing them across multiple surfaces. This dimensional consolidation allows machine automation for mounting while maintaining the ability to detect all six-dimensional forces and torques through strategic placement of gauges at specific locations on that single surface.
Solution Approach 2:
The patent divides the strain body into specific regions (convex portions and concave portions) with defined functional roles. The convex portions are designated for strain gauge mounting while concave portions serve other structural functions. This segmentation enables automated mounting processes to efficiently place gauges only in the convex regions on the single surface.
2Measurement precision
If strain gauges are mounted on multiple surfaces, then comprehensive strain detection is achieved, but the manufacturing complexity increases
Solution Approach 1:
The patent consolidates all strain gauge mounting to a single surface of the strain body, reducing the mounting process from multi-surface operations to a single-surface operation. This simplifies the manufacturing process while maintaining comprehensive six-dimensional force and torque detection capabilities through optimized gauge placement at specific locations on that surface.
Solution Approach 2:
The first surface of the strain body serves multiple functions: it provides the mounting platform for all strain gauges, maintains structural integrity, and enables comprehensive force detection. By making this single surface universal for both structural and sensing functions, the patent reduces manufacturing complexity while preserving detection capabilities.
3Measurement precision
If strain gauges are positioned to obtain sufficient strain signal, then detection performance improves, but the strain distribution becomes uneven causing some areas to experience excessive strain
Solution Approach 1:
The patent creates different local qualities within the strain body by forming convex and concave portions with distinct functional characteristics. The convex portions are designed with higher strain concentration to provide sufficient strain signals for accurate detection, while the concave portions experience lower strain and provide structural support. This local differentiation allows the strain body to simultaneously achieve high detection performance and maintain overall structural durability.
Solution Approach 2:
The patent modifies the geometric parameters of the strain body by introducing convex and concave portions with specific dimensional relationships. The convex portions have increased curvature and reduced thickness to amplify strain signals, while concave portions maintain greater thickness for structural strength. These parameter changes enable the strain body to generate sufficient strain signals in specific regions without compromising overall durability.
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 design significantly reduces production difficulty, improves efficiency and yield rates, and ensures accurate detection performance by optimizing strain gauge placement and stress distribution.
Implementation Method 1
the six-dimensional force sensor mainly builds a Wheatstone bridge using the resistance change effect after the deformation of a resistance strain gauge
Data Source
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AI summary
The embodiments of the present invention provides 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-dimensional force sensor.