Force Sensor Module Structure for Overload Damage Prevention
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Solution Overview
Problem
Existing force sensor modules can be damaged when subjected to loads greater than the expected design load, posing a risk to the second substrate and metasurface pattern.
Innovation Solution
A force sensor module design incorporating a housing, force transferring section, and strain element, where the force transferring section protrudes outside the housing to prevent excessive loads from damaging the sensor, utilizing a fluid spring and projection to accurately detect external forces without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the force sensor module uses a compact design with the force transferring section fully contained in the housing, then the device structure is simplified and smaller, but the sensor becomes vulnerable to damage when excessive loads are applied
Solution Approach 1:
The force transferring section protrudes from the housing surface in advance to create a mechanical stop before excessive force can reach the strain element. This preliminary geometric configuration prevents over-compression of the strain element by blocking the force transmission path when the protruding section contacts the loading object, thereby protecting the sensor from damage due to excessive loads
Solution Approach 2:
The protruding portion of the force transferring section acts as a mechanical cushion or buffer that absorbs or limits excessive external forces before they can damage the strain element. This beforehand protective structure ensures that even when loads greater than expected are applied, the strain element remains protected within its safe operating range
2Reliability
If the force transferring section protrudes outside the housing, then the sensor is protected from excessive loads, but the device structure becomes more complex and larger
Solution Approach 1:
The force transferring section serves multiple functions: it transfers force from the loading object to the strain element during normal operation, and simultaneously acts as a protective protrusion that limits excessive force transmission. This multi-functionality allows a single structural element to provide both sensing and protection without requiring separate components, thereby minimizing the overall volume increase
3Length of stationary object
If the end of the force transferring section lies in the same plane as the housing surface, then the protrusion amount is minimized, but the protective effect against excessive loads is reduced
Solution Approach 1:
The invention optimizes the protrusion length parameter of the force transferring section to achieve the minimum effective protrusion distance required to protect the strain element. By carefully calculating and setting this parameter, the design ensures that even a minimal protrusion provides sufficient protection against excessive loads while maintaining the end of the force transferring section as close as possible to the housing surface plane
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 prevents damage to the sensor even under excessive loads, enhances detection accuracy, and reduces external-force loss by ensuring the force transferring section does not exceed the housing plane, thus maintaining precise force measurement.
Implementation Method 1
a strain element that deflects in response to an external force, and detects the external force according to the amount of deflection of the strain element
Data Source
AI summary
A force sensor module includes: a force sensor configured to detect an external force according to the amount of deflection of a strain element that deflects in response to the external force; a housing that accommodates the force sensor; and a force transferring section configured to transfer the external force to the strain element, the force transferring section being accommodated in the housing so as to be in contact with the strain element and having a part that includes an end of the force transferring section and that protrudes outside the housing through a surface of the housing, the amount of protrusion of the part of the force transferring section measured from the surface of the housing being set such that the force sensor is not damaged even in a case where the end lies in the same plane as the surface of the housing.