Force Sensor Device with Integrated PCB and Housing Cover
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Solution Overview
Problem
Existing force sensors are complex and costly due to the need for separate components for signal processing and protection from environmental influences, particularly in harsh automotive applications, and lack cost-effective and energy-efficient designs.
Innovation Solution
A compact force sensor device with a power ring and housing cover that encloses electronic components, featuring an internal printed circuit board fixed to the power ring without additional components, and redundant force transducers for reliable measurement under varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components are used for signal processing and protection, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the force sensor, electronic components for signal processing, and protective housing into a single integrated device. The force ring with embedded strain gauges is directly mounted on the shaft, eliminating the need for separate signal processing units and external detection devices, thereby reducing overall device complexity while maintaining reliability through integrated design
2Device complexity
If retaining ring with welded connection is used, then signal processing is integrated, but manufacturing output decreases and unit costs increase
Solution Approach 1:
The patent divides the force sensor into modular components: the force ring with embedded strain gauges, the shaft, and the housing. This segmentation allows for independent manufacturing and assembly, improving productivity. The force ring can be produced separately and then mounted on the shaft, eliminating the need for complex welded connections while maintaining integration
3Device complexity
If compact design is implemented, then cost-effectiveness is improved, but measurement precision may be compromised
Solution Approach 1:
The patent applies local quality by embedding strain gauges directly into the force ring at specific locations where stress occurs. This localized measurement approach maintains high measurement precision while keeping the overall device compact. The strain gauges are positioned to measure deformation at critical points, ensuring accurate force measurement without requiring a large-scale design
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 provides a cost-effective, energy-efficient, and environmentally protected force sensor capable of reliably measuring forces in harsh conditions, ensuring consistent measurement results and reduced production costs.
Implementation Method 1
As a result of the direct or indirect application of force to the ring-shaped force sensor, it deforms, so that the force to be measured can be attributed to a change in displacement or length
Implementation Method 2
The deformation of the ring can be determined by strain measurement, and the force acting on the brake shoes can then be determined using a strain gauge system
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
The invention relates to a force sensor device 1, which is designed to detect a measured quantity of force and to generate an electrical signal based on the measured quantity. The force sensor device comprises a force ring 3 with a force application surface 6 and a receiving surface 5 for receiving a printed circuit board 20 on which passive and active electronic components are arranged. The printed circuit board 20 is mechanically or adhesively fixed to the receiving surface 5. The force sensor device 1 further comprises at least one force transducer 15, which is electrically connected to the printed circuit board 20 and is arranged and configured on the force ring 3 such that it detects deformations of the force ring 3 as a result of a force acting axially on the force ring 3.The force sensor device 1 further comprises a housing cover 30, which is connected to the force ring 3, so that the force ring 3 and the housing cover 30 enclose the circuit board 20 and the force transducer 15, as well as an external connection for tapping an electrical signal. (Fig. 2).