Force-Torque Sensor With Mechanical Amplifier and Modular Overload Protection
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Solution Overview
Problem
Existing 6-axis force-torque sensors face challenges in achieving high resolution while maintaining rigidity, leading to high costs due to the need for strain gauges and complete replacement upon overload.
Innovation Solution
A modular design with a deformation body connected via a coupling element to a mechanical amplifier, allowing for the deformation body to absorb forces and torques, which can be detached from the mechanical components to prevent complete device replacement upon overload, using a flexure mechanism and temperature compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are used to measure forces and torques with high resolution, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces strain gauges (electrical measurement system) with a mechanical amplifier that uses a lever system to amplify mechanical deformations. The deformation body undergoes deformation under applied forces/torques, and this deformation is mechanically amplified by the amplifier with lever arms to produce detectable movements without requiring strain gauges or signal amplification electronics.
2Reliability
If the entire device is replaced upon overload, then reliability is improved, but loss of time and cost increase
Solution Approach 1:
The patent divides the sensor into separable modules: a deformation body that absorbs overload and a mechanical amplifier that can be detached. When overload occurs, only the deformation body needs to be replaced while the amplifier can be reused, reducing replacement time and cost compared to replacing the entire sensor.
Solution Approach 2:
The coupling element acts as an intermediary connection between the deformation body and the mechanical amplifier. This detachable coupling allows the amplifier to be separated from the deformed body, enabling selective replacement of only the overloaded component while preserving the expensive amplifier assembly.
3Stability of the object's composition
If a rigid measuring system is used, then stability is improved, but measurement precision deteriorates due to small deformations
Solution Approach 1:
The system separates the rigid support structure from the deformation measurement function. The deformation body provides the necessary compliance for measurement while the amplifier and support structures maintain rigidity for stability, resolving the contradiction between structural stability and measurement sensitivity.
Solution Approach 2:
The mechanical amplifier changes the scale parameter of the deformation by using lever arms with different lengths. The small deformation of the deformation body is amplified into a larger movement at the amplifier output, increasing measurement resolution while the deformation body itself remains sufficiently rigid for structural stability.
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
Reduces costs and minimizes wear by allowing selective replacement of the deformation body, maintaining high resolution and accuracy in force and torque measurements while protecting the mechanical amplifier from overload.
Implementation Method 1
A force acting on the deformation body or a torque acting on the deformation body leads to a deformation of the length element
Implementation Method 2
an input-side input of a mechanical amplifier is fastened to the deformation body by means of a coupling element, wherein a material measure is arranged on an output-side output of the mechanical amplifier and a deformation of the length element leads to a movement of the material measure
Data Source
AI summary
A device measures a force and/or torque with a deformation body. The device includes a first fastening element, a second fastening element arranged spaced apart in a direction from the first fastening element and at least one length element arranged between the two fastening elements. The device has and comprising a first end, a second end and a length along a longitudinal direction. A force acting on the deformation body or a torque acting on the deformation body leads to a deformation of the length element. An input-side input of a mechanical amplifier is fastened to the deformation body by means of a coupling element. A material measure is arranged on an output-side output of the mechanical amplifier and a deformation of the length element leads to a movement of the material measure. The movement of the material measure can be detected by a scanning element.