Force-Torque Sensor Architecture With Overload-Protected Mechanical Amplifier
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Solution Overview
Problem
Conventional 6-axis force-torque sensors using strain gauges are costly, complex, and require complete replacement upon overload, leading to high maintenance costs.
Innovation Solution
A modular design with a deformation body connected via a coupling element to a mechanical amplifier, allowing the deformation body to absorb forces and torques, while the mechanical amplifier is protected from overload, enabling modular replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are used to measure forces and torques, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The device is divided into separate functional modules: a deformation body that experiences the full force/torque, a coupling element that transmits a portion of the deformation, and a mechanical amplifier that amplifies the transmitted deformation. This segmentation allows the sensitive measuring components to be isolated from the high-stress deformation body, reducing complexity and cost while maintaining measurement precision.
2Measurement precision
If strain gauges are used to measure forces and torques, then measurement precision is improved, but cost increases
Solution Approach 1:
The device is divided into separate functional modules: a deformation body that experiences the full force/torque, a coupling element that transmits a portion of the deformation, and a mechanical amplifier that amplifies the transmitted deformation. This segmentation allows the sensitive measuring components to be isolated from the high-stress deformation body, reducing complexity and cost while maintaining measurement precision.
3Measurement precision
If the entire device is used to measure forces and torques, then measurement accuracy is maintained, but reliability decreases under overload conditions
Solution Approach 1:
The coupling element is designed to absorb and protect the mechanical amplifier from overload conditions. When excessive forces or torques are applied, the coupling element prevents damage to the sensitive measuring components, allowing the device to withstand overload without requiring complete replacement. This protective mechanism maintains reliability while preserving measurement accuracy within the operational range.
Solution Approach 2:
The device is divided into separate functional modules: a deformation body that experiences the full force/torque, a coupling element that transmits a portion of the deformation, and a mechanical amplifier that amplifies the transmitted deformation. This segmentation allows the sensitive measuring components to be isolated from the high-stress deformation body, reducing complexity and cost while maintaining measurement precision.
4Device complexity
If the deformation body is directly connected to the mechanical amplifier, then device complexity is reduced, but reliability decreases under overload conditions
Solution Approach 1:
The coupling element is designed to absorb and protect the mechanical amplifier from overload conditions. When excessive forces or torques are applied, the coupling element prevents damage to the sensitive measuring components, allowing the device to withstand overload without requiring complete replacement. This protective mechanism maintains reliability while preserving measurement accuracy within the operational range.
Solution Approach 2:
The coupling element serves as an intermediary between the deformation body and the mechanical amplifier. It selectively transmits a portion of the deformation to the amplifier while filtering out excessive loads, thereby protecting the sensitive measuring components without requiring complex protection systems.
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 the need for complete sensor replacement, minimizes wear and failure, and lowers maintenance costs by allowing individual component replacement, while maintaining high measurement accuracy.
Implementation Method 1
a force or torque acting on the deformation body leads to a deformation of the length element
Implementation Method 2
a deformation of the length element leads to a movement of the measuring element
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device (10) for measuring a force (F) and/or a torque (M) with a deformation body (10) comprising a first fastening element (11), a second fastening element (12) arranged at a distance in a direction (Z) from the first fastening element (11), and at least one length element (15) arranged between the two fastening elements (11, 12) having a first end (15a), a second end (15b), and a length (L) along a longitudinal direction (R), wherein a force (F) or a torque (M) acting on the deformation body (10) leads to a deformation of the length element (15), wherein a drive-side input (21) of a mechanical amplifier (20) is attached to the deformation body (10) by means of a coupling element (30).wherein a measuring element (25) is arranged at an output-side output (22) of the mechanical amplifier (20) and a deformation of the length element (15) leads to a movement of the measuring element (25), wherein the movement of the measuring element (25) can be detected by a scanning element (40), wherein the device (1) comprises an evaluation unit (70) which is configured to evaluate the signals detected by the at least one scanning element (40) and to calculate from them the forces (F) and/or torques (M) acting between the two fastening elements (11, 12).