Heat Flux Sensor for Support State Detection
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Solution Overview
Problem
Existing support devices face challenges in monitoring the support state of target objects, particularly due to issues with load cells such as damage from high loads, increased size, and high costs, which can lead to processing failures and defective products.
Innovation Solution
A monitoring device using a heat flux sensor and an elastic member to detect the support state of a target object by measuring heat flux between the elastic member and the outside, allowing for determination of correct positioning and size without increasing the size of the support device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a load cell is used to monitor the support state, then the support state can be detected, but the device size increases and the cost increases
Solution Approach 1:
The patent replaces the mechanical load cell with a heat flux sensor that detects support state through thermal fields rather than mechanical deformation. The heat flux sensor measures heat flow through the elastic member, which changes based on the support state, thereby detecting position and contact status without mechanical contact or large structural components.
Solution Approach 2:
The patent changes the detection parameter from mechanical strain (load cell) to thermal flux (heat flux sensor). By monitoring changes in heat flow through the elastic member based on support state, the system achieves detection functionality with a compact sensor that has negligible impact on device size.
2Measurement precision
If a load cell is used to monitor the support state, then the support state can be detected, but the device cost increases
Solution Approach 1:
The patent replaces the expensive mechanical load cell with a more cost-effective heat flux sensor. The thermal detection method uses inexpensive thermal fields and simple sensor construction, significantly reducing manufacturing costs while maintaining detection capability for support state monitoring.
Solution Approach 2:
The heat flux sensor is a simple, inexpensive component compared to load cells. The patent utilizes this cost-effective sensing element to achieve the same monitoring function at a fraction of the cost, making the overall device more economically viable.
3Measurement precision
If a load cell is used to monitor the support state, then the support state can be detected, but the load cell may be damaged by large loads
Solution Approach 1:
The patent replaces the mechanical load cell with a heat flux sensor that operates in the thermal domain. This substitution eliminates the mechanical strain gauge that is vulnerable to damage from large loads, as the heat flux sensor detects support state through thermal conduction changes without experiencing mechanical stress.
Solution Approach 2:
The patent introduces thermal fields as an intermediary between the support structure and the sensor. The heat flux sensor monitors thermal conduction through the elastic member, which acts as a mediator transferring support state information thermally rather than mechanically, protecting the sensor from direct mechanical damage.
4Volume of stationary object
If the support device structure is simplified, then the device size is reduced, but the monitoring capability is lost
Solution Approach 1:
The heat flux sensor serves multiple functions: it detects support contact status, determines object position, and monitors support state simultaneously. This multi-functional capability allows the compact sensor to replace what would otherwise require multiple separate monitoring components, maintaining detection precision while minimizing device size.
Solution Approach 2:
The patent utilizes the elastic member's thermal properties as a sensing mechanism. By monitoring heat flux changes through the elastic member based on support state, the system achieves detection functionality without adding mechanical sensing components, thereby maintaining compact device structure while preserving monitoring capability.
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 effectively determines the support state and size of the target object, preventing processing failures by using a heat flux sensor that is rigid and thin, reducing the risk of damage and maintaining a compact device design.
Implementation Method 1
the elastic member is elastically deformed by a load applied from the support member. The heat flux sensor outputs a signal corresponding to the heat flux flowing between the elastic member and the outside
Data Source
AI summary
A support device comprises a piston rod and a fixed member arranged so that a target object is placed therebetween, and an elastic member is provided to the target object side of the fixed member. A monitoring device includes a heat flux sensor and a detection part. When the target object is supported between the piston rod and the fixed member due to force applied by the piston rod, the heat flux sensor outputs a signal corresponding to the heat flux flowing between the elastic member, which is compressed by the load applied from the piston rod, and the fixed member. Based on the signal output by the heat flux sensor, the detection part detects the support state of the target object supported by the support device, or the size of the target object.