Load Sensor Wire Gap and Diameter Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing load sensors struggle to widen their dynamic range effectively by increasing the number of conductor wires, as the gap between wires must be carefully managed to allow for adequate deflection and capacitance change.
Innovation Solution
A load sensor configuration with two base members and electrically-conductive elastic bodies, where conductor wires are disposed such that their diameter and gap satisfy specific conditions (D≤0.3 mm, G≥0.6 mm, or D>0.3 mm, G≥2D) to maximize capacitance change with increasing wire count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of conductor wires is increased to widen the dynamic range, then the measurement precision is improved, but the device complexity increases due to tighter spacing requirements
Solution Approach 1:
The patent applies parameter changes by establishing specific quantitative relationships between wire diameter and gap spacing. The gap between adjacent conductor wires is set to satisfy: gap ≥ 0.6mm when wire diameter ≤ 0.3mm, and gap ≥ 2×wire diameter when wire diameter > 0.3mm. This parameter optimization allows increasing the number of wires while maintaining adequate spacing for deflection and capacitance change, thus widening the dynamic range without excessive device complexity
Solution Approach 2:
The patent applies local quality by allowing different wire diameters and corresponding gap spacings in different regions of the sensor array. This enables optimization of wire density in specific areas based on local measurement requirements, improving overall measurement precision while managing device complexity through localized parameter adjustment
2Reliability
If the gap between conductor wires is increased to allow adequate deflection, then the reliability is improved, but the area occupied by the sensor increases
Solution Approach 1:
The patent optimizes the gap parameter to balance deflection capability and sensor area. By setting the gap to satisfy gap ≥ 0.6mm (for ≤0.3mm wires) and gap ≥ 2×wire diameter (for >0.3mm wires), the design ensures adequate space for elastic body deflection and capacitance change while minimizing the overall sensor area. This parameter optimization allows the sensor to maintain reliability without excessive area occupation
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
This configuration allows for a significant widening of the dynamic range of the sensor, enabling more precise load detection by ensuring appropriate deflection of the elastic bodies and base members, thereby enhancing the sensor's ability to detect a broader range of loads.
Implementation Method 1
a load sensor configured to detect a load applied to a sensor part from outside, based on change in capacitance
Implementation Method 2
two electrically-conductive elastic bodies respectively disposed on opposing faces of the two base members
Data Source
AI summary
A load sensor includes: two base members disposed so as to face each other; two electrically-conductive elastic bodies respectively disposed on opposing faces of the two base members; and a plurality of conductor wires disposed between the two electrically-conductive elastic bodies. The plurality of conductor wires are disposed under a condition that, when a diameter of each conductor wire is not greater than 0.3 mm, a gap between the plurality of conductor wires is not less than 0.6 mm, and when the diameter of each conductor wire is greater than 0.3 mm, the gap between the plurality of conductor wires is not less than twice the diameter of each conductor wire.