Modular Force Torque Sensing With Remote Electronics for Robot Arms
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Solution Overview
Problem
Dexterous robots require a robust, low-cost, and easily configurable force/torque sensor system that is not currently available due to existing sensors being complex, expensive, fragile, and heavy, with entire sensor replacement needed upon component failure.
Innovation Solution
A modular force/torque sensor system comprising a multi-axis load cell and a sensor interface, where the load cell is positioned on the robotic arm and sends analog signals to a remotely located sensor interface via a cable or wireless communication, allowing for customization, immunity to noise, and easy repair, using readily available components and low-cost manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a 6-axis force/torque sensor with sensors and associated electronics in a single package is used, then measurement precision is improved, but device complexity increases and reliability decreases
Solution Approach 1:
The patent divides the force/torque sensing system into separate modular components: load cells (sensing elements) and electronics (signal conditioning and processing). This segmentation allows independent optimization of each component, reducing overall system complexity while maintaining measurement precision through dedicated signal processing for each axis.
Solution Approach 2:
The patent extracts the electronic components from the sensing elements, placing electronics remotely from the load cells. This extraction reduces the complexity at the sensing location, allows for better thermal management, and enables independent replacement of sensing elements without replacing electronics, thereby resolving the complexity issue while preserving measurement capability.
2Measurement precision
If a 6-axis force/torque sensor with integrated electronics is used, then measurement precision is improved, but reliability decreases due to single-point failure
Solution Approach 1:
By segmenting the sensor system into separate load cell modules and electronic processing units, the patent eliminates single-point failure risks. Each load cell can be independently replaced if failed, and the electronic system can be maintained separately, significantly improving overall system reliability while maintaining precise measurement capabilities through the distributed architecture.
3Measurement precision
If a traditional integrated force/torque sensor is used, then measurement precision is improved, but cost increases
Solution Approach 1:
The patent segments the sensor system into standardizable modular components that can be manufactured independently using conventional processes. Load cells can be produced as separate precision elements while electronics are manufactured separately, allowing for economies of scale and reduced assembly costs compared to integrated high-precision sensors, thereby reducing overall cost while maintaining measurement precision.
4Measurement precision
If an integrated force/torque sensor is used, then measurement precision is improved, but weight increases
Solution Approach 1:
The patent extracts heavy electronic components from the sensing location and places them remotely. This extraction significantly reduces the weight at the critical sensing point on the robotic end effector, while the electronics can be positioned in locations optimized for thermal management and accessibility, thereby reducing overall sensor system weight while preserving full measurement precision capability.
5Ease of repair
If a modular sensor system with remote electronics is used, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The patent segments the sensor system into independently replaceable load cell modules and electronic processing units connected through standardized interfaces. This segmentation dramatically simplifies repair operations, as failed components can be quickly swapped without affecting other parts of the system. The modular design with clear separation of functions reduces operational complexity despite the distributed architecture, enabling easy maintenance while preserving measurement precision.
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 system provides high-resolution force and torque sampling, immunity to noise, and is robust and cost-effective, capable of withstanding nominal and overload events, with easy customization and repair, making it suitable for unstructured production environments.
Implementation Method 1
A modular force/torque sensor system includes a multi-axis load cell. The load cell may include three load cells arranged in an equilateral triangle, with force vectors spaced 120° apart and intersecting at an origin.
Data Source
AI summary
A modular force/torque sensor system is disclosed. In various embodiments, a sensor interface device includes a first communication interface configured to receive an analog output associated with a sensor located remotely from the sensor acquisition device; a processor configured to use the analog output associated with the sensor to generate a sequence of discrete values derived from the analog output associated with the sensor; and a second communication interface coupled to the processor and configured to send at least a subset of the sequence of discrete values derived from the analog output associated with the sensor to a control module.