Multi-Range Sensor Assembly for Construction Machinery Force Detection
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Solution Overview
Problem
Existing sensors used to detect supporting reaction forces in construction equipment, such as cranes, struggle with measurement accuracy under low loads due to their wide-ranging nature.
Innovation Solution
A sensor assembly comprising a connecting part and a bearing part with at least two sensing units of different measuring ranges, arranged to have distinct initial gaps from the connecting part, allowing for accurate detection of forces across varying load extents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If wide-range sensors are used to detect supporting reaction forces, then the sensor can handle high loads, but measurement accuracy deteriorates under low loads
Solution Approach 1:
The sensor assembly is divided into multiple sensing units (first sensing unit and second sensing unit) with different measuring ranges. The first sensing unit has a larger measuring range for high loads, while the second sensing unit has a smaller measuring range for high accuracy under low loads. This segmentation allows the system to select the appropriate sensing unit based on the load magnitude, resolving the contradiction between handling high forces and maintaining measurement precision under low forces.
Solution Approach 2:
The patent implements dynamic switching between different sensing units based on the applied load. When the load exceeds a predetermined threshold, the first sensing unit is activated; when the load is below the threshold, the second sensing unit is activated. This dynamic adaptation allows the sensor assembly to optimize measurement accuracy across different operating conditions, transforming the static sensor limitation into a dynamic solution.
2Measurement precision
If multiple sensing units with different measuring ranges are used, then measurement accuracy across varying loads is improved, but device complexity increases
Solution Approach 1:
Multiple sensing units are merged into a single integrated sensor assembly that handles both high and low load measurements. The first and second sensing units are combined in one assembly with shared structural components, allowing the system to achieve multi-range measurement capability without proportionally increasing overall device complexity. The merging approach consolidates what would otherwise be separate sensor systems into a unified structure.
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 sensor assembly ensures accurate detection of supporting reaction forces by utilizing sensing units with different measuring ranges, providing high measurement precision in respective working conditions, thus enhancing the safety and stability of construction equipment.
Implementation Method 1
the first sensing unit has a columnar sensing structure and comprises a columnar body and a plurality of first strain gauges that are arranged around the circumference of the columnar body; the second sensing unit has a spoke-type sensing structure and comprises an outer rim, a hub, and spokes arranged between the outer rim and the hub, wherein the hub has a top surface protruding from the spokes and a blind hole that is arranged axially and open toward the connecting part, the spokes are provided with second strain gauges on a side
Data Source
AI summary
A sensor assembly, a force detection device and method, and construction machinery, the sensor assembly comprising a connecting part used for connecting a base to be tested and a bearing part used for bearing, the bearing part being connected to the connecting part, the bearing part comprising at least two sensing units with different measuring ranges, and the at least two sensing units being arranged to have a different initial gap (b1, b2) from the connecting part, so that corresponding initial gap (b1, b2) are eliminated when a load applied to the bearing part reaches different extents. The different initial gaps (b1, b2) are eliminated by means of the load reaching a different extent, so that the sensing units with different measuring ranges can provide detection feedback in the respective working conditions in which the units have the highest measurement precision and thereby ensure the accuracy of detection results.