Optical Multi-Axial Force Sensor with Integrated Cavity
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Solution Overview
Problem
Existing integrated sensors for multi-axial force measurement are costly and complex to produce, with optical sensors requiring large deformations and interferometer-based sensors being sensitive to interference during assembly.
Innovation Solution
A component with an integrated sensor device for optical, multi-axial measurement of force or torque, featuring a cavity with first and second support elements having optical elements, and a transmission device generating independent beams for precise position change measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges or piezoelectric transducers are used for multi-axial force measurement, then measurement capability is achieved, but production complexity and costs increase significantly
Solution Approach 1:
The patent replaces mechanical/electrical sensor systems (strain gauges, piezoelectric transducers) with an optical measurement system. Optical elements (mirrors, light sources, detectors) are used to detect force-induced deformations through optical path changes, eliminating the need for complex electrical sensing and signal processing chains while achieving multi-axial measurement capability.
Solution Approach 2:
The patent integrates the optical sensor system directly into the component structure being measured. The optical elements are positioned within the component itself, merging the measurement function with the structural element, thereby simplifying the overall system by eliminating separate sensor housings and reducing the number of integration steps.
2Device complexity
If optical sensors are used for multi-axial force measurement, then production costs decrease, but large deformations are required which may not be compatible with all components
Solution Approach 1:
The patent uses optical elements that can detect very small deformations through optical path length changes, even when the mechanical deformation of the component is minimal. The optical measurement system amplifies the detection capability beyond what the physical deformation provides, allowing measurement of sub-micrometer displacements without requiring large component deformations.
3Measurement precision
If interferometer-based optical sensors are used, then measurement precision is improved, but sensitivity to interference during assembly occurs
Solution Approach 1:
The patent incorporates the optical measurement system into the component during the manufacturing process, specifically during the forming operation. The optical elements are positioned and secured while the component is being formed, establishing the measurement baseline before the component enters service. This preliminary integration eliminates subsequent assembly steps that could introduce interference or misalignment.
Solution Approach 2:
The patent uses a light guide or optical fiber as an intermediary to transmit optical signals between the optical elements and the detection system. This intermediary protects the optical path from external interference during assembly and operation, allowing the interferometer to function reliably without being sensitive to assembly-induced vibrations or misalignments.
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 enables cost- and production-efficient multi-axial force measurement with high precision and stability, overcoming the limitations of existing technologies by using cold solid recasting or cold forming for secure optical element fixation.
Implementation Method 1
a transmission device (300) which is designed to be connected to an energy source and to transmit or generate at least two beams in mutually independent directions when connected to the energy source, the beams passing through the cavity between the first optical elements and the second optical elements, respectively
Implementation Method 2
The first optical elements (220) and the second optical elements (240) are configured to generate information about a relative position change of the first support element (210) with respect to the second support element (230) based on the at least two beams (331, 332)
Implementation Method 3
Advantageously, the fixing of the supporting elements is carried out via cold solid recasting or cold forming of the supporting elements and/or the component
Data Source
AI summary
A component has an integrated sensor device for an optical, multi-axis measurement of a force applied to the component. The component includes a cavity and a first support element having one or more first optical elements and a second support element having one or more second optical elements. The first support element and the second support element are formed in the cavity and partially inserted into the component. A transmission device generates at least two beams in independent directions when connected to a power source. The beams pass through the cavity between the first optical elements and the second optical elements. The first optical elements and the second optical elements are adapted to generate information about a relative positional change of the first support element with respect to the second support element based on the at least two beams. The transmission device provides the information for measuring the force application.