Optical Sensor with Flexible Cover and Refractive Fillers
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Solution Overview
Problem
Current sensor devices for robotics have limitations in detecting pressure and force over a broad range due to their rigid structure, limited surface area, and restricted measuring capabilities, which hinders their ability to accurately determine the magnitude and direction of forces in various environments.
Innovation Solution
A sensor device with a dome-shaped cover layer and light reflecting layer, utilizing filler elements with different refractivities to expand the sensitive surface area and improve light refraction, allowing for a broader detection range and enhanced sensitivity to lateral pressures, while minimizing external light interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid surface sensor device is used, then the structure is stable, but the contact surface is point-like and provides limited information about the object
Solution Approach 1:
The patent applies a flexible cover layer made of elastomeric material over the rigid sensor array. This flexible shell allows the sensor surface to conform to the curved surfaces of gripped objects, transforming the point-like contact into a distributed surface contact that provides comprehensive tactile information while maintaining structural stability through the rigid support structure underneath.
2Reliability
If a flexible cover layer is added to increase surface contact, then the grip stability improves, but the device complexity increases
Solution Approach 1:
The patent implements a relatively thin flexible cover layer that provides the necessary conformability without excessive thickness. This thin film approach achieves grip stability through surface conformity while minimizing the addition of structural complexity and maintaining ease of integration with the underlying rigid sensor array.
3Measurement precision
If optical elements are used to detect force direction, then the measurement precision improves, but the device becomes more complex and susceptible to external light interference
Solution Approach 1:
The patent replaces complex mechanical force direction sensors with an optical detection system using light-emitting elements and light-sensitive elements. This substitution achieves precise force direction measurement through optical path changes caused by filler element deformation, while the incompressible filler material provides mechanical stability and reduces susceptibility to external light interference.
Solution Approach 2:
The patent utilizes changes in optical parameters (light path, refraction) in response to mechanical deformation of the filler elements. By monitoring how light travels through and is refracted by the incompressible filler material, the system precisely detects force direction and magnitude without requiring complex mechanical sensing mechanisms.
4Loss of information
If the sensor surface is made elastic to fit object surfaces, then information about surface characteristics can be collected, but the useful surface area is limited by light emission and detection angles
Solution Approach 1:
The patent replaces angle-constrained optical detection with a system that detects light path changes through incompressible filler elements. This substitution allows the elastic cover layer to fully conform to object surfaces and utilize its entire surface area for sensing, as the detection mechanism responds to local filler element deformation rather than being limited by light emission or detection angles.
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 device achieves a larger detection area and improved accuracy in measuring force and pressure across a wide range, with reduced signal processing complexity and increased mechanical stability, enabling more precise robotic interactions.
Implementation Method 1
at least one light emitting element (20) arranged on the carrier element (24), at least one light detecting element (22) arranged on the carrier element (24)
Implementation Method 2
a light reflecting layer (14) arranged below the flexible cover layer (12)
Implementation Method 3
filler elements with different refractivities to expand the sensitive surface area and improve light refraction
Data Source
AI summary
The invention is a sensor device comprising a carrier element (24), at least one light emitting element (20) arranged on the carrier element (24), at least one light detecting element (22) arranged on the carrier element (24), a cover layer (12) reflecting at least one part of the light emitted by the light emitting element (20) to the at least one light detecting element (22), and at least one transparent filler element (16, 18) filling at least partly the space between the carrier element (24) and the cover layer (12) and being made of a flexible material.