Piezoelectric Sensor Array for Powder Press Force Measurement
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Solution Overview
Problem
Conventional powder press force measurement methods are limited by the inability to accurately detect nonuniform force applications, inaccuracy in small force measurements, and space constraints, leading to measurement errors and potential mechanical component damage.
Innovation Solution
The integration of piezoelectric sensors along the force paths of linear drives in the powder press allows for precise and space-efficient force measurement, enabling detection of nonuniform force applications and tilting, with multiple sensors providing consistent accuracy across a wide range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauge force sensors are used to measure pressing forces directly, then measurement precision is improved, but device complexity and installation space requirements increase
Solution Approach 1:
The force measurement system is segmented into multiple measurement points along the force path. Instead of using a single complex sensor, the patent employs multiple simpler sensors (including piezoelectric sensors and strain gauges) positioned at different locations (press axis, transverse axes) to collectively capture the complete force state, thereby improving measurement precision while managing device complexity through modular segmentation
Solution Approach 2:
The patent introduces intermediary measurement elements such as piezoelectric sensors that convert mechanical force directly into electrical signals, and strain gauge sensors that measure deformation as an intermediate physical quantity before calculating force. These intermediaries enable precise force measurement without requiring direct complex sensor installations at all critical points
2Area of stationary object
If a single force sensor is installed to save space, then installation space is reduced, but the ability to detect nonuniform force application is lost
Solution Approach 1:
The measurement system is divided into multiple segmented sensors positioned at different locations along the force path (press axis, transverse axes). This segmentation allows detection of nonuniform force distribution and tilting while keeping individual sensor sizes small, thus resolving the contradiction between space efficiency and comprehensive measurement capability
Solution Approach 2:
The patent extends measurement from a single axial dimension to multiple dimensions by positioning sensors along the press axis and transverse axes. This multi-dimensional arrangement enables detection of nonuniform force application and tilting without requiring a single large sensor, achieving both space efficiency and comprehensive measurement
3Device complexity
If a single pressure sensor is used in the press axis, then device complexity is reduced, but the ability to determine nonuniform force application is lost
Solution Approach 1:
The measurement system is segmented into multiple simple pressure/force sensors positioned at different locations (press axis, transverse axes) rather than using a single complex sensor. This segmentation maintains relatively simple individual sensor designs while collectively achieving comprehensive force measurement and nonuniformity detection
Solution Approach 2:
Multiple simple sensor measurements are merged and processed together to determine the complete force state, including magnitude, distribution, and uniformity. The control unit combines data from sensors at different locations to achieve comprehensive measurement capability that exceeds the sum of individual sensor capabilities
4Measurement precision
If widely varying force values are measured with the same accuracy, then measurement precision across different force ranges is improved, but device complexity increases due to multiple sensors
Solution Approach 1:
The patent employs piezoelectric sensors that maintain consistent measurement precision across a wide range of force values, from small ejection forces to large pressing forces. The piezoelectric effect provides a linear response over a broad parameter range, eliminating the need for multiple sensors with different measurement ranges and reducing overall device complexity
Solution Approach 2:
The piezoelectric sensors serve multiple functions: measuring both small forces (ejection forces) and large forces (main pressing forces) with uniform accuracy. This universal measurement capability across different force magnitudes reduces the need for multiple specialized sensors, thereby improving precision across the force range while managing device complexity
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 solution enables precise measurement of both main pressing and ejection forces with uniform accuracy, allowing for controlled nonuniform force applications and protection of mechanical components, while minimizing space requirements.
Implementation Method 1
a piezoelectric sensor is connected along the force path of at least one linear drive to the upper press tool and/or to the lower press tool and/or to a transverse press tool
Data Source
AI summary
A powder press has a die plate that supports at least one die, at least one upper press tool at an upper tool carrier, at least one lower press tool at a lower tool carrier, at least one upper linear drive acting on the upper tool carrier, at least one lower linear drive acting on the lower tool carrier or on the die plate, possibly a further linear drive acting on a transverse tool carrier, and a force measuring apparatus. The force measuring apparatus measures forces acting on the upper, lower and/or transverse tool carrier. Each linear drive may be at least two linear drives engaging eccentrically at the upper or lower tool carrier, respectively. The parallel spaced linear drives act together on a force transferring element, and the force transferring element acts on a tool carrier via spaced piezoelectric sensors.