Probe Sensor Segmentation for Reproducible Force Detection
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Solution Overview
Problem
Existing probe systems used in material-processing machines for determining workpiece positions lack precise and reproducible probing behavior due to the non-uniform distribution of pressure forces across sensors, leading to inconsistent signal generation and wear on sensitive components.
Innovation Solution
A probe system with pressure-sensitive sensors and mechanical transmission elements, where the transmission elements are designed to direct compressive forces orthogonally to the sensor surfaces, ensuring maximum signal sensitivity and reproducibility, and a mounting element that maintains precise positioning and flexibility to prevent deformation and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the probe element is connected to the housing via a small plate that is resilient in the axial direction, then the positioning of the test element relative to the housing and sensors is ensured, but the exact position of the application of force into the sensors cannot be guaranteed in a reproducible manner after repeated deflection
Solution Approach 1:
The probe element is segmented into multiple arms (at least two arms) that are offset from each other, with each arm having its own transmission element and sensor arrangement. This segmentation allows independent force transmission paths, ensuring that the position of force application remains consistent and reproducible even after repeated deflections, as each arm-sensor pair operates independently without相互 interference.
2Measurement precision
If pressure-sensitive sensors are used, then extremely small deflection movements lead to probe switching, but the non-uniform distribution of pressure forces across sensors leads to inconsistent signal generation
Solution Approach 1:
Each sensor is equipped with its own dedicated transmission element (such as a ball or roller) that makes contact with a specific arm of the probe element. This local quality ensures that pressure forces are uniformly distributed to individual sensors through their respective transmission elements, maintaining consistent signal generation while preserving the high sensitivity of pressure-sensitive sensors to even minimal deflection movements.
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 probe achieves extremely precise and reproducible probing behavior with minimal deflection movements, reducing wear on sensitive components and ensuring consistent signal generation even after repeated use.
Implementation Method 1
sensors (5), each with a pressure-sensitive surface (5.1), which generate electrical signals when subjected to pressure forces having a directional component orthogonal to the pressure-sensitive surface (5.1)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The probe has sensors (5), with pressure sensitive surfaces, producing electrical signals during impact of pressure force. A retaining unit (3) is separate and/or discrete construction and formed point symmetric. A pressure key unit is movably supported relative to the sensors. The key unit, sensors and a transfer unit (4) stays in effective mechanical connection so that level change of the signals is produced through contact of key unit.