Solid-State Robot Bumper for Multi-Angle Impact Sensing
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Solution Overview
Problem
Existing robot bumper systems are limited in detecting impact location, force, and direction due to mechanical complexity, weight, cost, and aesthetic issues, with current designs requiring multiple moving parts and failing to accurately sense impacts from various angles.
Innovation Solution
A robot bumper assembly featuring membrane switch arrays on the periphery and top edges, with a force transmission layer and absorption layer, allowing for precise detection of impacts and force measurement without mechanical seams or pinch points, and enabling detection from multiple angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid bumper with springs and pivots is used, then impact energy is absorbed, but mechanical complexity and number of moving parts increases
Solution Approach 1:
The patent replaces the mechanical spring-pivot system with a solid-state force transmission layer that directly transmits impact forces to membrane switches. This eliminates moving parts while maintaining impact detection capability, resolving the contradiction between strength and device complexity.
Solution Approach 2:
The patent uses a flexible force transmission layer that can deform under impact and transmit forces to the sensor array. This thin film structure provides impact absorption and transmission without requiring complex mechanical mounting, addressing both strength and complexity concerns.
2Device complexity
If carbon puck type contacts are used, then mechanical mounting complexity is reduced, but weight and manufacturing cost increase
Solution Approach 1:
The patent employs a thin flexible force transmission layer instead of heavy carbon puck structures. This maintains mechanical simplicity while dramatically reducing weight, as the membrane and force transmission layer are lightweight polymer-based materials.
Solution Approach 2:
The patent changes the material parameters from heavy carbon pucks to lightweight flexible polymers and membranes. This parameter change maintains the functional simplicity while reducing weight, resolving the contradiction between device complexity and weight.
3Measurement precision
If spaced bumper assembly is used, then impact detection is enabled, but dust and debris accumulation occurs
Solution Approach 1:
The patent merges the bumper body and sensor array into a single integrated structure with no gaps. The force transmission layer covers the entire sensor array, eliminating spaces where dust and debris could accumulate, while maintaining full impact detection capability across the bumper surface.
Solution Approach 2:
The flexible force transmission layer acts as a continuous protective film that seals the sensor array, preventing dust and debris ingress while allowing force transmission. This resolves the contradiction between detection capability and susceptibility to harmful factors.
4Ease of manufacture
If limited number of switches are used, then manufacturing cost is reduced, but impact location detection precision decreases
Solution Approach 1:
The patent segments the bumper surface into multiple sensor zones using a matrix array of membrane switches. This segmentation allows precise localization of impact points while using cost-effective membrane switch technology, resolving the contradiction between manufacturing ease and measurement precision.
Solution Approach 2:
The patent transitions from a limited number of discrete switches to a two-dimensional matrix array of sensors. This dimensional expansion provides comprehensive impact location detection across the bumper surface while maintaining manufacturing feasibility through standardized sensor elements.
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 provides robust, aesthetically pleasing, and efficient impact detection with a virtually unlimited number of zones, accurately localizing impact points and approximating impact force, while eliminating mechanical complexity and reducing dust accumulation.
Implementation Method 1
a force transmission layer and absorption layer, allowing for precise detection of impacts and force measurement
Implementation Method 2
a force transmission layer and absorption layer, allowing for precise detection of impacts and force measurement
Data Source
AI summary
A robot bumper including a bumper body having a forward surface and a top surface angling away from the forward surface. The bumper body conforms to a shape of a received robot chassis. The robot bumper also includes a force absorbing layer disposed on the bumper body, a membrane switch layer comprising a plurality of electrical contacts arranged along the top surface of the bumper body, and a force transmission layer disposed between the force absorbing layer and the membrane switch layer. The force transmission layer includes a plurality of force transmitting elements configured to transmit force to the membrane switch layer.