High Capacity Scale With Electromagnetic Actuator
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Solution Overview
Problem
Conventional scales are unable to simultaneously weigh both heavy and light objects with high resolution, as they either fail to withstand the weight of heavy objects or lack the sensitivity to detect small changes in weight accurately.
Innovation Solution
A scale design incorporating a low capacity sensing mechanism, a lever assembly, and an electromagnetic actuator that neutralizes loads, allowing for a wide range of weights to be measured with minor division resolution, using a servo controller and power amplifier to generate drive signals and produce an electromagnetic field, enabling the scale to handle heavy loads while detecting slight changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional scale is designed to weigh heavy objects (100 lb), then it can withstand the weight, but it cannot detect small changes in weight with high resolution (1/32 oz)
Solution Approach 1:
The scale system is divided into two functional segments: a robust mechanical support structure capable of bearing heavy loads (100 lb capacity) and a sensitive low-capacity sensing mechanism (1/32 oz resolution). The lever assembly acts as an intermediary that transfers load from the support structure to the sensitive sensing mechanism, allowing each component to operate within its optimal capacity range.
Solution Approach 2:
The lever assembly serves as a mechanical intermediary between the heavy load support structure and the low-capacity sensing mechanism. By positioning the fulcrum strategically, the lever transforms the heavy load into a manageable force that the sensitive sensor can detect with high precision, enabling the system to simultaneously achieve high weight capacity and fine resolution.
2Measurement precision
If a conventional scale is designed for high resolution measurement, then it can detect small weight changes, but it cannot withstand heavy objects
Solution Approach 1:
The scale system is divided into two functional segments: a robust mechanical support structure capable of bearing heavy loads (100 lb capacity) and a sensitive low-capacity sensing mechanism (1/32 oz resolution). The lever assembly acts as an intermediary that transfers load from the support structure to the sensitive sensing mechanism, allowing each component to operate within its optimal capacity range.
Solution Approach 2:
The electromagnetic actuator functions as an active counterweight system that applies opposing force to balance the load on the lever. By using the electromagnetic actuator to counterbalance the weight, the sensitive sensing mechanism only needs to detect small deviations from equilibrium rather than directly measuring the full heavy load, thereby preserving both high resolution and heavy load capacity.
3Measurement precision
If different scales are used for different weight ranges, then each scale can be optimized for its specific range, but the system complexity and number of devices increase
Solution Approach 1:
The scale system achieves multi-functionality by combining a heavy-duty support structure with a sensitive sensing mechanism through a lever assembly. This single unified system can measure both heavy objects (100 lb) and light objects (1/32 oz resolution) without requiring multiple separate scales, thereby reducing system complexity while maintaining measurement precision across different weight ranges.
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 scale achieves a weight capacity-to-resolution ratio of four or more orders of magnitude, providing both high resolution (1/32 oz) and the ability to weigh up to 100 lbs, enhancing its adaptability and efficiency in various applications.
Implementation Method 1
an electromagnetic actuator operatively coupled to the low capacity sensing mechanism and the lever to neutralize the load on the lever based on the lever movement
Implementation Method 2
a low capacity sensing mechanism capable of detecting lever movement associated with a load on the lever
Data Source
AI summary
A scale can include a low capacity sensing mechanism operatively coupled to a load, wherein the low capacity sensing mechanism may detect movement of the load. A transfer mechanism can be operatively coupled to the low capacity sensing mechanism, wherein the low capacity sensing mechanism may enable the scale to weigh both relatively heavy loads and relatively light loads to a minor division resolution associated with the low capacity sensing mechanism.