Segmented Force Sensor Interfaces for Parasitic-Force Mitigation
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Solution Overview
Problem
Current force sensors face challenges in accurately measuring forces due to the impact of parasitic forces, particularly in smaller designs, which are exacerbated by integration forces and coefficient of thermal expansion mismatches, leading to sensor inaccuracies.
Innovation Solution
The implementation of three or more defined contact features on the sensing element, such as segmented press-fit structures and defined integration contact areas, minimizes the impact of parasitic forces by aligning these features optimally with sensing gauges to reduce integration errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensing element is designed with traditional integration methods, then the sensor can be integrated into the system, but parasitic forces and integration errors significantly degrade measurement accuracy
Solution Approach 1:
The sensing element is divided into multiple discrete contact features (three or more) instead of a continuous integration surface. This segmentation allows each contact feature to be optimally positioned to minimize parasitic forces while maintaining structural integrity and integration capability.
Solution Approach 2:
Different regions of the sensing element are given different functions: the three or more contact features are specifically designed and positioned to minimize parasitic forces, while other regions maintain standard integration properties. This local optimization resolves the contradiction between integration requirements and measurement accuracy.
2Measurement precision
If the sensing element uses three or more defined contact features, then parasitic forces are minimized and accuracy improves, but the device complexity increases
Solution Approach 1:
The multiple contact features are integrated into a single sensing element component rather than being separate parts. This merging maintains the complexity-reducing benefits of integration while achieving the accuracy improvements of multiple contact points through the defined contact features.
3Reliability
If integration contact areas are defined on the sensing element, then integration forces are decoupled from measured forces, but manufacturing precision requirements increase
Solution Approach 1:
The contact features are pre-defined during sensing element manufacturing with optimal positions and geometries that inherently minimize parasitic forces. This preliminary design eliminates the need for post-manufacturing adjustments and reduces the actual precision requirements during assembly and integration.
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 approach enhances sensor accuracy by decoupling integration forces, reducing errors, and maintaining consistent sensor output across different integration scenarios without additional components, thus improving the reliability of force measurements.
Implementation Method 1
the strain on the sensing element may be measured and used to generate an electrical signal that is indicative of the forces acting on the component of the braking system
Data Source
AI summary
In a particular embodiment, a sensing element that deforms in response to applications of forces to the force sensor apparatus, the sensing element including three or more defined contact features configured to interface with a counterpart; and one or more sensing gauges coupled to a top surface of the sensing element and configured to generate a signal indicating the degree that the sensing element deforms in response to the application of forces to the force sensor apparatus; wherein the sensing element includes three or more defined contact features that interface with a counterpart.