Sensor-Integrated Actuator Bracket for Coupling Loosening Detection
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Solution Overview
Problem
Existing actuator bracket systems experience loose coupling over time due to repeated movement and vibration, leading to imprecise control and potential structural damage, as they fail to accurately monitor the securement of the coupling between the actuator, bracket, and controller.
Innovation Solution
Incorporating sensors, such as force gauges, strain gauges, or accelerometers, into the actuator bracket to measure characteristics like stress, strain, or acceleration, which detect loosening or decoupling by comparing measurements from multiple sensors positioned at different points along the bracket and actuator, ensuring precise coupling and reducing risk of sensor damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are incorporated into the actuator bracket to monitor coupling security, then the reliability of coupling detection is improved, but the device complexity increases
Solution Approach 1:
The sensor is integrated directly into the actuator bracket structure, merging the sensing function with the mechanical coupling component. This eliminates the need for separate sensing devices and reduces overall system complexity while maintaining reliable coupling detection through direct measurement of bracket characteristics.
Solution Approach 2:
The actuator bracket serves dual functions: its mechanical role in coupling the actuator to the controller and its sensing role in detecting coupling security. The bracket's structural characteristics (stress, strain, acceleration) are utilized as the sensing mechanism, making the component multi-functional and reducing the need for additional dedicated sensing elements.
2Measurement precision
If multiple sensors are positioned at different points along the bracket to detect loosening, then the measurement precision of coupling degradation is improved, but the device complexity increases
Solution Approach 1:
The bracket is divided into multiple sensing zones with sensors positioned at different locations (e.g., near the actuator interface, near the controller interface, and at intermediate points). Each sensor monitors specific local characteristics, and the combined data provides comprehensive precision in detecting coupling degradation patterns and locating loosening events.
Solution Approach 2:
Different sensors are positioned to detect local characteristics at specific critical points along the bracket. Each sensing location is optimized to detect particular types of degradation or stress concentrations, providing targeted high-precision measurement where it is most needed for coupling security assessment.
3Reliability
If sensors are coupled to the bracket at the first end to measure characteristics of the actuator coupling, then the reliability of actuator coupling monitoring is improved, but the risk of sensor damage from vibration and movement increases
Solution Approach 1:
The sensor is integrated into the bracket structure in a manner that provides mechanical protection against vibration and movement-induced damage. The bracket's own structure serves as a cushioning and protective element, absorbing and distributing mechanical stresses before they reach the sensor, thereby maintaining sensor reliability in harsh operational environments.
Solution Approach 2:
The sensor is merged with the robust bracket structure, utilizing the bracket's inherent mechanical strength and damping properties to protect the sensor. The integration allows the sensor to benefit from the bracket's structural integrity and vibration absorption characteristics, reducing the risk of damage while maintaining monitoring reliability.
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 enables real-time monitoring and detection of coupling degradation or failure, preventing imprecise control and structural damage by ensuring the actuator bracket and controller remain securely coupled, thereby maintaining precise operation and extending the lifespan of components.
Implementation Method 1
the first sensor is to measure a characteristic of the first end when the bracket is coupled to the actuator... sensors, such as force gauges, strain gauges, or accelerometers, to measure characteristics like stress, strain, or acceleration
Implementation Method 2
sensors, such as force gauges, strain gauges, or accelerometers, to measure characteristics like stress, strain, or acceleration
Data Source
AI summary
Actuator bracket having a sensor is disclosed. An example apparatus includes a bracket to couple a controller to an actuator. The bracket has a first end, a second end opposite the first end, and a first side extending from the first end to the second end. The first end is to couple to an actuator and the second end is to couple to a controller. The apparatus also includes a first sensor coupled to the first side at the first end of the bracket. The first sensor is to measure a characteristic of the first end when the bracket is coupled to the actuator.