Six-Axis Force Sensor Elastic Body with 0.18 mm Groove Control
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Solution Overview
Problem
Existing six-axis force sensors suffer from irreversible damage due to overload protection mechanisms that activate when deformation exceeds 0.18 mm, leading to excessive wear and tear.
Innovation Solution
An anti-overload sensor elastic body with integral structure, featuring rigid boundary blocks, rings, deformation beams, and auxiliary beams with controlled groove widths, along with an overload protection plate and flexible sealing structures, to prevent damage by limiting deformation to within 0.18 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire cut groove is added at the end of the force beam to limit deformation, then overload protection is achieved, but the sensor deformation range is restricted to exceed 0.18mm causing irreversible damage
Solution Approach 1:
The elastic body is divided into multiple functional regions: main deformation beams for normal measurement, anti-overload auxiliary beams with wire cut grooves for overload protection, rigid boundary blocks, and rigid boundary rings. This segmentation allows different parts to perform different functions - normal deformation measurement and overload limitation - simultaneously without interfering with each other
Solution Approach 2:
The anti-overload auxiliary beams act as intermediary elements between the main deformation beams and the rigid boundary structure. These auxiliary beams with wire cut grooves engage first during overload conditions, limiting the deformation of the main beams before they reach dangerous levels, thus protecting the primary measurement structure
2Object-affected harmful factors
If the wire cut groove width is set to not less than 0.18 mm for protection, then the sensor is protected from complete damage, but the sensor has already exceeded the normal use range of 0.10 mm causing overload
Solution Approach 1:
The wire cut grooves are pre-formed in the anti-overload auxiliary beams at specific positions and with specific dimensions (width ≤ 0.18mm) during manufacturing. These pre-formed features create predetermined failure points that will engage at controlled deformation levels, preventing the sensor from reaching catastrophic failure states
Solution Approach 2:
The wire cut groove width parameter is precisely controlled to be less than or equal to 0.18mm, which is a critical threshold value. This parameter change creates a distinct mechanical behavior where the groove engages at a specific deformation level, providing a clear transition from normal operation to protected state without allowing excessive deformation
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
Effectively prevents sensor overload in directions other than the set axis, ensuring safety and accuracy by avoiding destructive damage, while enabling overload protection in the set axis direction.
Implementation Method 1
the main deformation beams (3) and the anti-overload auxiliary beams (4) are uniformly distributed in the annular space around a set axis (5) and connect the rigid boundary ring (2) and the rigid boundary block (1)... when the deformation of the main deformation beams (3) in the direction of the set axis (5) reaches a set value
Data Source
AI summary
The invention relates to the field of sensor technology, and in particular to an anti-overload sensor elastic body in form of an integral structure, in which the anti-overload auxiliary beam is provided with a wire cut groove running through along the length direction of the set axis, the cross section of the wire cut groove in the direction perpendicular to the set axis comprises two parallel boundary lines having a distance less than or equal to 0.18 mm therebetween; and in which the boundary line is one of a curve, a combined line of at least two straight lines, and a combined line of straight line and curve, and is in an axisymmetric or centrosymmetric pattern. In the invention, by providing three anti-overload auxiliary beams and wire cut grooves provided on them, the overload of the sensor in directions other than the set axis is effectively prevented, avoiding destructive damage and increasing the safety of the sensor. When the deformation of the main deformation beams in the direction of the set axis reaches the set value, the six-axis force sensor adopting such elastic body can also realize overload protection in the direction of the set axis, further increasing the safety.