Spherical Force Transfer Element for Compact Sensor Packaging
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Solution Overview
Problem
Current force sensors face challenges in achieving high performance with small packaging and economical calibration, as mechanically-coupled, amplified solutions are not practically and economically viable.
Innovation Solution
A force sensor system comprising a substrate, cover, sensor, processor, load bearing element, and spherical force transfer element, where the cover defines cavities for the sensor and processor, allowing for compact design and calibration, with the force transfer element transferring input forces to the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an amplified/compensated force sensor is provided, then performance is improved, but package size increases
Solution Approach 1:
The force transfer element is disposed partially within the sensor cavity, with portions extending into different cavities (sensor cavity and processor cavity) in a nested arrangement. This allows multiple functional elements to occupy overlapping spatial volumes, achieving compact packaging while maintaining the amplified/compensated sensor structure needed for high performance.
Solution Approach 2:
The force transfer element extends in multiple directions from the opening in the cover, with portions disposed within different cavities at different heights. This three-dimensional arrangement allows the force transfer path to navigate through vertical and horizontal space efficiently, reducing the overall package footprint while maintaining functional performance.
2Volume of stationary object
If an uncompensated/unamplified force sensor is provided, then package size is reduced, but performance deteriorates
Solution Approach 1:
The force transfer element acts as an intermediary mechanical component that couples the input force to the sensor. By providing a dedicated force transfer path through this element, the system achieves amplified/compensated performance without requiring a large package, as the intermediary element efficiently transmits and conditions the force signal within a compact volume.
3Measurement precision
If a mechanically-coupled, amplified force sensor is provided, then performance is improved, but calibration becomes impractical and expensive
Solution Approach 1:
The force transfer element is designed as a separate, removable component that can be extracted from the sensor assembly. This extraction capability allows the force transfer element to be independently calibrated or replaced, simplifying the calibration process and reducing costs by eliminating the need to calibrate the entire assembled sensor unit.
Solution Approach 2:
The sensor system is segmented into distinct functional components: the sensor mounted on the substrate, the processor in its cavity, and the force transfer element that can be separately handled. This segmentation allows calibration to be performed on individual components rather than the complete assembly, making the process more practical and economically viable.
Data Source
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AI summary
A force sensor system includes a substrate (102), a cover, a sensor (106), and a spherical force transfer element. The cover is coupled to the substrate, and has an inner surface, an outer surface, an opening extending between the inner and outer surfaces, and a wall structure extending from the inner surface that defines a sensor cavity between the inner surface and the substrate. The sensor (106) is mounted on the substrate (102), is disposed within the sensor cavity, and is configured to generate a sensor (106) signal representative of a force supplied to the sensor (106). The spherical force transfer element is disposed partially within the sensor cavity, is movable relative to the cover, extends from the opening in the cover, and engages the sensor (106). The spherical force transfer element is adapted to receive an input force and is configured, upon receipt of the input force, to transfer the input force to the sensor.