Tool Holder with Dual Piezoresistive Force Sensing
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Solution Overview
Problem
Existing tool holders in metalworking processes, including incremental sheet forming, lack a simple and universal method to measure working forces effectively, leading to potential loads or overconstraints on tools and workpieces, which hinders process control and optimization.
Innovation Solution
A tool holder equipped with a first sensing device for detecting axial forces and a second sensing device for measuring lateral forces, utilizing piezoresistive layers made of amorphous diamond-like carbon films, such as DiaForce® sensors, to enable precise force measurement in stiff environments with minimal displacement, allowing for self-steering adaptronic systems and universal application across various metalworking processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a tool holder is equipped with multiple sensing devices for measuring forces, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensing functions (axial force measurement and lateral force measurement) into a single integrated tool holder structure. The first sensing device and second sensing device are merged into one coherent system with a unified mounting structure, allowing simultaneous measurement of multiple force components without requiring separate independent measurement systems.
Solution Approach 2:
The tool holder is designed as a universal measurement platform that can simultaneously perform multiple functions: measuring axial forces through the first sensing device, measuring lateral forces through the second sensing device, and providing a standardized mounting interface for tools. This multi-functional design eliminates the need for separate specialized holders for different measurement needs.
2Measurement precision
If piezoresistive layers are used for force detection, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces an intermediary mounting structure that provides a standardized interface between the piezoresistive sensing layers and the tool holder body. This intermediary structure includes predefined mounting surfaces and attachment mechanisms that facilitate precise positioning of the sensing devices without requiring extremely tight tolerances in the overall manufacturing process. The intermediary layer absorbs and compensates for minor manufacturing variations.
3Adaptability or versatility
If the tool holder is designed for universal application in various metalworking processes, then adaptability is improved, but device complexity increases
Solution Approach 1:
The tool holder incorporates a standardized mounting interface and modular sensing device arrangement that enables its use across different metalworking processes including incremental sheet forming, milling, and other machining operations. The universal design features allow the same tool holder structure to accommodate various tool types while maintaining consistent measurement capabilities, eliminating the need for process-specific specialized holders.
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
Enables accurate measurement of both axial and lateral forces, allowing for improved control and optimization of metalworking processes by maintaining tool tip position precision and handling high loads, suitable for incremental sheet forming, robotics, and other metalworking processes.
Implementation Method 1
a first sensing device for detecting an axial force... utilizing piezoresistive layers made of amorphous diamond-like carbon films
Implementation Method 2
utilizing piezoresistive layers made of amorphous diamond-like carbon films, such as DiaForce® sensors
Data Source
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AI summary
The invention relates to a tool holder (10) comprising a first sensing device (18) for detecting an axial working force. For providing a tool holder (10) that can be universally used with different metal working machines for a more precise controlling of a metal working process in response to the actual working forces, the invention proposes to equip the tool holder (10) with a second sensing device (20) for detecting a lateral force. Preferably, such tool holder (10) is used in an Incremental Sheet Forming process.