Embedded Piezoelectric Tool Holder for Decoupled Force Sensing
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Solution Overview
Problem
Current tool holder sensing mechanisms face issues such as sensor peeling, complex assembly, low accuracy, high cost, and interference between axial detections due to the use of multiple strain-gauge-like sensors.
Innovation Solution
An intelligent tool holder with embedded piezoelectric sensing elements in a connecting portion, allowing for multi-axis decoupling and high-sensitivity sensing, simplifying assembly, and reducing costs by using symmetrically-configured piezoelectric elements for precise detection of global forced conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple strain-gauge-like sensors are adhered to the surface of the tool holder, then sensing coverage is improved, but assembly complexity increases and sensors are easily peeled off
Solution Approach 1:
The patent merges multiple sensing functions into a single integrated piezoelectric sensor element embedded within the tool holder body. This eliminates the need for multiple separate strain-gauge-like sensors and their complex adherence processes, while maintaining comprehensive sensing coverage through the embedded element's strategic positioning and multi-axis detection capability.
Solution Approach 2:
The patent replaces the mechanical adherence system (adhering multiple strain gauges to the surface) with an embedded integration system where piezoelectric elements are incorporated directly into the tool holder's structural body. This substitution eliminates peeling issues and assembly complexity while improving measurement precision through direct structural integration.
2Measurement precision
If multiple strain-gauge-like sensors are adhered to the surface of the tool holder, then sensing coverage is improved, but sensor reliability deteriorates due to peeling
Solution Approach 1:
The patent merges the sensor system with the tool holder structure by embedding piezoelectric elements within the body. This integration ensures that sensors move as a unified structure with the tool holder, eliminating relative motion and peeling that cause reliability issues with adhered sensors, while maintaining comprehensive sensing coverage.
Solution Approach 2:
The patent replaces the unreliable mechanical adherence system with a robust embedded integration system. The piezoelectric elements are incorporated into the tool holder's structural body, creating a permanent, peeling-resistant connection that significantly improves sensor reliability and stability under machining conditions.
3Measurement precision
If ten to twelve strain-gauge-like sensors are used, then detection accuracy is improved, but total cost increases
Solution Approach 1:
The patent merges multiple sensing functions into fewer integrated piezoelectric elements with multi-axis detection capabilities. A single embedded piezoelectric element can detect forces in multiple directions simultaneously, replacing the need for ten to twelve separate strain gauges and significantly reducing total sensor cost while maintaining high detection accuracy.
Solution Approach 2:
The patent implements universal piezoelectric sensing elements that perform multiple detection functions simultaneously. These elements can detect forces in x, y, and z directions, as well as torque and vibration, replacing multiple specialized sensors and reducing both quantity and total cost while preserving comprehensive detection accuracy.
4Ease of manufacture
If strain-gauge-like sensors are adhered to the surface, then assembly process becomes complicated, but manufacturing precision is maintained
Solution Approach 1:
The patent replaces the complex surface adherence assembly process with a simplified embedded integration process. Piezoelectric elements are incorporated directly into the tool holder body during manufacturing, eliminating the need for separate adherence operations and the associated positioning precision challenges, while maintaining or improving manufacturing precision through integrated production.
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 provides a stable, accurate, and cost-effective sensing mechanism with reduced interference and complexity, enhancing detection precision and reducing the number of sensors required.
Implementation Method 1
provided with a plurality of embedded holes respectively embedded with a sensing element therein to kinetically detect sensed data including stress and strain of the tool-holder main body
Data Source
AI summary
An intelligent tool holder includes a tool-holder main body and a sensing reading device. The tool-holder main body includes a connecting portion which is provided with a plurality of embedded holes respectively embedded with a sensing element therein to kinetically detect sensed data including stress and strain of the tool-holder main body which are correspondingly formed as being loaded from the processing tool. The sensing reading device includes a housing to outwardly cover the connecting portion of the tool-holder main body. A sensing reading module is provided to read the sensed data of the sensing element transmitted therefrom. An active sensing method having a particular rotational angle is provided, thereby increasing sensing properties, lowering the coupling effects and detecting a global forced condition in a processing procedure.