Tool Load Sensor Temperature Compensation for Stable Output
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Solution Overview
Problem
Electric tools equipped with load sensors, such as pressure-sensitive conductive elastomers, face issues with mechanical strength deterioration due to temperature variations, leading to unstable output and operability problems, particularly in low-temperature environments where the sensor's resistance value becomes insensitive to load changes.
Innovation Solution
A tool design incorporating a switch and a controller that includes a load sensor to detect pressing force and correct output, using a pressure-sensitive conductive elastic member and a substrate with conductive particles, and a temperature sensor to adjust for temperature variations, ensuring stable operation by referencing load-resistance value features at different temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure-sensitive conductive elastomer is used as a load sensor, then the sensor shows conductivity when deformed under load, but the mechanical strength deteriorates and hardness changes with temperature variations
Solution Approach 1:
The patent applies parameter changes by introducing temperature compensation mechanisms that adjust the resistance value readings based on detected temperature. The control unit modifies the output signal to compensate for temperature-induced changes in the elastomer's mechanical properties, thereby maintaining reliable load detection across varying temperatures without changing the sensor material itself.
Solution Approach 2:
The patent implements feedback by using a temperature sensor to continuously monitor the temperature around the load sensor and feeding this information back to the control unit. The control unit then adjusts the resistance value interpretation based on the temperature feedback, compensating for the mechanical strength deterioration and hardness changes that occur with temperature variations.
2Measurement precision
If the hardness of rubber decreases at high temperature or increases at low temperature, then the resistance value becomes insensitive to load, but the sensor structure remains the same
Solution Approach 1:
The patent changes the operational parameters by introducing temperature-dependent correction factors. The control unit adjusts the interpretation of resistance values based on temperature readings, effectively changing the measurement scale to account for hardness variations. This allows the same sensor structure to maintain measurement precision across different temperatures by dynamically adjusting the measurement parameters.
Solution Approach 2:
The patent introduces a temperature sensor and control unit as intermediary components between the load sensor and the output signal. These intermediaries measure the temperature and mediate the relationship between the load sensor's resistance changes and the final output, compensating for the insensitivity caused by temperature-induced hardness changes without modifying the load sensor structure itself.
3Ease of operation
If the resistance value is high in non-pressure state and reduces under load, then the sensor shows conductivity, but the output becomes unstable due to mechanical strength deterioration
Solution Approach 1:
The patent uses feedback from temperature sensors to continuously monitor environmental conditions and feed this information to the control unit. The control unit then adjusts the resistance value interpretation in real-time based on temperature feedback, compensating for mechanical strength deterioration and maintaining stable output that ensures ease of operation across different temperatures.
Solution Approach 2:
The patent substitutes the purely mechanical load detection system with an electromechanical system that includes temperature sensing and electronic compensation. By replacing the mechanical assumption of constant sensor properties with electronic measurement and software-based correction, the system maintains operability and stability despite mechanical strength deterioration.
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 stabilized output that is not affected by the characteristics of the load sensor, maintaining consistent motor rotational speed and operability across varying temperatures, thereby enhancing the tool's performance and usability.
Implementation Method 1
a load sensor that is configured to detect a load corresponding to a pressing force according to a manipulation of the switch manipulation part
Implementation Method 2
a temperature sensor to adjust for temperature variations, ensuring stable operation by referencing load-resistance value features at different temperatures
Data Source
AI summary
A tool includes a switch and a controller. The switch is configured to cause an electric component to operate. The switch includes a switch manipulation part and a load sensor. The switch manipulation part is configured to manipulate the switch. The load sensor is configured to detect a load corresponding to a pressing force according to a manipulation of the switch manipulation part. The controller is configured to correct an output corresponding to the load detected by the load sensor. The switch is configured to cause the electric component to operate based on the output corrected by the controller.