Output Torque Calculation via Elastic Device Angle Difference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing output torque measurement systems in industrial automation, particularly in robot arms, are cumbersome and costly due to the need for additional torque sensors, which complicate the drive system and increase production costs without effectively addressing positioning errors and safety risks.
Innovation Solution
A device comprising a motor, a first sensor to measure the rotor angle, a transmission device, an elastic device with a second sensor to measure the output angle, and a processor that calculates output torque using the angles, reduction ratio, and shear moduli, eliminating the need for an additional torque sensor by estimating torque based on angle measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque sensor is added to the drive system to prevent damage and collision, then safety and reliability are improved, but device complexity and production costs increase
Solution Approach 1:
The patent uses angle sensors to measure rotor and output angles, then calculates torque indirectly through computational modeling rather than directly measuring it with a physical torque sensor. This creates a virtual copy of torque measurement functionality through software algorithms based on angular displacement data, eliminating the need for additional hardware torque sensors while maintaining the ability to detect excessive torque conditions for safety purposes
Solution Approach 2:
The patent replaces the mechanical torque sensor with an electrical/electronic measurement system using angle sensors and a processor. The mechanical direct measurement approach is substituted with an electrical measurement of angles combined with computational calculation of torque, reducing mechanical complexity while achieving the same safety function
2Reliability
If a torque sensor is added to the drive system to prevent damage and collision, then reliability is improved, but production costs increase
Solution Approach 1:
The patent creates a virtual torque measurement system using existing angle sensors and computational algorithms, replacing the need for expensive physical torque sensors. This software-based approach significantly reduces production costs while maintaining the safety function of detecting excessive torque conditions
Solution Approach 2:
The patent uses inexpensive angle sensors that are already part of the control system to perform the torque measurement function, rather than using costly torque sensors. The angle sensors are cheaper components that can be repurposed for torque calculation, reducing overall system cost
3Reliability
If a torque sensor is added to the drive system, then safety is improved, but wire arrangement and system layout become more complex
Solution Approach 1:
The patent merges the torque measurement function with the existing angle sensing system. The same angle sensors used for position control are also used for torque calculation, consolidating multiple functions into existing components and eliminating the need for separate torque sensor wiring and additional connection harnesses
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
Accurately estimates output torque without additional sensors, reducing system complexity and costs while maintaining precision, with an average error of 2.429% compared to actual torque measurements, thus enhancing safety and positioning control in industrial automation.
Implementation Method 1
the elastic device comprises a second input portion, a second output portion and a rotation axis... There is a first distance between the second input portion and the rotation axis, there is a second distance between the second output portion and the rotation axis
Implementation Method 2
The processor is electrically connected to the first sensor and the second sensor and calculates an output torque carried by a final output end of the output torque calculation device according to the first angle and the second angle
Data Source
AI summary
An output torque calculation device and a method thereof is provided, and the output torque calculation device includes a first sensor, a second sensor, a rotor, a reducer, a processor, and an elastic device. An input portion of the reducer and an output portion of the reducer are respectively connected to the rotor and an input portion of the elastic device, and an output portion of the elastic device is configured to connect to a load. The output torque calculation method comprises: detecting a first angle of the rotor by the first sensor; detecting a second angle of the output portion of the elastic device by the second sensor; and calculating a torque carried by a final output end of the output torque calculation device by the processor according to the first angle and the second angle.