Torque Sensor Component Pairing via Pre-Calibration Data
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Solution Overview
Problem
Existing torque sensor systems require final system calibration, which is cumbersome and impractical for post-manufacturing component servicing or replacement due to calibration inapplicability when components with different operating characteristics are added or replaced.
Innovation Solution
A method where individual components, such as shafts and magnetic field sensors, are pre-calibrated and marked with unique identifiers for their characteristics, allowing software to correct deviations and enable pairing without requiring re-calibration of the entire system, facilitating interchangeable components and reduced assembly effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If final system calibration is performed on assembled torque sensor systems, then measurement precision is improved, but ease of repair deteriorates because calibration cannot be applied when components are replaced
Solution Approach 1:
The patent divides the calibration process into component-level calibration (done individually for each shaft and sensor) rather than system-level calibration (done on the complete assembly). Each component receives its own calibration data stored in memory, allowing components to be calibrated separately and then assembled without requiring re-calibration of the entire system.
Solution Approach 2:
The patent performs calibration on individual components (shaft and sensor) before final assembly. The calibration data is stored in memory devices attached to each component. This preliminary calibration eliminates the need for time-consuming system-level calibration after assembly, and allows components to be replaced and reassembled without recalibration.
2Measurement precision
If final system calibration is performed on assembled torque sensor systems, then measurement precision is improved, but loss of time increases due to cumbersome calibration process
Solution Approach 1:
The calibration process is segmented into independent component-level calibrations performed on shafts and sensors separately before assembly. This eliminates the need for time-consuming system-level calibration after assembly, significantly reducing total calibration time while maintaining measurement precision through component-specific calibration data.
Solution Approach 2:
Calibration is performed in advance on individual components before they are assembled into the final system. The calibration data is stored in memory devices on each component, allowing rapid assembly without requiring time-consuming post-assembly calibration procedures.
3Ease of manufacture
If individual components are pre-calibrated and marked with unique identifiers, then ease of manufacture is improved through interchangeable components, but device complexity increases due to pairing and data management requirements
Solution Approach 1:
The patent creates universal, interchangeable shaft and sensor components that can be mixed and matched from inventory. Each component type can be used with any other component type of the same category, eliminating the need for unique paired assemblies. This universality simplifies manufacturing and servicing while the memory-stored calibration data maintains measurement accuracy.
Solution Approach 2:
The patent uses unique identifiers (such as barcodes or RFID tags) on each component that copy or reference calibration data stored in memory devices. This allows the system to quickly identify and apply the correct calibration parameters for each component without complex manual pairing procedures, reducing the perceived complexity while enabling component interchangeability.
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 efficient assembly and recalibration of torque sensor systems by using pre-recorded calibration data for individual components, allowing for seamless integration and adjustment, reducing the need for re-calibration during final assembly and enabling easier servicing.
Implementation Method 1
non-contact magnetic field sensors positioned in proximity to the magnetically-conditioned regions
Implementation Method 2
shafts and disks having integrated magnetized portions, such as magnetoelastic sensing features
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
A system and method are provided related to replacing components of a fully assembled torque sensor system having been previously calibrated, whereby the new system with its new components, which may be installed in a larger system, can be recalibrated at the location where the component replacement or servicing occurs. Individual components are provided with individual characteristics information, either on or associated with the shipped component, so the end user may retrieve the information and enter it in the software, such as that associated with a control unit, which is used with the fully assembled torque sensor. A database storing information about each manufactured component and their respective characteristics information, and fully assembled systems and their collective characteristics information, may be maintained and accessible by end users.