Torque Sensor Using Magnetic Field for Precision Measurement
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Solution Overview
Problem
Existing torque sensors require high precision in manufacturing, leading to increased costs and decreased accuracy due to wear between ramp portions and follower pins, resulting in low measurement accuracy over time.
Innovation Solution
A torque sensor design featuring a driving unit with rotatable driving blocks and a resilient unit with compression members, allowing for accurate torque measurement without the need for high precision in manufacturing, using a measuring unit that captures the rotation and compression distance of the blocks within a block-receiving groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ramp portions are formed with high precision, then initial measurement accuracy is improved, but manufacturing cost increases and wear occurs over time reducing accuracy
Solution Approach 1:
The patent replaces the mechanical ramp portion and follower pin contact system with a magnetic field-based measurement system. The driving block contains a magnet that interacts with a magnetic sensor, eliminating mechanical contact and wear while maintaining measurement accuracy. This substitution resolves the contradiction by achieving high measurement precision without requiring high-precision mechanical manufacturing of contact surfaces.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the driving block and the measurement system. Instead of direct mechanical contact between ramp portions and follower pins, the magnetic field transmits the rotational position information to the sensor. This intermediary approach allows for easier manufacturing of the driving block while maintaining high measurement accuracy.
2Reliability
If ramp portions and follower pins are used, then torque measurement function is achieved, but wear between components occurs reducing precision over time
Solution Approach 1:
The patent eliminates the mechanical contact between ramp portions and follower pins by using a magnetic coupling system. The driving block with an integrated magnet interacts with a magnetic sensor without physical contact, completely preventing wear between components and ensuring long-term measurement reliability.
Solution Approach 2:
The patent extracts and removes the follower pin component from the system, replacing it with a non-contact magnetic sensing mechanism. This elimination of the follower pin removes the source of wear and improves the long-term reliability of the torque measurement function.
3Measurement precision
If high precision manufacturing is required for driving components, then measurement accuracy is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent replaces precision mechanical components (ramp portions requiring high-precision machining) with a magnetic system where the driving block can be manufactured with standard tolerances. The magnetic field provides precise measurement without requiring the driving block to have high-precision geometric features.
Solution Approach 2:
The driving block is designed to perform multiple functions: it transmits torque from the input shaft and simultaneously carries the magnet for position sensing. This integration simplifies the overall structure and reduces manufacturing complexity compared to separate precision mechanical components.
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 design improves measurement accuracy while reducing manufacturing costs by allowing for easier production and minimizing wear, thus providing a more reliable and cost-effective torque sensing solution.
Implementation Method 1
the one of the resilient members is compressed a distance that is proportional to the torque
Implementation Method 2
a resilient unit including a pair of resilient members flanking the driving block
Data Source
AI summary
A torque sensor includes a driving rod, a driving body connected fixedly to the driving rod, and a driving block extending from the driving body and having two opposite pushing surfaces, a driven body permitting the driving body to rotate relative thereto as a result of application of a torque to the driving rod, a driven rod extending from the driven body, and a block-receiving groove formed in the driven body. A first measuring module is connected to the driving block. A second measuring module is connected to the driven body, and cooperates with the first measuring module so as to measure the torque. Two resilient members flank the driving block. Each of the resilient members is disposed between and abuts against the corresponding pushing surface and the driven body.