Torque Sensor Wireless Two-Way Communication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional torque sensors have limited range and functionality due to one-way analog data communication, restricting data access and adjustment capabilities, and lack real-time misalignment detection, which affects data quality and usability.
Innovation Solution
A torque sensing system enabling two-way wireless communication via Wi-Fi and Bluetooth with smartphones and tablets, allowing real-time data reading, adjustment of metrics, and misalignment detection using strain gages, accelerometers, and a Wheatstone bridge circuit, with signals transmitted via RF coupling to a processor and antenna.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If one-way analog cable connection is used for data communication, then the system structure is simple, but the communication range is limited and real-time parameter adjustment is prevented
Solution Approach 1:
The patent replaces the mechanical cable connection system with wireless communication technology (Wi-Fi and Bluetooth modules). This substitution eliminates the physical cable constraint, enabling wireless data transmission between the torque sensor and mobile devices, thereby achieving real-time parameter adjustment and extended communication range without increasing system complexity
Solution Approach 2:
The patent introduces mobile devices (smartphones or tablets) as intermediary components between the torque sensor and the user. These devices run specialized applications that enable two-way wireless communication, allowing users to remotely adjust parameters such as threshold values, range settings, and units of measurement in real-time, thus enhancing system adaptability
2Length of stationary object
If conventional one-way communication is used, then the device complexity is low, but the communication range is restricted to the same room
Solution Approach 1:
The patent replaces the cable-based mechanical connection with wireless communication technology (Wi-Fi and Bluetooth modules). This substitution removes the physical distance limitation imposed by cables, enabling data transmission over much longer distances and allowing users to access torque data and adjust parameters from remote locations, thereby significantly extending communication range
3Measurement precision
If no misalignment detection system is installed, then the device complexity is low, but data quality is negatively impacted by shaft misalignments
Solution Approach 1:
The patent introduces accelerometers mounted on the torque transmitting shafts as intermediary sensing elements. These accelerometers detect misalignment conditions and transmit this information to the processing system, enabling real-time detection and indication of misalignment issues that could affect torque measurement accuracy, thereby maintaining data quality without requiring complex mechanical alignment systems
Solution Approach 2:
The patent implements a feedback mechanism where accelerometers continuously monitor shaft alignment conditions and provide real-time information to the processing system. This feedback loop enables the system to detect and indicate misalignment issues, allowing users to correct alignment problems before they significantly impact measurement accuracy, thus maintaining high data quality
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 real-time data transmission and adjustment of torque and misalignment metrics over long distances, enhancing data quality and user interaction, and allowing remote monitoring and control.
Implementation Method 1
a foil type variable resistor is mounted on a structural component that exhibits a physical characteristic that allows it to elastically flex. The strain gage, or a set of strain gages, is mounted in a flexure zone in the structural component such that the resistance of the strain gage or gages changes in portion to the degree of flexure experienced
Implementation Method 2
The variation in resistance is readily converted by a Wheatstone bridge circuit shown in FIG. 19 to a variable voltage that can be processed by known electronics such as analog-to-digital converters and conventional microprocessors
Implementation Method 3
The signals are then sent by an rf coupling to a processor on the shaft
Implementation Method 4
The housing processor, in turn, supplies data to a wireless transmission system using either Wi-Fi or Bluetooth technology by way of an antenna on the sensor housing
Implementation Method 5
accelerometers to provide misalignment signals to a processor on the shaft
Data Source
AI summary
A torque sensing system which includes a torque sensor capable of wirelessly communicating torque and misalignment data to a smartphone or a tablet using a protocol such as Wi-Fi or Bluetooth technology, and wirelessly communicating commands from the smartphone or table back to the torque sensor. The torque sensor electronics include an rf coil for taking power off of a stationary housing to a rotary shaft and one or more accelerometers for indicating misalignments.