Wave Reducer Angle Sensing Corrected for Thrust Force Variation
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Solution Overview
Problem
Existing wave reducers with strain gauge-based detection systems experience errors in angle sensor detection due to changes in thrust force, leading to inaccuracies in rotation angle measurement.
Innovation Solution
A wave reducer design incorporating a cam with a non-circular outer surface, a flex gear that is flexurally deformable, an internal gear meshing with the flex gear, an angle sensor, a thrust sensor, and a circuit that corrects the angle sensor output based on the thrust sensor output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If strain gauges are used to detect rotation angle in the wave reducer, then the angle sensor can be configured with simple bridge circuits, but the detection accuracy deteriorates when thrust force varies during operation
Solution Approach 1:
The angle sensor is segmented into two independent detection systems: a primary angle detection function using bridge circuits with strain gauges, and a separate thrust force detection function using dedicated thrust sensors. This segmentation allows independent optimization of each function while eliminating mutual interference, resolving the contradiction between simple configuration and accurate measurement under varying thrust conditions
Solution Approach 2:
A correction mechanism acts as an intermediary between the thrust force variations and the angle sensor output. The correction unit receives both the angle sensor signal and thrust sensor signal, then applies correction based on the thrust force magnitude to compensate for its effect on the angle measurement. This intermediary correction process eliminates the harmful coupling between thrust force and angle detection accuracy
2Adaptability or versatility
If the wave reducer operates under varying thrust forces during acceleration or external loading, then the reducer can handle dynamic workloads, but the amplitude of bridge circuit output values changes causing detection errors
Solution Approach 1:
A feedback mechanism is implemented where the thrust sensor continuously monitors the thrust force acting on the cam, and this information is fed back to the correction unit. The correction unit uses this feedback to dynamically adjust the angle sensor output, compensating for thrust-induced amplitude variations. This feedback loop maintains measurement precision across the full range of dynamic workloads
Solution Approach 2:
The system explicitly measures and compensates for parameter changes in the bridge circuit output amplitude caused by thrust force variations. By detecting the amplitude changes through thrust sensors and applying correction based on these parameter changes, the system maintains accurate angle detection despite operating under varying dynamic loads
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 effectively corrects for errors in angle sensor output caused by thrust force variations, enhancing the accuracy of rotation angle detection in wave reducers.
Implementation Method 1
an angle sensor located in the flex gear and having an output value that is variable in accordance with a rotation angle of the cam, a thrust sensor located in the flex gear and having an output value that is variable in accordance with a thrust force applied to the cam
Data Source
AI summary
A wave reducer includes a cam, a flex gear, an internal gear, an angle sensor, a thrust sensor, and a circuit. The angle sensor is located in the flex gear and an output value thereof changes in accordance with a rotation angle of the cam. The thrust sensor is located in the flex gear and an output value thereof changes according to a thrust force applied to the cam. The circuit is electrically connected with the angle sensor and the thrust sensor. The circuit corrects an output value of the angle sensor based on an output value of the thrust sensor.