Wireless Clamping Force Sensor via Electromagnetic Induction
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Solution Overview
Problem
Existing clamping force monitoring systems in machine tools are prone to errors and damage due to the complexity and cost of laying electrical and hydraulic lines, which can be fault-prone and require additional space, especially when the machine table rotates.
Innovation Solution
A sensor device with strain gauges, a transmission module unit, and an antenna element using electromagnetic transmission technology is integrated onto the clamping element, allowing for wireless data and energy transmission, eliminating the need for cables and reducing the risk of damage during rotation, and enabling direct measurement of clamping force near the point of application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical and hydraulic lines are laid for sensor and control system connection, then clamping force monitoring is enabled, but the system becomes fault-prone and space-consuming during table rotation
Solution Approach 1:
The patent replaces mechanical cable connections with electromagnetic induction coupling. The sensor device uses a transmission module with antenna that communicates wirelessly with the control system through electromagnetic fields, eliminating the need for physical electrical and hydraulic lines to pass through the rotating table, thus reducing mechanical complexity and fault points
Solution Approach 2:
The patent introduces an intermediary electromagnetic field coupling system between the sensor device on the clamping element and the control system. The transmission module and receiver create an indirect communication path through electromagnetic induction, allowing data transfer without direct physical line connections that would be damaged during rotation
2Ease of operation
If lines are led up to the lead-in for power supply and data transfer, then the sensor system can operate, but additional space is required and fault risk increases
Solution Approach 1:
The patent substitutes mechanical line routing with electromagnetic wireless transmission. The transmission module on the sensor device communicates with the control system through electromagnetic fields, eliminating the need for physical space dedicated to cable routing through the rotating table structure
3Adaptability or versatility
If two types of lines (power supply and data transfer) are required, then complete system functionality is achieved, but cost increases
Solution Approach 1:
The patent implements a multi-functional electromagnetic transmission system. The same transmission module with antenna handles both power supply and data transfer functions through electromagnetic induction coupling, eliminating the need for separate physical lines for each function and reducing overall system cost
4Use of energy by moving object
If cables are used for sensor connection, then electrical supply and data transmission are enabled, but the cables can be damaged during table rotation
Solution Approach 1:
The patent replaces mechanical cable connections with electromagnetic field-based power and data transmission. The transmission module communicates wirelessly with the control system, eliminating physical cables that would be subjected to mechanical stress and damage during table rotation
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
This solution provides accurate, reliable, and fault-proof monitoring of clamping force with reduced complexity and cost, eliminating the need for additional lines and allowing continuous operation without battery replacement, while enabling precise measurement and identification of the clamping element and workpiece.
Implementation Method 1
at least one strain gauge, which can be arranged on a surface of the clamping element of the clamping device and is deformable under the clamping force
Implementation Method 2
transmission module unit based on electromagnetic transmission technology, connected to the at least one strain gauge, for detecting a voltage that is indicative of the deformation of the at least one strain gauge
Implementation Method 3
an antenna element connected to the transmission module unit for transmitting a signal, which is indicative of the detected voltage, and for receiving electromagnetic energy for electrical supply of the transmission module unit and of the at least one strain gauge
Data Source
AI summary
A sensor device (16a-16d) is provided for monitoring a clamping force (F) exerted by a clamping element (11a-11d) of a clamping device (12a-12d) on a component (14), with at least one strain gauge (30a-30d), which can be arranged on a surface (90, 91) of the clamping element (11a-11d) of the clamping device (12a-12d) and is deformable under the clamping force (F), a transmission module unit (36) based on electromagnetic transmission technology connected to the at least one strain gauge (30a-30d) for detecting a voltage (U5) that is indicative of a deformation (f) of the at least one strain gauge (30a-30d), and an antenna element (38) connected to the transmission module unit (36) for transmitting a signal that is indicative of the detected voltage (U5), and for receiving electromagnetic energy for electrical supply of the transmission module unit (36) and at least one strain gauge (30a-30d).