Wireless SAW Strain Sensing in Machining Force Paths
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Solution Overview
Problem
Current sensor solutions for monitoring cutting forces in machining processes are invasive, expensive, and limited to dedicated R&D centers due to their complex measurement chains and impractical integration into production systems, making widespread implementation challenging.
Innovation Solution
A wireless and passive sensing system using surface acoustic wave (SAW) sensors and transceiving antennas, which can detect strain on cutting tools and workpieces, allowing for remote monitoring without the need for power sources or complex amplification circuits, and can operate effectively in environments with metal and fluids that interfere with electromagnetic signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensor solutions are used to monitor cutting forces, then measurement capability is achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces conventional mechanical sensor systems with acoustic emission-based detection. Instead of using complex force sensors and measurement chains, the system uses acoustic emission sensors to detect stress waves generated during cutting, thereby substituting a mechanical measurement system with an acoustic field-based system that is simpler and more robust
Solution Approach 2:
The patent extracts the essential measurement function from the complex conventional system by focusing only on detecting acoustic emission signals from the cutting zone. This extraction approach eliminates unnecessary components of traditional force measurement systems while retaining the core capability to monitor cutting forces through acoustic signal analysis
2Measurement precision
If invasive sensor solutions are implemented, then cutting force data is obtained, but ease of operation and integration are reduced
Solution Approach 1:
The patent segments the measurement system into independent acoustic emission sensors that can be placed on existing machine components without requiring system-wide modifications. This segmentation allows the sensors to be independently installed and operated, greatly simplifying integration into production systems while maintaining measurement capability
3Reliability
If complex measurement systems are deployed, then monitoring capability is achieved, but productivity and cost-effectiveness deteriorate
Solution Approach 1:
The patent implements a self-service measurement system where acoustic emission sensors automatically detect and record cutting zone conditions without requiring external intervention or complex processing systems. The sensors autonomously monitor stress waves and provide real-time feedback on tool condition, enabling reliable tool life prediction while maintaining high machining productivity through minimal system overhead
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 cost-effective, flexible, and practical monitoring of cutting forces in various machining processes, improving tool life prediction, reducing scrap, and enhancing machining productivity by providing real-time data on tool wear and process conditions.
Implementation Method 1
A wireless and passive sensing system using surface acoustic wave (SAW) sensors and transceiving antennas, which can detect strain on cutting tools and workpieces
Implementation Method 2
the at least one SAW sensor and the at least one transceiving antenna arrangement are arranged to receive energy from an interrogation signal and output a strain response signal detected by the at least one SAW sensor in response to the interrogation signal
Data Source
Figure 1a~1b
Figure 2~3
Figure 4a~4c
AI summary
Provided is a sensing system for wireless and passive monitoring of strain during a manufacturing process that depends on force to apply the energy into the manufacturing process, the sensing system comprising: at least one surface acoustic wave (SAW) sensor for detecting strain, the at least one SAW sensor being positioned in a force path located on or in the structure of one or more objects under test; and at least one transceiving antenna arrangement being connectable to the at least one SAW sensor, wherein the at least one SAW sensor and the at least one transceiving antenna arrangement are arranged to receive energy from an interrogation signal and output a strain response signal detected by the at least one SAW sensor in response to the interrogation signal.