Optimized Design of Small-scale Six-Dimensional Force Sensor with Composite Beam Structure
A six-dimensional force sensor elastic body structure with a composite configuration of three horizontal beams and three vertical beams was designed.The outer diameter of the sensor was reduced to 40 mm,and after complete assembly,the final outer diameter was 45 mm.Finite element analysis was conducted under various load conditions to investigate the strain distribu-tion.Based on the strain distribution characteristics,a Wheatstone bridge scheme for the sensor was designed,and the output volt-age formulas for each direction were derived.On this basis,the Box-Behnken response surface method was employed to optimize the elastic body structure.The average strain on the strain gauges attached to the elastomer was chosen as the optimization objec-tive.The optimal design parameters were obtained using a multi-objective genetic algorithm,resulting in the average strains in the Fx,Fy,Fz,Mx,My,and Mz directions being 1.583 3,1.563 2,1.733 8,1.511 3,1.510 9,and 2.171 times their respective val-ues before optimization.A prototype was fabricated,and calibration experiments were conducted.The decoupling matrix was ob-tained using the least squares method.The first-class errors of the sensor were determined as 0.18%,0.42%,0.41%,0.05%,0.49%,and 0.6%,respectively,while the maximum second-class error was 1.665%.The sensor demonstrates high accuracy,minimal cross-coupling,and the feasibility of the proposed structure is verified.
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