Topology structure design and optimization of a new-type strain torque sensor for robotic joints
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摘要: 协作机器人的柔性控制依赖于关节的力矩感知能力。基于应变式传感器测量原理，提出一种S型双连孔结构的应变式扭矩传感器。首先，依据传感器测量的基本原理，提出基于应变式传感器的构型设计方法。其次，通过传感器整体结构力学仿真试验，验证结构的可靠性。最后，运用中心复合设计(CCD)响应面法对传感器局部尺寸参数进行优化，使传感器表面应变提高93 MPa，从而提高了传感器的灵敏度。Abstract: The flexible control of collaborative robots relies on the torque sensing capability of the joints. Based on the measurement principle of strain sensors, a strain-based torque sensor with an S-shaped double-hole structure was proposed. Firstly, according to the basic principles of sensor measurement, a configuration design method based on strain gauges was proposed. Secondly, the reliability of the structure was verified through mechanical simulation tests of the overall sensor structure. Finally, the central-composite design (CCD) response surface method was ued to optimize the local dimensional parameters of the sensor, which increases the surface strain of the sensor by 93 MPa, thereby enhancing the sensitivity of the sensor.
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Key words:
- torque sensor /
- resistive strain gauge sensor /
- flexure structure design
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图 3 S型双连孔弹性体初步参数仿真应力云图
Figure 3. Preliminary parameter simulation stress contour plot for S-type double-hole flexure structure
图 4 各方向解耦应变仿真分析图
Figure 4. Simulation analysis diagram of decoupling strain in all directions
图 5 应变片理想粘贴区域与弹性体应变效果图
Figure 5. Effect diagram of ideal adhesive area and flexure structure strain
图 8 响应面设计模型残差正态分布图
Figure 8. Normal probability plot of residuals for response surface design model
图 9 弹性体结构响应面优化后的应力云图
Figure 9. Stress cloud diagram of optimized response surface of flexure structure
表 1 各种材料应力−应变参数
Table 1. Stress-strain parameters of various materials
参数 45钢 7075-T6 6061-T6 2024-T4 σYS/MPa 530 512 275 320 σY/MPa 481.0 482.1 483.8 483.2 με 1068 3596 3724 3311 
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表 2 优化模型评价指标
Table 2. Evaluation indicators of optimization model
名称 p值 方差 调整方差 信噪比 f1 < 0.000 1 0.988 0.976 9 36.00 f2 < 0.000 1 0.988 0.977 2 40.54 f3 < 0.000 1 0.985 0.971 7 38.29
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表 3 优化前后参数对比
Table 3. Parameters comparison before and after optimization
模型优化 L1/mm L2/mm L3/mm b/mm 优化前 28 4 3 10 优化后 27 5 3.25 12 模型优化 f1(x)/MPa f2(x)/(mm·mm−1) f3(x)/(mm·mm−1) 优化前 482 0.012 0.114 优化后 514 0.028 0.148
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表 4 构型特点对比
Table 4. Table of configuration comparison and characteristics
弹性体构型 特点 S型双连孔 应力应变更集中，应变片区域弹性应变好 改进轮辐双连孔 结构简单，应力应变分散不均，易受串扰影响 支撑梁 + 挠性结构 结构复杂，挠性结构不完全对称，制造困难，映射关系不明确
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