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Development of a six-axis force/moment sensor for wind tunnel model test

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2013 Meas. Sci. Technol. 24 115101

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IOP PUBLISHING MEASUREMENT SCIENCE AND TECHNOLOGY
Meas. Sci. Technol. 24 (2013) 115101 (10pp) doi:10.1088/0957-0233/24/11/115101

Development of a six-axis force/moment


sensor for wind tunnel model test
Wenjun Wang
State Key Laboratory of Automotive Safety and Energy, Tsinghua University, Beijing 100084,
Peoples Republic of China
E-mail: wangxiaowenjun@tsinghua.edu.cn

Received 25 June 2013, in final form 27 July 2013


Published 1 October 2013
Online at stacks.iop.org/MST/24/115101

Abstract
A novel structure for a six-axis force/moment sensor is proposed in this paper. Parallel plate
structures are combined in the one-block structure of the sensor. A method for estimating the
sensitivity and stiffness is developed by comparing the results of numeric estimations with
those of finite element method (FEM) analyses. A detailed FEM model was used to analyse
the surface strain in the area where the strain gauge was attached. Tests carried out on the
characteristics revealed a sensitivity design error of less than 8.5%, a relative measurement
error of less than 2.13%, and an interference error of less than 9.51%. A performance
enhancement method is also proposed.

Keywords: six-axis force/moment sensor, parallel plate structure, sensitivity design, FEM
(Some figures may appear in colour only in the online journal)

1. Introduction In this study, we developed a six-axis force/moment


sensor for the simultaneous measurement of all six components
Different structures of six-axis force/moment sensors have of the aerodynamic force applied to test models in a wind
been proposed for specific applications. The parallel plate tunnel. Figure 1 shows a typical application of the sensor
structure (PPS) can be used to achieve high sensitivity in a wind tunnel study of the non-steady aerodynamic force
and high stiffness simultaneously. The simple deformation acting on the body of a moving vehicle model. Aschwanden
characteristics of the PPS facilitate the estimation of its et al [7] performed a wind tunnel experiment using a similar
sensitivity and stiffness in the design phase. The PPS is adopted arrangement and method.
Both high-sensitivity and high-frequency responses are
in the design of many six-axis force/moment sensors. Park
necessary for this type of application. A method for estimating
and Kim [1] developed a six-axis force/moment sensor for
the sensitivity of the six-axis force/moment sensor and the
an intelligent robot gripper. Kim [2] developed a small six- resonance frequency of the sensor-model system is essential to
axis force/moment sensor for the fingers of a robot. Kim et al the design process. The PPS was adopted for the basic sensing
[3] also developed the same type of sensor for an intelligent element in the development of our six-axis force/moment
foot in a humanoid robot. The flexibility of the PPS in real sensor because of its high sensitivity and stiffness. The detailed
applications was demonstrated in these studies. design process and characteristic test results are presented
Finite element method (FEM) analysis is widely used below.
in the design of multi-axis force/moment sensors. Kim [4]
proposed a design process for the wrist force/moment sensor 2. Basic deformation of PPS
of an intelligent robot. Chao and Chen [5] put forward
an optimal FEM-based design methodology for a new type The strain gauge force sensor should produce the largest
of wrist force sensor. Joo et al [6] designed a six-axis possible strain for a unit force input. However, the deflection
force/moment sensor using a combination of a PPS and a produced by the input force should be minimal. The PPS shown
ring-type structure. FEM was used to analyse the detailed PPS in figure 2(a) was used for the basic force-sensing element
deformation and surface strain distribution. because of its high sensitivity and stiffness. Hatamura et al [8]

0957-0233/13/115101+10$33.00 1 2013 IOP Publishing Ltd Printed in the UK & the USA
Meas. Sci. Technol. 24 (2013) 115101 W Wang

300

10
Y4 Z2

2w
=2l

0
by
2d Mz X4
z

ty
Z1
Y2

41
tz
bz
Lz X3
Figure 1. Wind tunnel vehicle model test. X1
Z3
x Y1
Strain gauge

2d
Ly
P P y
+

M
x
Y3
X2 Z4
2d M y
L

bx
Weight = 2kg
tx

Lx
+
t

(a) b (b) Figure 3. Structure of proposed six-axis force/moment sensor.

Figure 2. Parallel plate structure.


attached to the points indicated by G, where the letter
subscripts indicate the measured force and moment, and the
and Joo et al [6] analysed the deformation behaviour of the
number subscripts indicate the location of the gauge on the
PPS using theoretical equations and FEM, respectively. The
full bridge circuit shown in figure 5. The surface strain at
cantilever deformation can be ignored if the load P is close to the location of the gauge is also indicated in figure 4, where
the PPS, in which case the parallel plate deformation shown C denotes the compression strain and T denotes the tension
in figure 2(b) is dominant. strain.
The maximum surface strain occurs at the point of As shown in figures 4(a) and (b), Fx (x-direction force
connection of the deformable plate and the rigid block, where component) and Fy can be measured using two PPSs connected
the strain gauge is attached. The value of this maximum strain in parallel. The four deformable plates connecting parts B
is given by and C were arranged in the same plane. This arrangement
3PL enables the PPS to be used for measuring Fz, Mx (x-direction
= (1)
2Ebt 2 moment component) and My. The deformation modes are
where L is the length of the plate, b is the width of the plate, t shown in figures 4(c)(e), respectively. The compact structure
is the thickness of the plate, and E is the Youngs modulus of of the sensor in the z-direction is another advantage of the
the material. The deflection is given by arrangement. Figure 4( f ) shows the deformation mode under
PL3 Mz.
= . (2)
2Ebt 3
These basic equations were used to set the sensitivity and 3.2. Design of sensitivity and stiffness
stiffness of the six-axis force/moment sensor. For a given material, the sensitivity and stiffness of
the proposed six-axis force/moment sensor are primarily
3. Design of six-axis force/moment sensor dependent on the size of the deformable plates and their relative
spatial location. These key parameters can be used to estimate
3.1. Overall design the sensitivity and stiffness of the sensor in the initial design
phase.
Considering the space limitation of the application, a flat shape
was preferred for the six-axis force/moment sensor to facilitate
3.2.1. Translational deformation mode. As shown in
its installation in the narrow space between the shaker and
figures 4(a)(c), the deformations of the plates under Fx, Fy
the bottom of the scaled vehicle model. The novel structure
or Fz are almost the same as those of the PPS previously
shown in figure 3 was therefore proposed for the simultaneous
mentioned. The gain of the force sensor is defined as
measurement of the six components of the aerodynamic force.
out
The relatively high-stiffness parts, denoted by AD in Gf = (3)
figure 3, were connected by three groups of deformable plates, Fin
denoted by X1X4, Y1Y4 and Z1Z4. The scaled vehicle model where out is the total output strain of the full bridge circuit,
was mounted on part A, and part D was mounted on the strut. and Fin is the input force of the sensor. In these cases, the four
The three dimensions of the deformable plate are denoted by deformable plates can be regarded as equivalent to two PPSs.
L, b and t, respectively. The reference coordinate system of the Moreover, the total output strain of one full bridge circuit is
six-axis force and moment to be measured is also illustrated four times that of one strain gauge attached to the deformable
in figure 3. The xy plane was set at the same level as the four plates of the PPS. Therefore, from equation (1), the gain of the
deformable plates denoted by Z1Z4. force sensor can be obtained as
3L
The deformation modes due to the respective force Gf = . (4)
components are shown in figure 4. The strain gauges were Ebt 2

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Meas. Sci. Technol. 24 (2013) 115101 W Wang

GFz1:T Z1 Z2
X1 Y2 Y4
z GFy2:C GFz2:C
X4 GFy4:C
GFx1:T x z
GFx4:C GFz3:T
y x
x
GFx2:C y GFz4:C y
GFx3:T
X2
X3 GFy3:T
Y3 Y1 GFy1:T
Z4 Z3
(a) Fx (b) Fy (c) Fz

G :T GMy1:T
Z 1 GMx3:T GMx1:T Z Z1 My3
Z2
GMz3:T GMz4:C Y4
2
z z Y2
x GMx2:C x GMy2:C
GMx4:C
y GMy4:C y x
y
Z3 Y1
Z4 GMz2:C
Z3 Z4 GMz1:T
Y3
(d) Mx (e) My (f) Mz

Figure 4. Deformation modes.

T C GMz4: - b - t
1 4 Y4
GMz3: + b+ t
Output
Y2
2 3
C T
Input x
y
Y1
Figure 5. Gauge bridge.
Y3 GMz1: + b+ t
GMz2: - b - t
Furthermore, on the basis of equation (2), the stiffness of the
proposed sensor in the corresponding direction is given by Figure 6. Deformation caused by Mz.

4Ebt 3
kf = . (5) the moment sensor because only the moment arm d needs to
L3
be adjusted.
However, as discussed later, it was confirmed by FEM that
3.2.2. Rotational deformation mode. As shown in the design error of Mz was extremely large compared to those
figures 4(d)( f ), the deformations of the plates under Mx, My of the components about the other axes. A more precise Mz
or Mz are obviously different from those of the PPS shown estimation model is therefore proposed for the sensor design.
in figure 2. As shown in figure 4(d), Mx twists plates Z1Z4.
As shown in figures 4(e) and ( f ), the tangential directions of
the two ends of each of plates Z1Z4 or plates Y1Y4 are not 3.2.3. Deformation due to Mz. For the measurement of
parallel under My or Mz. However, to estimate the sensitivity Mz using plates Y1Y4, as shown in figure 6, the sensitivity
and stiffness in the initial design phase, a simple method that estimation requires the calculation of both b (the strain due
ignores the difference between the actual deformation and that to the y-direction deformation, which is approximately the
of the PPS shown in figure 2 can be used. PPS deformation) and t (the strain due to the x-direction
Mx is equal to the moment generated by the reaction forces deformation). The reason is that both strains contribute to the
of the two equivalent PPSs formed by plates Z1Z4, where the output of the bridge circuit, as shown in figure 6, wherein
moment arm dMx is the distance between the PPS and the x- the tension strain is indicated by + and the compression is
axis. The moment arms dMy and dMz are also defined as shown indicated by .
in figure 3. The gain of the moment sensor can therefore be A calculation model is proposed to determine the
estimated using quantitative relationship between the sensitivity and the design
3L parameters. In the model, plates Y1Y4 are replaced by
Gm = . (6) equivalent springs, as shown in figure 7. The x-direction
Ebt 2 d
The stiffness of the moment sensor can be estimated using stiffness can be calculated using the size of the plate and the
Youngs modulus of the material:
4Ebt 3 d 2
km = (7) Ebt
L3 . kx = (8)
where d is the moment arm relative to the specific axis. Here, L
the advantage of this method is that the sensitivity and stiffness The y-direction stiffness is associated with the bending
of the force sensors are not affected by the design process of deformation, which is regarded in the model as the PPS

3
Meas. Sci. Technol. 24 (2013) 115101 W Wang

Table 1. Key parameters.


Mz
By equations (6) By equations (15)
Axis Fx Fy Fz Mx My and (7) and (18)
L (mm) 10 10 10 10 10 10
b (mm) 20 20 20 20 20 20
t (mm) 1 1 1.2 1.2 1.2 1
d (mm) 40 100 60
l (mm) 60
w (mm) 10
Gf (St N1) or 21 21 14 359 143 344 142
Gm (St N1 m1)
kf (N m1) or 5.8 106 5.8 106 1.0 107 1.6 104 1.0 105 2.1 104 7.9 104
1
km (N m rad )
m (kg) or I (kg m2) 5.88 5.88 5.88 0.17 0.61 0.65
f (Hz) 158 158 208 49 64 29 56
P (N) or (N m) 116.1 116.1 116.1 34.8 126.7 134.0
N (N) or (N m) 1142.9 1142.9 1714.3 66.9 167.8 69.8 169.0

The reaction force of the equivalent springs and the load Mz are
therefore
fx = kx x (12)

fy = ky y (13)

Mz = 4( fx w + fy l). (14)
The stiffness is given by
 
Mz Ebt 2 Ebt 3 2
kMz = =4 w + 3 l . (15)
L L
To design the sensitivity, the strain related to the x-direction
Figure 7. Model of Mz sensor. deformation can be obtained using
fx
t = . (16)
Ebt
Also, the strain related to the y-direction deformation is given
by
3L fy
b = . (17)
Ebt 2
Considering that the strain output of the bridge circuit is four
times the sum of t and b, the gain can be obtained as
4(t + b ) L(3lt + wL)
GMz = = . (18)
Mz Ebt(L2 w 2 + t 2 l 2 )
Figure 8. Geometric constraint.
3.2.4. Key parameters. Following the trade-off between
sensitivity and stiffness, the key parameters (shown in figure 3)
deformation. From equation (2), the y-direction stiffness can of a specific scaled vehicle model for the wind tunnel test were
be obtained as set according to the specifications listed in table 1. A material
Ebt 3 with Youngs modulus E = 72.6 GPa was used. The stiffness
ky = . (9) of the sensor was used to estimate the resonance frequency of
L3
the modelsensor system.
Considering the geometric constraint of the structure shown in
The vehicle model inertial load is vital to the proposed
figure 8, the deflection of the equivalent springs is given by
sensor when applied to a wind tunnel model vibration test.
x = sin = w (10) The maximum inertial load P was calculated to check the
capacity of the sensor under the most severe experimental
y = cos = l. (11) conditions expected, which is when the vibration frequency
is 10 Hz and the amplitude is 5 mm or 3 . The load

4
Meas. Sci. Technol. 24 (2013) 115101 W Wang

Figure 9. FEM model.

Table 2. Estimation by simplified equations versus FEM.


Gain ((m m1) N1 or (m m1) N1 m1) Eigenfrequency (Hz)
Axis Equations (4) or (6) Equation (18) FEM Equations (5) or (7) Equation (15) FEM

Fx 20.7 14.2 158 129


Fy 20.7 13.6 158 110
Fz 14.3 9.6 208 126
Mx 358.7 287.1 49 26
My 143.5 91.3 64 39
Mz 344.4 141.8 131.5 29 56 38

capacity N was calculated using the gain estimation equations sensitivity for the FEM validation. Second, barring the thin
and the maximum strain in the linear elastic range of the plates, the deformation of the rest of the sensor structure
material (about 6000 m m1) observed during the capacity was not considered for the estimation equations, whereas
test using the early prototype of the sensor. All the values the deformation of the entire sensor structure was taken into
thus obtained were greater than the expected maximum load, account for the FEM validation. For example, figure 11 shows
with the exception of the significantly erroneous value of Mz the strain distribution in the direction of L on plate X2 for
calculated using the gain estimation equation (6). Fx = 1000 N.
The FEM gain of My is also approximately 70% of
3.3. FEM calculation the estimated gain. However, as shown in figure 12, an
asymmetrical strain distribution in the plates was obtained
An FEM model was built to validate the above sensitivity in the case of FEM.
and stiffness design method. As shown in figure 9, the detailed The asymmetric strain distribution can be explained by
deformation shape and strain distribution can be obtained using the specific structure of the sensor. As shown in figure 3, the
the model, which has a fine mesh of deformable plates. The stiffness of part C is apparently higher than that of part B, i.e.,
attachment point of the strain gauge is shown in red. The details the values of the support stiffness at the two ends of each of
of the strain gauge attachment point are shown in figure 10. plates Z1Z4 are different. The strain at the end connected to
The average strain of the elements in the attachment area was part C is therefore greater than that at the end connected to
used to calculate the gain of the sensor for the FEM validation. part B.
The FEM results and the estimation results obtained by the The FEM gain of Mx was approximately 80% of the
simplified equations are compared in table 2. estimated gain. As shown in figure 13, the two-dimensional
The FEM gains are approximately 70% of the estimated surface strain distribution due to the twist deformation and the
values for Fx, Fy and Fz. Considering that the deformations attachment of the strain gauge can be studied using FEM.
of the plates are almost the same as the PPS deformation Owing to space limitation, the strain gauges that make up
in these cases, the estimation error might be primarily due the bridge circuit that measures Mx can be attached along
to the following two factors. First, the estimation equations the outer line to the surfaces of plates Z1Z4. The strain
give the maximum strain at the end of the plates, whereas distribution in the direction of L is shown in figure 14. The
the average strain of all the elements in the area where gain will be 261 (m m1) N1 m1 if the gauges GMx1
the strain gauge was attached was used to calculate the GMx4 are attached along the centre line of the plates, i.e., at the

5
Meas. Sci. Technol. 24 (2013) 115101 W Wang

Figure 10. Details of the gauge attachment point.

Figure 11. Strain distribution on X2 (Fx = 1000 N).


Figure 12. Strain distribution on Z4 (My = 100 N m).

attachment points of gauges GMz1GMz4. Similar to the gains estimated by equation (18). The strain distribution is shown in
for the other axes, this gain is 73% of the estimated gain, which figure 15.
was 359 (m m1) N1 m1. Table 3 compares the maximum surface strain of the
The FEM gain of Mz was only 38% of that estimated by elements in the gauge area with the analytically obtained strain
equation (6), whereas the accuracy of the estimation model in for assumed applied force and moment of 1000 N and 100 N m,
section 3.2.3 was acceptable. The FEM again was 93% of that respectively. The difference can be attributed to the effect of

6
Meas. Sci. Technol. 24 (2013) 115101 W Wang

Figure 13. Deformation and strain distribution on Z4 (Mx =


100 N m).

Figure 16. Six-axis force/moment sensor.

Table 3. Maximum strain (FEM versus analytical).


Axis Fx Fy Fz Mx My Mz

FEM (m m1) 4139 3940 3182 7417 2795 3665


Analytical 5175 5175 3575 8968 3588 3545
(m m1)
FEM/analytical 80% 76% 89% 83% 78% 103%

Figure 14. Strain distribution on Z4 (Mx = 100 N m). This effect of the series connection and the compliance of
the entire structure of the sensor barring the plates contribute
to the lower stiffness of the sensor in the FEM calculation.
Compared to equation (7), equation (15) produces a more
reasonable estimate of Mz-axis, i.e., the stiffness estimated by
the equation is higher than that obtained by FEM.

4. Fabrication and test of characteristics

4.1. Fabrication
The proposed six-axis force/moment sensor shown in figure 16
was produced from a single aluminium alloy (A7075-T6)
block by wire cutting. The Youngs modulus E was 72.6 GPa.
The single-block structure reduces the hysteresis of the sensor
output, which is caused mainly by friction between adjacent
parts.
Figure 15. Strain distribution on Y3 (Mz = 100 N m).
4.2. Test of characteristics
the elastic support of the thin plates, which was considered for
FEM but not in the analytical method. A special apparatus was developed for the calibration test of
As regards the eigenfrequency of the model-sensor the proposed six-axis force/moment sensor. The method for
system, the FEM results were lower than the estimated generating the pure force and pure moment is similar to that
values. Only the deflection of the plates in the direction of a six-component force/moment sensor testing machine [9].
of L was considered by the estimation equations (5) and As shown in figure 17, each axis can be loaded by a
(7). The deflections of the plates in other directions affect rearrangement of the experimental apparatus. The calibration
the compliance of the sensor along the corresponding axes. results of Fx-axis and Mx-axis are shown in figures 18 and 19,

7
Meas. Sci. Technol. 24 (2013) 115101 W Wang

(a) (b) (c)

(f)
(d) (e)

Figure 17. Characteristic test.

Table 4. Relative errors.


Load direction Fx Fy Fz Mx My Mz

Nonlinearity + 0.06% 0.18% 0.14% 1.10% 0.96% 0.83%


0.19% 0.20% 0.34% 1.32% 0.90% 0.95%
Hysteresis + 0.11% 0.21% 0.27% 1.70% 1.66% 1.29%
0.37% 0.25% 0.47% 2.13% 1.40% 1.57%
Max load in calibration (N) or (N m) 117.6 117.6 117.6 29.4 58.8 58.8

Figure 18. Calibration results for Fx input. Figure 19. Calibration results for Mx input.

respectively. Also, table 4 indicates that the maximum relative


error was less than 2.13%. The gain matrix C was used to describe the characteristics
Table 5 compares the calibration results and the FEM of the proposed six-axis force/moment sensor:
gains. The strain that was measured using an assumed gauge
factor of 2 was corrected to the actual strain using the actual 61 = C61 F61 (19)
gauge factor of 2.12. The relative errors of the FEM and
calibration results are less than 8.5%. where is the strain output and F is the force/moment input.
A hammering test was used to the dynamic characteristics In real applications, the inverse matrix of C can be used to
of the model-sensor system. The lowest resonance frequency determine the six-axis force/moment. The gain matrix C is
(roll resonance) was about 28 Hz. The experimental result was listed in table 6.
almost the same as that obtained in the case of FEM, which To evaluate the interference error of the proposed six-axis
was 26 Hz (see table 2). force/moment sensor, a virtual force/moment input vector

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Meas. Sci. Technol. 24 (2013) 115101 W Wang

Table 5. Gain (FEM versus calibration).


1 1 1
Gain (St N ) or (St N m ) Fx Fy Fz Mx My Mz
FEM 14.2 13.6 9.6 289.9 91.3 131.5
Calibration 15.5 14.7 10.1 306.2 91.8 140.1
FEM Calibration
8.5% 7.5% 5.2% 5.3% 0.5% 6.1%
Calibration

Table 6. Gain matrix.


Load input
Fx Fy Fz Mx My Mz
1 1 1 1 1
Strain output ((m m ) N ) ((m m ) N m )

Fx 15.496 0.014 0.056 0.301 0.176 1.401


Fy 0.021 14.652 0.032 10.735 0.031 4.448
Fz 0.003 0.003 10.132 0.371 0.580 3.403
Mx 0.023 0.541 0.448 306.190 4.353 1.184
My 0.033 0.199 0.075 33.010 91.767 0.021
Mz 0.048 0.056 0.125 2.311 1.751 140.094

Table 7. Interference error.


Load input
Strain output Fx Fy Fz Mx My Mz
Fx 99.75% 0.10% 0.55% 0.09% 0.18% 0.97%
Fy 0.13% 100.49% 0.31% 3.09% 0.03% 3.08%
Fz 0.02% 0.02% 98.33% 0.11% 0.58% 2.36%
Mx 0.15% 3.71% 4.35% 88.23% 4.38% 0.82%
My 0.21% 1.36% 0.72% 9.51% 92.38% 0.01%
Mz 0.31% 0.38% 1.21% 0.67% 1.76% 97.05%

Figure 20. My bridge circuit under the action of Mx.

was developed using the matrix C1 and uniform strain output


.


1 ..
F61 = C . (20) Figure 21. Symmetric arrangement of gauges in the My bridge
61
circuit.
For an input F , the constitution of the strain output relative to in the measurements of the strain gauges is shown in figure 20.
is given in table 7. The results of the FEM analysis indicate that the absolute value
All other interference errors were less than 4.38%, with
of the strain on the high-stiffness end is greater than that on
the exception of the strain output of the My bridge due to the Mx
the low-stiffness end. In figure 20, the tension strain TL > TS
input, which constituted 9.51% of the total bridge output. This
and the compression strain CL > CS. The bridge circuit of the
relatively large interference error is considered to be mainly
due to the asymmetric gauge attachment position of the My My sensor is therefore unbalanced.
bridge. As shown in figure 10, the strain gauges GMy1GMy4 This systematic interference error from the Mx input to
were arranged along the centre line of plates Z1Z4 on the basis the My bridge output can be eliminated by rearranging the
of the initial design shown in figure 4(e). strain gauges in the My bridge, as shown in figure 21. The
The bridge circuit for measuring My is unbalanced because bridge circuit is balanced because all four gauges are attached
of the asymmetric strain distribution under Mx. On the basis of to the end connected to part B, i.e., the values of the supporting
the deformation mode shown in figure 4(d), the strain variation stiffness of all four strain gauges of the My bridge are the same.

9
Meas. Sci. Technol. 24 (2013) 115101 W Wang

5. Conclusion References

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