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Geometrical Optimization
Geometrical Optimization
Geometrical optimization of dual octal ring force sensor for wide range
loading using GRA
Vijay A. Kamble a,⇑, Jayant K. Kittur b, Vasudev D. Shinde c
a
Research scholar, VTU, Belagavi and Department of Mechanical Engineering, Textile and Engineering Institute, Ichalkaranji, India
b
Departmentof Mechanical Engineering, KLS Gogte Institute of Technology,Belagavi, India
c
Department of Mechanical Engineering, Textile and Engineering Institute, Ichalkaranji, India
a r t i c l e i n f o a b s t r a c t
Article history: In the design of a force sensor, capacity of strain gauge plays an important role. Force sensor capacity
Available online xxxx depends on the deformation limit of strain gauge. Normally, force sensors are built as per specific range
of load capacity. An optimal dual octal ring force sensor was developed for the measurement of wider
Keywords: ranges of loading. This force sensor had two limbs with gaps which distinguish light or heavy load in a
Multi capacity dual octal ring. It gives low stiffness for light load causing high sensitivity, while high stiffness for heavy
Dual octal ring loading prevents over-straining. In the shape optimization process, displacements at certain points were
GRA
maximized without violating stress constraints. The top octagon height, top octagon thickness, bottom
Optimization
Force sensor
octagon height, and bottom octagon thickness were treated as design variables. The use of Grey regres-
sion analysis (GRA) multi-optimization technique proposed reduction in mass by 12% with increase in
deflection by 27%.It is a one-step, two-range weighing system, which could prove beneficial to the agri-
cultural products sorting process.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International e-Con-
ference on Frontiers in Mechanical Engineering and nanoTechnology.
1. Introduction ring force sensors for wide-range loading. In some cases, use of multi
component stiffening flexures are used for varying sensitivity which
To enhance the quality and productivity, industries are opting for increases weight and not frugal and will pose accuracy as single
computerized mass measuring instruments. The automated data is monolithic parts are not used. Chang and Lin designed a G-
utilized for inspections and comprehensive calculation. In the mass shapedforce sensor to measure two force ranges [3].
measurement system, force sensors convert force into electrical sig- The G-shaped force sensor has mechanical points which can
nals. It is made up of elastic element and strain gauges mounted on distinguish light and heavy loads. During shape optimization, the
the surface of the elastic element at proper location. The applied displacement at a particular region is maximized without violating
force on the elastic element will be measured in terms of resistance stress constraint. The coefficients of the elliptic curve function
and voltage of strain gauge, which is measured using Wheatstone were treated as design variables. The slope of the stress response
bridge circuit. The value of the force applied can be obtained from is increased by approximately 20%, which enhances the sensitivity
the value of change in voltage [1]. Different types of force sensors of the force sensor. The relationship between e.m.f. and load
in practice are S shape, Pan Cake and Beam type force sensor, which applied is generated. Osman et al. illustrated Multicapacity force
deflect linearly. Force sensors are used in various measuring instru- sensors for force measurement. It gives spot on the design, manu-
ments such as electronic balances, testing machines, flow meters, facturing and development of force transducer with multi- capac-
industrial scales, and in automation as force sensors [2]. More num- ity [4]. Kluger et al. demonstrated the nonlinear flexures used in
ber of force sensors is required to cover different load ranges, these force sensors to enlarge force range and resolution. [5]. Theforce
increase handling efforts, in addition to increase the cost of purchas- sensor having low stiffness offers high sensitivity for small forces
ing force sensors. This work concerns the introduction of dual octal whereas force sensors with high stiffness opposes over-straining
at high forces [6]. Uchimura and Masuyama patented multi-
⇑ Corresponding author. range force sensor scale used for heavy and light range load capac-
E-mail address: vakamble@dkte.ac.in (V.A. Kamble). ities. It used two different output signals based on predetermined
https://doi.org/10.1016/j.matpr.2021.03.745
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International e-Conference on Frontiers in Mechanical Engineering and nanoTechnology.
Please cite this article as: V.A. Kamble, J.K. Kittur and V.D. Shinde, Geometrical optimization of dual octal ring force sensor for wide range loading using
GRA, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.03.745
V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx
values of the light-range and heavy- range force sensor [7] and This paper deals with wide range loading capacity force sensor, in
claimed improved version with use of number of force sensors two stages with higher sensitivity forfirst stage (for light load) and
[8] and varying range weighing applications [9]. Yalof and Doren higher stiffness for second stage (heavy load)It is a one-step, two-
proposed adjusting the sensitivity of the force sensor will provide range weighing system, which could prove beneficial to the agri-
an accurate measurement over a wide range of pressures [10]. cultural products sorting process.
Suzuki et al. [11] patented a multi-range force sensor weighing In section 2, model of a single piece dual octal ring force sensor
scale which includes low and high range force sensors for weight isdescribed which is used to measure a wide range of load. Sec-
determination. Stratana et al. developed a ring type mechanical tion 3 describes finite element analysis which is used to evaluate
force transducer considering shape optimization, modification the displacement and strain induced in the structural member.
and characterization with different optimization codes [12] Sta- Section 4 describes Grey Relational analysis (GRA) which is used
noetal have done additive manufacturing and characterization of to optimize the dimensions of elastic elements to minimize the
a force sensor with embedded strain gauges. [13] Singh et al. devel- volume of the structural elements and to increase the sensitivity
oped and metrologically evaluated an Industrial Force Transducer to light load. Section 5 describe analysis of variance (ANOVA).
[14]. Mole patented variable force sensor arrangement operative
for precisely measuring loads [15].
Force sensors can measure forces with high accuracy and min-
imum possible uncertainties, but they have some issues that 2. Dual octal ring force sensor
restrict their usage, the first issue is; each force sensor has a unique
capacity that cannot be exceeded and if this happens it may lead to For the design of force sensors, a dual octal ring is used as a
its collapse or at least change in its performance perhaps signifi- spring element. Dual octal ring force sensors are designed as
cantly worse. The manufacturers of these devices recommend shown in Fig. 1. Two vertical limbs are provided in the top ring,
not using their devices to measure forces at a range of less than separated with a small gap portion at the center. For light loading
10% of their rated capacities. To cover the traceability within the in first range, there is no contact between the two special limbs of
wide range of force measurement, maybe from milli-Newton the force sensor. In the second range for heavy loading, contact
(mN) up to several Mega-Newton (MN) many force sensors of dif- between the two components occurs. Stiffness of the spring ele-
ferent capacities must be available. These reference transducers ment is varied to differentiate the sensitivity, as the stiffness of
are very costly devices. Hence the concept of a single force sensor the force sensor element for the second range is increased. And
capable of operating at different capacities was proposed (multi- for the first range, the stiffness of the spring element will be less
capacity concept). To avoid the confusion between two technical as compared to the second stage. Thus, the sensitivity dual octal
terms, it is important to clarify the difference between the multi- ring will be improved for light loading conditions [17].
capacity force transducer and a multi-component or a multi-axis
force sensor. The multi-capacity is a force transducer capable of
measuring the force in uniaxial direction at a wide force measure-
ment range or multi-force measurement ranges, while the multi- 2.1. Design methodology
component is a sensor that measures forces, torque and moments
occurring in more than one direction as the one used to evaluate To analyze the strain of a dual octal ring 3D model is prepared
the PTB 2 kNm torque standard machine. [16]. Based on the liter- using Ansys software as shown in Fig. 1. The selected variable
ature cited, a greater number of traditional force sensors were design parameters are top octagon height (HU), bottom octagon
assembled together to use as multi capacity force sensors. This cre- height (HL), top octagon thickness (TU), bottom octagon thickness
ates a bulky and costlier force sensor. In some cases, multi compo- (TL). The thickness of the middle limb is kept constant as 10 mm.
nent stiffening flexures were used for varying sensitivity which Middle gap in the limb is kept equal to maximum deflection
increases weight and non-frugal solution. This will create accuracy occurred in the top ring after application of maximum light load
problems; as multiple components are used. Also, it creates com- i.e., 294 N. Displacement and strain values at the inner surface of
plex design issues in the context of strength of mechanics. In some octal rings are considered as the constraints [18]. The overall
cases, a greater number of spring elements is assembled instead of height and thicknesses are considered as design variables for the
a single piece product which creates a question mark to certainty. dual octal ring force sensor as shown in Fig. 1.
Fig. 1. Dual octal ring force sensor and its 2D, 3D model.
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V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx
Table 1
Taguchi L9 orthogonal array.
Sr. No. Height of top octagon (mm) Thickness of top octagon (mm) Height of bottom octagon (mm) Thickness of bottom octagon (mm)
1 90 4 90 4
2 90 6 100 6
3 90 8 110 8
4 100 4 100 8
5 100 6 110 4
6 100 8 90 6
7 110 4 110 6
8 110 6 100 8
9 110 8 90 4
Fig. 2. Meshed models and strain contour plots of single and dual octal ring force sensors.
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V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx
Table 2
Structural analysis of dual octal ring element.
grade (GRG) is obtained to evaluate the multiple performance 4.1. signal-to-noise ratio (S/N)
Characteristics.[23] As a result, conversion of complicated multiple
performance characteristics can be a single performance character- The simulation results were then converted to signal-to-noise
istic. The various steps in GRA include normalization of process ratio (S/N) to measure the quality characteristics deviating from or
parameters for calculating grey relational coefficient (GRC). In near the desired value using Eqs. (1) and (2). For volume, strain under
order to optimize volume and sensitivity simultaneously, grey light load in bottom ring (eb1) and strain under heavy load in top ring
relational analysis (GRA) has been utilized. For multi response (et2) - smaller the better criterion is used. Whereas for deflection,
optimization using GRA, the steps used for analysis are as shown strain under light load in top ring (et1) and strain under heavy load
in the flow chart in Fig. 3. [24] in bottom ring (eb2), the bigger the better criteria are used.
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V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx
!
1X R Table 4
S=N ¼ 10 log10 y2 ð1Þ Analysis of Grey relational coefficient for Deflection.
R j¼1 j
Deflection S/N Normalised Deviation GRC
! 0.375 8.518 0.919 0.081 0.861
1X R
1 36.053
S=N ¼ 10 log10 ð2Þ 0.016 0.092 0.908 0.355
R j¼1 y2j 0.088 21.125 0.541 0.459 0.521
0.361 8.856 0.909 0.091 0.846
0.349 9.148 0.900 0.100 0.834
0.011 39.114 0.000 1.000 0.333
4.2. Normalization
0.511 5.836 1.000 0.000 1.000
0.192 14.339 0.744 0.256 0.662
Normalization of simulation data is done in the range of 0 to 1. 0.254 11.906 0.818 0.182 0.733
The obtained S/N ratio data are converted to normalized values
using Eqs. (3) and (4) for smaller the better criterion and bigger
the better criterion respectively.
Table 5
maxx0i ðkÞ x0i ðkÞ Analysis of Grey relational coefficient for strain under heavy load in top ring (et2).
xi ðkÞ ¼ ð3Þ
maxx0i ðkÞ minx0i ðkÞ et2 S/N Normalised Deviation GRC
1366.000 62.709 1.000 0.000 1.000
x0i ðkÞ minx0i ðkÞ 682.000 56.676 0.439 0.561 0.471
xi ðkÞ ¼ ð4Þ 51.957
maxx0i ðkÞ minx0i ðkÞ 396.150 0.000 1.000 0.333
1123.000 61.008 0.842 0.158 0.760
761.440 57.633 0.528 0.472 0.514
1117.000 60.961 0.837 0.163 0.755
4.3. Deviation sequence
1336.000 62.516 0.982 0.018 0.965
611.100 55.722 0.350 0.650 0.435
Deviation sequence is calculated using Eq. (5) 497.770 53.941 0.184 0.816 0.380
Doi k ¼ x0 ðkÞ xi ðkÞ ð5Þ
Grey relational coefficients are calculated based on deviation et2 S/N Normalised Deviation GRC
sequence and S/N ratio normalization values following Eq. (6) 1247.000 61.917 0.861 0.139 0.783
646.000 56.205 0.420 0.580 0.463
Dmin þ fDmax
cðx0 ðkÞ; xi ðkÞ ¼ Þ ð6Þ 415.240 52.366 0.124 0.876 0.363
Dmin þ fDmax 376.000 51.504 0.057 0.943 0.347
1533.000 63.711 1.000 0.000 1.000
Were, 589.050 55.403 0.358 0.642 0.438
Dmin = min. min D0, (k) 697.630 56.873 0.472 0.528 0.486
Dmax = max. max D0, (k) 345.360 50.765 0.000 1.000 0.333
D0 (k) is the deviation sequence & 1384.000 62.823 0.931 0.069 0.879
Table 3 Table 8
Analysis of Grey relational coefficient for Volume. Analysis of Grey relational coefficient for strainunder light load in bottom ring (eb1).
Volume S/N Normalised deviation GRC eb1 S/N Normalization deviation GRC
36,730 91.300 0.000 1.000 0.333 737.750 57.3582 0.864 0.136 0.786
49,110 93.823 0.550 0.450 0.526 386.480 51.7425 0.441 0.559 0.472
62,310 95.891 1.000 0.000 1.000 249.200 47.931 0.154 0.846 0.372
52,940 94.476 0.692 0.308 0.619 217.900 46.7651 0.066 0.934 0.349
49,300 93.857 0.557 0.443 0.530 909.080 59.172 1.000 0.000 1.000
55,120 94.826 0.768 0.232 0.683 346.620 50.7971 0.370 0.630 0.442
53,470 94.562 0.711 0.289 0.633 406.640 52.1842 0.474 0.526 0.487
58,670 95.368 0.886 0.114 0.815 196.840 45.8823 0.000 1.000 0.333
56,570 95.052 0.817 0.183 0.732 820.790 58.2846 0.933 0.067 0.882
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V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx
Table 9
Ranking the performance parameters of force sensor.
Table 12
Analysis of variance (ANOVA).
Table 10
gopt ¼ T þðAð1=2=3Þ TÞ þ ðBð1=2=3Þ T þ ðCð1=2=3Þ TÞÞ ð8Þ
Ranking of Grey relational grade of predicted model.
T = overall mean of the response
HU(A) TU(B) HL(C) TL(D)
Að1=2=3Þ ; Bð1=2=3Þ ; Cð1=2=3Þ = average values of response at the first or
L1 0.567 0.718 0.591 0.715
L2 0.620 0.565 0.584 0.573 second or third levels of parameters A, B and C respectively.
L3 0.647 0.550 0.658 0.546 The best combination of the process parameter is set with
Max 0.647 0.718 0.658 0.715 A3B1C3D1 from the response table for grey relational grade as
Min 0.567 0.550 0.584 0.546
shown in Table 10.
Delta 0.080 0.168 0.074 0.170
Rank 3 2 4 1
Simulation is carried out again based on predicted model
dimensions. Predicted validation grey relational grades are calcu-
lated using Eq. (7). The predicted and experimental values of opti-
mal process parameters are tabulated in Table 11.
1 Xm
cðx0 ; xi Þ ¼ cðx0 ðkÞ; xi ðkÞÞÞ ð7Þ
m i¼1
5. Analysis of variance
Grey relational grades are obtained as shown in Table 9 and
variations in grade values are as shown in Fig. 4.From table 9, it The maximum deflection in top ring under light load, volume of
is seen that experiment 7 showing the best response values each model, maximum strain value in top ring and bottom ring
amongst all experiments, as larger the grey relational grade; so, under light load (et1, eb1), maximum strain value in top ring and
ranked one as the corresponding characteristics is the better. bottom under heavy load (et2, eb2) are considered as responses
After calculating grey relational coefficients, it is required to for designed experiments and analysis of variance (ANOVA) is car-
predict the value of grey relational grade and also to find optimal ried out for each to find most significant parameters which affect
Table 11
Predicted and experimental values of optimal parameters.
Sr. No. Process Parameters Initial Setting Predicted Value FEA Validation
1 Optimal Parameters A3B1C3D2 A3B1C3D1 A3B1C3D1
2 Volume (mm3) 53,470 47,170
3 Deflection (mm) 0.511 0.65075
4 HSU 1336 1647
5 HSL 697.630 1515
6 LSU 1080 1082
7 LSL 406.640 893
8 Grey Relational Grade 0.762 0.905 0.911
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V.A. Kamble, J.K. Kittur and V.D. Shinde Materials Today: Proceedings xxx (xxxx) xxx