Online One-Week Design Sprint
In this collaborative sensor design workshop, we share our experiences on integrating strain gauge (SG) based torque and force sensing across many types of systems and apply them to your specific project. We work over a one week sprint together with your team, helping bring you to a complete integration concept, including SG sensing metal shapes, SG mounting position, customized shapes and mounting for the rotating and stationary PCB, etc. The workshop is tailored to the specific stage you are at in your design process, and begins with us delving into your specific case, and together deciding which topics to focus on during the rest of the workshop.
Sensor Design Topics
We have a whole long list of potential topics for these workshops and will tailor each of them to the specifics needed for your torque/angle sensor needs and specific design challenges.
- System overview: Torque metal + SGs + electronics for our technology
- Delving into your current project stage and topology constraints (if any), current design (if any), and together deciding which further topics to focus on or skip
- Key performance metrics: Zero-point stability, small torque measurement, bandwidth/latency, and how these compare to other sensing methods
- Sensing metal shape: Tube vs. spokes vs. disc, and bending vs. shear strain
- Sensing metal materials, and how much strain to design for
- Bending sensitivity: Avoiding aberrant torque signal due to bending. Simple cancellation by adding a second SG vs. mechanically isolating bending forces.
- Asking the right questions in your FEA modeling, and deciding what extent of modeling is warranted/useful
- Together we consider PCB sizes/shapes for your project. Radial space optimized vs. axial space optimized designs.
- Optimizing your specific design for manufacturing – ease and accuracy of strain gauge mounting and wire soldering, integration of PCB holders, and convenient sealant process, including examples
- In-depth SG bonding process: Surface prep, bonding, sealing
- Supply chain considerations: Suppliers of SG and bonding services in Europe/US and in China/India. Cost examples. Bonding outsourcing vs. inhousing.
- Testing and calibration.
Design Workshop Format
5 days of collaborative work, incl. full live support over Slack, where we share design iterations from both sides. At least 1h of daily meetings, including open knowledge sharing of our experience working in the field, tailored to your specific needs/interests.
Example Tailored Schedule
As projects can vary greatly in topology, design constraints – from early design studies to production already getting started. This all influences which topics are most relevant to you. We therefore strive to tailor the workshop to your specific case, and please do not hesitate to reach out about any specific needs you may have.
Find below an example of a tailored sensor design workshop schedule – in this case, for an early stage “clean sheet” design team getting started on a mid-drive for an e-bike.
Collaborative Work
During the workshop days, we provide an online message chatroom (in Slack), where all files can be shared both ways, and where we are available throughout our working hours here for detailed feedback and questions. Between the meetings, we also work on our side reviewing your progressing CAD and making our own adjustments to PCB shapes etc., as well as adjusting and preparing subsequent meeting topics based on how your design progresses / or based on the wishes of participants on where to steer the focus.
You can work in your own tools. We like to use OnShape CAD and open-source tools for FEA.
Instructor
Kristian Lindberg has many years of experience in mechanical design, FEA, electrical design, practical strain gauge sensor design, bonding, and general manufacturing.
Kristian holds a M.Sc.EE from the Danish Technical University.
Inquire below if you are interested in this sensor design workshop.