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Controlling rotating systems like power trains, milling and boring machine, rotating measurement devices, implies the knowledge of the force and torque due to a contact of the tool to work pieces or other devices. The highly dynamically tracking of tool loads in a rotating system requires a sensor which is installed in the force flow of the shaft drive. Different areas of design and optimization are incorporated:
- mechanical design to get the right strains for the strain gauges without losing too much stiffness in different degrees of freedom (DOF)
- placing of strain gauges to get an optimum mechanical channel separation
- electrical design of bridges and amplifiers in given design space and optimizing signal to noise ratio
- post processing of signals for optimal decoupling of different DOF.
The requirements, the design process and the integrated solution of a measurement adapter and its performance is shown as case study concerning friction stir welding. The HSK 100 and HSK 40 measurement adapters were developed by ERAS GmbH for Brötje-Automation, a system supplier for aircraft manufacturing equipment.