Design and Fabrication of an Optimized Six-Axis Force-Torque Sensor

Force-torque sensors hold significant applications across various industries, including industrial automation, robotics, aerospace, medicine, and laboratory settings. In this paper the purpose is to optimize, simulate, and fabricate a six-axis force-torque sensor capable of measuring forces and torques along x, y and z axes. This endeavor faces challenges, including the meticulous installation of strain gauges, the design of an optimal structure and the creation of a sensor which is not excessively complex to fabricate. Careful attention is devoted to precise installation of strain gauges due to their sensitivity and crucial role in accurate measurement. Furthermore, the sensor structure is strategically designed to be optimal yet not intricate to fabricate, balancing between accuracy, optimality and feasibility of fabrication. Utilizing a genetic optimization algorithm with multi-objective functions instead of single-objective functions, this paper aims to determine the optimal dimensions. The application of multi-objective functions allows for more nuanced and flexible optimization process, catering to the complex requirements of the sensor design. Subsequently, the final design is simulated using ANSYS software to create a finite element model, providing a detailed analysis of the sensor’s behavior under various conditions. This approach ensures a comprehensive understanding of the sensor’s characteristics and limitations. A comprehensive analysis of the results is carried out, with the primary objective of minimizing manufacturing costs while ensuring that performance characteristics, such as an accuracy level of lOmN for force axes and 3.5mNm for torques, are demonstrated by the sensor. In order to sense strains, 16 Double strain gauges are employed. Sensor circuits are configured using six Wheatstone bridges, and calibration procedure is operated using a setup constructed in human and robot interaction laboratory.