Custom multi-component force transducer design using topology optimization

Abstract This paper proposes an innovative design framework for a multi-component force transducer subject to reversible load direction using topology optimization. Multi-component force transducers are used widely in industries ranging from robotics to healthcare. In this work, the proposed design framework is applied to a specific force transducer, a wind tunnel balance used within aeronautic ground testing. The axial component is one of the six components of the wind tunnel balance, and this component is difficult to design because the axial force is typically much smaller than other force components. This paper uses topology optimization to obtain a non-intuitive axial component design. To realize the design requirements, a new design formulation is suggested to amplify the gauge reading under a small axial loading and to suppress the gauge reading under nonaxial loadings. Prototypes are manufactured and their performances are experimentally verified. The proposed framework can be applied to any type of force transducer that needs to amplify a response from a certain force and to suppress the other responses.