This paper presents the development of an optical force sensor architecture directed to prototyping and cost-effective applications, where the actual force requirements are still not well defined or the most suitable commercial technologies would highly increase the cost of the device. The working principle of this sensor consists of determining the displacement of a lens by measuring the distortion of a refracted light beam. This lens is attached to an elastic interface whose elastic constant is known, allowing the estimation of the force that disturbs the optical system. In order to satisfy the requirements of the design process in an inexpensive way, this sensor can be built by fast prototyping technologies and using non-optical grade elements. To deal with the imperfections of this kind of manufacturing procedures and materials, four fitting models are proposed to calibrate the implemented sensor. In order to validate the system, two different sensor implementations with measurement ranges of ±45 N and ±10 N are tested with the proposed models, comparing the resulting force estimation with respect to an industrial-grade load cell. Results show that all models can estimate the loads with an error of about 6% of the measurement range.
Keywords: Prandtl–Ishlinskii model; cost-effective sensor; hysteresis correction; optical force sensor; perceptron; printable sensor.