Study on the interdimensional coupling performance of three-dimensional force sensors used for polarization detection in vibrating screen exciters

Purpose Vibrating screens are widely used for material classification, but their core component – the exciter – can experience polarization phenomena under long-term cyclic loading. Such phenomena may accelerate structural deterioration, cause severe damage to the exciter, and ultimately lead to equipment failure. Therefore, accurate detection and characterization of polarization phenomena in vibrating screens are of great importance. Design/methodology/approach A column-type three-dimensional force sensor was developed to detect polarization phenomena in vibrating screens. Finite element simulations were carried out to examine the strain distribution characteristics under different dimensional conditions. The effects of axial slot length and alternative Wheatstone bridge configurations on the mechanical performance of the sensor were systematically investigated. Findings The results indicate that the optimal strain-zone bridge configuration can more effectively characterize the coupling interference among forces in different directions. Moreover, when the columnar structure is subjected to radial forces in arbitrary directions, its deformation trends remain highly consistent, while axial forces exert a uniform influence on the radial bridge outputs. These findings provide a theoretical basis for improving the decoupling performance of column-type sensors. Research limitations/implications The main limitation of this study is the absence of experimental validation. Nevertheless, the results derived from theoretical analysis can serve as a reasonable prediction and reference for future experimental outcomes. Originality/value This study introduces a novel column-type three-dimensional force sensor together with an optimized bridge configuration strategy for detecting polarization phenomena in vibrating screens. The proposed approach not only enables accurate monitoring of the exciter’s operating state but also offers new insights into the structural design of columnar elastic bodies, thereby contributing to the advancement of multidimensional force sensor technology under complex industrial conditions.