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Turning an active component into a sensor means that we can include a transducer in-line in a system and both track data
and perform actions based on the data. As an example, an automated manufacturing line could include a force sensor
on several different machines to track certain data, such as pressing force or torque. Having this sensor included in the
manufacturing line allows the users to track performance or simply track the normal data so when abnormalities occur,
they can determine whether a machine needs a repair or replacement. The active part of the systems means that the
component can act autonomously when the data tells it to, rather than needing human intervention.


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Turning an Active Component into a Sensor


The age of industrial automation and big data is upon us. Manufacturers that fall behind in equipping their facilities
and products with innovation that allows for automated processes, remote monitoring and better efficiency through
technology, will quickly fall behind. This is due to the fact that automation helps to significantly improve process quality
because it eliminates human error. It also creates long-term cost savings by speeding up several processes, or by helping
to monitor products in use and in real-time to optimize performance and stability over time through better data collection.

Among the many technologies that enable automation and better data collection, force measurement plays a significant
role that’s growing with new innovations built for OEM applications. Interface has always provided custom solutions that
allow customers to integrate sensors into a product for real-time monitoring, but we have recently upgraded our own
manufacturing automation to develop OEM application sensors in higher volumes.

One of the most highly requested solutions is turning an active component into a sensor for OEM applications. In today’s
white paper, we’ll be discussing the benefit of this and provide specific application examples that highlight how turning an
active component into a sensor can help our customers reach their automation and big data, as well as performance and
reliability, goals.

How It Works


Including a sensor in a system can be done in a few different ways. Either the system is designed from the beginning to include a force sensor, the sensor can be retrofitted into an old system, or a component can be taken out of a machine and modified to perform the original function but also optimized as a force sensor.

The benefit of retrofitting is that the user can turn an active component into a sensor on old machines, ultimately allowing the user to bring older systems into the automated or Industry 4.0 age at limited costs. However, today, many manufacturers are asking that their products be developed with sensors integrated into the design from the start to meet the requirements of industry 4.0.

There are also quite a few different types of force measurement sensors being used. The types of sensors include pressure, hanging force, weight, torque, collision detection and more. The common industries looking to use force measurement to turn an active component into a sensor include medical, oil and gas, industrial, automotive, agriculture and more.

Applications Examples in the Real World


Interface has worked on or theorized several different applications where the ability to measure force data in real-time and create actions based on the data collected is incredibly valuable. Electronics miniaturization and more advanced sensor technology have allowed us to get to a point where we can develop custom or off-the-shelf force sensors to fit into a wide variety of products and systems, allowing more industries and manufacturers to take advantage of these solutions. Included below is a breakdown of a few examples where we’re able to enhance a system with force sensing capabilities.

One exciting example is in the medical prosthetics sector. Typically, prosthetics are made without any electronic components and are simply created to support a limbless individual with a limited range of motion. Using a force sensor and an electric motor, Interface can help create an actuated limb that provides force feedback and tell the prosthetic joint to move in certain ways. This enhances the overall mobility of the limb and provides the user with more capabilities.


Another way force feedback can be used is in dynamic response for stability. Imagine a container is holding biohazardous waste and needs to be moved from one place to another without spilling over. A force sensor can be used in a stabilization system to provide force feedback whenever the container is off its normal axis and tell the system to stabilize in the other direction.

In the oil and gas industry, force sensors have been used for a long time to measure pressure and force within the pump to allow real-time monitoring and avoid damage. By turning an active component into a sensor within an oil pump, not only can users monitor the activity but can also rest assured that when the sensor provides excessive pressure or force measurements it can automatically shut off the pump without any human intervention.


And, going back to the industry 4.0 example list above, factories around the world can directly gauge components on machines within a manufacturing line to monitor automated processes. This allows the user to monitor performance in real-time. However, in a situation with a lights off facilities, which means the facility continues to run without humans on the floor, an active component being transducerized means it can automatically stop a machine if it is in danger of breaking or disrupting the line and ruining products. This saves costs and reduces overall wastes because hazards are dealt with automatically based on real-time data and automated processes due to the active component being able to also collect data and act upon it.

The potential applications for OEMs to use active components with integrated or retrofitted sensor technology are still being explored, but the benefit of automating and adding capabilities to systems new and old is exciting and incredibly valuable. Interface has invested heavily in these types of capabilities, specifically volume manufacturing and customization, to serve the new age of industry 4.0 and big data.

About Interface OEM Solutions


Interface is a top pick by original equipment manufacturers, because we are an OEM that designs, engineers, builds, and tests the world’s leading precision force and torque measurement solutions.

Interface is the partner you can trust to develop and manufacture the precise standards that are needed for every element we build that is essential in your application. We are experts in engineering Interface products for OEMs to sell as a stand-alone product or component within a product.

Whether you are looking for a uniquely designed precision load cell, torque transducer, multi-axis sensor, or miniature load cell, Interface has the capability and capacity to deliver high volume components. Specifications that are unique to a proprietary component is what we specialize in through our OEM solutions team. We can help with creating customized load pins, tension links, load shackles and instrumentation.

Interface is the partner you can trust to develop and manufacture the precise standards that are needed for every element we build that is essential in your application. We are experts in engineering Interface products for OEMs to sell as a stand-alone product or component within a product.

Whether you are looking for a uniquely designed precision load cell, torque transducer, multi-axis sensor, or miniature load cell, Interface has the capability and capacity to deliver high volume components. Specifications that are unique to a proprietary component is what we specialize in through our OEM solutions team. We can help with creating customized load pins, tension links, load shackles and instrumentation.