Mounting Plates 101
Load cells are utilized in various applications, from structural rocket testing to integration in advanced robotics. The mounting profoundly influences the accuracy and reliability of a load cell’s measurements. A mounting plate is an engineered support foundation designed to provide a stable and prepared surface for a load cell.
More than a simple component, these plates are meticulously crafted to optimize load cell performance by efficiently distributing the applied load across the supporting structure. They provide the solidity that ensures the sensor operates within its specified parameters. Mounting plates are machined to the tightest specifications, often with flatness tolerances as low as 0.0002 T.I.R. (Total Indicator Runout). This meticulous attention to detail ensures a flat, smooth mating surface for the load cell, minimizing local deformation and maximizing measurement accuracy.
The dedicated, high-quality surface of Interface Mounting Plates addresses common challenges such as uneven load distribution, thermal expansion, and potential side loads, often eliminating the need for additional, complex assemblies.
Five Reasons Mounting Plates Maintain Accuracy and Stability
Interface Mounting Plates are meticulously engineered plates that provide additional stability and a precise foundation essential for optimal load cell performance. A load cell is a highly sensitive sensor designed to detect minute changes in force. Any external interference can introduce errors into its readings, no matter how small. Mounting plates address several key challenges, including these top five.
#1 Load Distribution – Mounting plates’ primary function is evenly distributing the applied load over the supporting structure. Without proper distribution, localized stresses can occur, leading to inaccurate readings and potential damage to both the load cell and the foundation.
#2 Prepared Surface – To operate correctly, load cells require a flat, stable, and precisely machined surface. Mounting plates provide this ideal foundation, ensuring consistent contact and preventing irregularities in the mounting surface from affecting measurements.
#3 Minimizing Deflections and Crosstalk – In any force measurement system, deflections, even microscopic ones, can introduce errors. This is particularly crucial with multi-axis sensors where off-axis loading due to plate bending can lead to apparent crosstalk between different measurement axes. Mounting plates, especially those designed with stiffness in mind, prevent such deflections, maintaining the integrity of the measurement.
#4 Thermal Expansion and Side Loads – Structures expand and contract with temperature changes, and external forces like wind loading or shifting loads can introduce significant side loads. Interface mounting plates, particularly the top plates, are designed to accommodate these movements without compromising the load cell’s accuracy. In contrast, the high side load capacity of Interface load cells often eliminates the need for separate expansion assemblies.
#5 Emulating Calibration Conditions – A load cell should be used in conditions that closely mimic its calibration environment for the most accurate results.
How Interface Mounting Plates Achieve Superior Performance
Interface’s commitment to precision engineering is evident in the design and manufacturing of our mounting plates. Interface mounting plates are crafted from the best-grade alloy steel and stainless steel. These materials are chosen for their strength, durability, and ability to maintain their integrity under various loading conditions.
While mounting plates are generally crucial for compression load cells, it’s important to note that they are specifically designed for this purpose and will not adequately support a universal load cell used in tension. This highlights the specialized nature of these components.
Key Features and Benefits of Interface Mounting Plates
- Seamless Design: Interface Mounting Plates are designed to work seamlessly with Interface load cells, ensuring optimal compatibility and performance.
- Quality Material and Machining: Made with the highest-quality components and processes, from material selection to precision machining, every step in the manufacturing process is geared toward delivering superior quality and reliability.
- Performance Specifications: The mounting plates are created to maintain the specifications of the intended product. This is a crucial benefit, as they actively contribute to preserving the load cell’s accuracy and performance specifications.
- Support: They are engineered to distribute the load over the foundation of the supporting structure, preventing localized stress and ensuring even force application.
- Contact Surface: This provides a prepared surface for the load cell, guaranteeing a flat, stable, and precisely machined interface for optimal contact.
- Easy Installation: Mounting plates eliminate the requirement for expansion assemblies in most installations. Thanks to the design of the top plate and the high side load capacity of Interface load cells, external expansion mechanisms are often unnecessary, simplifying installation and reducing complexity.
- Standard and Custom Options: As our online datasheet defines, Interface has a wide range of mounting plates. Available in standard and custom options: Interface offers a wide range of standard models: TP-101, TP-102, TP-103, TP-104, TP-301, TP-302, TP-303, BP-101, BP-102, BP-103, BP-104, BP-108, BP-302, BP-303, and BP-308 are available. Interface provides custom solutions for unique application requirements.
Top and Bottom Plate Distinction
Bottom Plates are typically fabricated from mild steel and ground flat. They mate with the load cell and distribute the load evenly over the foundation or supporting structure. They provide the load cell with a prepared surface specifically designed for the sensor.
Top Plates distribute the load, and their hard surface allows movement due to thermal expansion, load shifting, and other side loads. The load cell’s high side-load capacity accommodates these forces.
Double Plate Mounting (Sandwich Mount) is used in situations requiring extremely stiff systems or where localized deformation needs to be minimized; a double plate or “sandwich” mounting arrangement may be used. In such cases, the plates must be suitably thick to ensure uniform deflection.
Beyond Standard Mounting Plates: Force Plates
Interface continues to innovate our accessories and measurement solutions, including our Force Plates. These advanced systems feature multiple multi-axis sensors installed between two plates. Force plates are ideal for applications that require:
- Larger Capacities: When a single 6-axis sensor isn’t sufficient for the applied loads.
- Reaction to High Moments: Their design effectively allows them to react to significant rotational forces.
- Complex Load Introduction: Suitable for scenarios where loads are introduced over a larger area, such as robotic arms, where they provide feedback on forces during operation.
See this actual force plate application in detail, go to Manufacturing: 6-Axis Force Plate Robotic Arm.
It’s worth noting that force plates’ performance depends on their characteristics and other system components. In-situ calibration may be recommended for precise measurements, especially with larger sensors or complex load introductions.
Mounting considerations are paramount in designing any accurate test and measurement system. Interface Mounting Plates are not just accessories but integral components that stabilize load cells, distribute loads effectively, and create the optimal environment for precise force measurement.
By understanding the technical design and utilizing Interface’s high-quality products, engineers can ensure their load cells perform to their highest potential, delivering reliable and accurate data crucial for various applications.
Interface provides comprehensive resources and expert application engineers to help with specific mounting instructions, datasheets, or custom solutions. TIP: Our new Accessories Selection Guide is a valuable resource for pairing Interface products with the available accessories.