Recap of Precision Machine Building and Automation Webinar
Machines have a long and fascinating history, starting with human ingenuity. Sensors started finding a place in machines with functional testing using standard low-profile load cells to measure forces, fatigue, and durability.
The use of high-accuracy measurement instruments soon grew into the adoption of miniature sensors for integration into machines for real-time feedback. We now see requirements to transition to wireless and demands for more data using multi-axis sensors, advancing to the automation of functions and control using sensors and instrumentation.
Interface’s webinar, Powering Up Precision Machine Building and Automation is a detailed one-hour technical discussion exploring the essential role of sensor technology in today’s industrial landscape. The recorded event captures key trends, tips, and applications valuable to machine builders, engineers, testing labs, and manufacturers.
The webinar, led by Interface application experts Jeff Boyd and Jason Graham, delves into the critical relationship between machine building and accurate measurement. They review popular sensor technologies used in machines and automation, including load cells, torque transducers, multi-axis sensors, load pins, and digital instrumentation. The conversation provides device working principles, specifications, and ideal applications.
What’s driving the growth of sensors in industrial applications? The need to strategically integrate sensor technology into machine designs for tasks like force control, assembly line monitoring, and robot guidance is on the rise. Sensor data from force, torque, and weight measurement devices are used for real-time process control, condition monitoring, and predictive maintenance, paving the way for a more automated future.
One of the most significant trends in advancing manufacturing is the use of robotics for smart factory automation. These types of machines are designed and coded to perform a variety of mundane and repetitive tasks on a manufacturing line or within an industrial facility. This allows humans to utilize their skills to work on more complex and productive tasks.
The center of gravity (CG) represents the point where the entire weight of the robot can be considered to respond and act. It is a critical factor that determines a robot’s stability and balance, especially during operation. Interface suggests using their force plate option to install at the base of the robotic arm. The 3-axis load cells are installed between two force plates and then at the bottom of the robot, creating one large 6-axis Force Plate. The sensors’ force data is displayed and monitored with two BX8 Multi-Channel Bridge Amplifier and Data Acquisition Systems on the customer’s computer.
Load cells and torque transducers in automation systems enhance task accuracy by providing precise measurement, real-time feedback, consistency, error detection and correction, optimization, quality assurance, and data-driven insights. This results in improved productivity, reliability, and quality of output across various industrial applications.
Press forming is a method to deform different materials. For instance, materials such as steel can be bent, stretched, or formed into shapes. A force measurement solution is required to monitor the forces being applied by the press-forming machine. This ensures quality control and traceability during the production process. For large press forming machines, Interface recommends installing the 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell. When the material is placed under the punch plate to form a shape, the 1000 measures the force applied. The force results captured are sent to the INF-USB3 Universal Serial Bus Single Channel PC Interface Module, where they can be graphed and logged on the customer’s PC with the provided software.
Utilizing Interface’s instrumentation solutions, like our DAQ devices, can provide real-time monitoring, accuracy, comprehensive data capture, variability analysis, quality assurance, process optimization, predictive maintenance, and support for continuous improvement efforts.
Best Practices in Using Interface Products in Machines and Automation Applications
- Proper Sensor Selection: Choose load cells that are suitable for your specific application in terms of capacity, accuracy, size, and environmental conditions. Consider factors such as the type of load (tension, compression, or both), operating temperature range, and required precision.
- Mounting: Ensure load cells are mounted securely and in a manner that minimizes external forces and moments. Follow installation recommendations for mounting orientation and avoid overloading or side-loading the load cells.
- Environmental Considerations: Factors such as temperature, humidity, and vibration can affect load cell performance. To shield the load cells from adverse conditions, use protective enclosures, seals, or coatings.
- Wiring and Connections: Use high-quality cables and connectors to ensure reliable signal transmission and minimize interference. Properly route and secure wiring to prevent damage or accidental disconnection.
- Overload Protection: Effective measures to protect load cells from overloads or impacts are of the utmost importance. This can be achieved using mechanical stops, overload limiters, or protective features integrated into the machine’s control system.
- Regular Maintenance: Perform routine inspections and maintenance checks to identify any signs of wear, damage, or drift in performance. Replace worn components, clean dirt or debris, and recalibrate as necessary to maintain accuracy and reliability.
- Calibration: Regularly calibrate the load cells using certified calibration equipment and procedures. Perform calibration adjustments if environmental conditions significantly change or if accuracy drifts beyond acceptable limits.
- Integration with Control Systems: Integrate load cell measurements seamlessly into the machine’s control system for real-time monitoring and feedback. Use appropriate signal conditioning equipment and communication protocols to interface with PLCs, HMIs, or other control devices.
- Operator Training: Ensure that personnel involved in operating or maintaining the machine are properly trained in handling load cells and interpreting measurement data. Provide clear instructions for troubleshooting common issues and responding to alarms or warnings.
- Documentation: Maintain detailed records of load cell specifications, installation procedures, calibration results, maintenance activities, and any modifications or repairs. Keep documentation readily accessible for reference and compliance purposes.
By following these best practices, you can maximize the performance, reliability, and longevity of load cells in machine-building applications! The ForceLeaders record event provides critical trends and the latest advancements in sensor technology, including miniaturization, wireless integration, and the rise of the Industrial Internet of Things (IIoT)—leverage sensor data to unlock automation potential and build smarter and more responsive machines. Watch the webinar in full to learn more.
Interface Products Highlighted During the Webinar for Use in Machines and Automation
1100 ULTRA PRECISION UNIVERSAL LOWPROFILE® LOAD CELL
1200 AND 1201 SERIES IO-LINK LOAD CELL UNIVERSAL OR COMPRESSION-ONLY
SSLP STAINLESS STEEL LOW PROFILE UNIVERSAL LOAD CELL
AT104 COMPACT SIZE FORCE AND TORQUE TRANSDUCER
AT105 CONTACTLESS FORCE AND TORQUE TRANSDUCER
T31, T32, T33, AND T34 SPINDLE STYLE ROTARY TORQUE TRANSDUCERS
3A SERIES 3-AXIS FORCE LOAD CELLS
6ADF SERIES 6-AXIS DIN FLANGE-TYPE LOAD CELLS
9890 STRAIN GAGE, LOAD CELL, AND MV/V INDICATOR
BX8-AS BLUEDAQ SERIES DATA ACQUISITION SYSTEM WITH INDUSTRIAL ENCLOSURE
ILMP STANDARD STAINLESS STEEL LOAD MONITORING LOAD PIN
WTSATL LIGHTWEIGHT ALUMINUM WIRELESS TENSION LINK
If you want to explore Interface products for your machine building and automation needs, contact us today! Our experts can help you select the right sensor for your specific machine and automation project.
