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Enhancing Structural Testing with Multi-Axis Load Cells

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Multiple industries use structural tests for quality control, regulatory requirements, failure analysis, predictive maintenance, design and performance verification, and safety assurance.

Structural tests measure the tension, design proofing, and lifecycle fatigue validation. Load cells provide valuable measurement data in structural testing. These tests apply to assessing the structural components for rockets, aircraft, automobiles, EV batteries, heavy equipment, and infrastructure projects.

There are times when more data is valuable beyond a standard load cell. Multi-axis sensors are essential tools for structural testing, providing valuable insights into the behavior of structures under various loading conditions. These sensors measure forces in multiple directions, enabling engineers to identify potential weaknesses, assess structural integrity, and optimize designs.

Multi-axis sensors offer several technical advantages for structural testing compared to traditional single-axis load cells. Interface’s 2-axis, 3-axis, and 6-axis load cells are all excellent options for structural testing.

TIP:  Use the new Interface Multi-Axis Selection Guide to evaluate the different designs, capacities, and capabilities quickly.

Primary Benefits of Using Multi-Axis Load Cells for Structural Testing

  • Extensive data acquisition: The primary advantage of multi-axis sensors is they can simultaneously measure forces in multiple directions, thoroughly analyzing the force distribution on a structure.
  • Improvements to structural design: The data obtained from multi-axis sensors can be used to refine structural design models, leading to more robust, efficient, and safe structures.
  • Reduction in complexity: Multi-axis load cells can replace multiple single-axis load cells, simplifying test setups and reducing the required data channels. The benefits are saving time during test setup and data analysis.
  • High accuracy: Multi-axis load cells are designed to minimize crosstalk between axes, ensuring accurate measurements even when forces are applied in multiple directions, which is critical in structural test data.
  • Early detection of structural issues: Using multi-axis sensors can help to identify subtle changes in structural behavior that may indicate early signs of damage or deterioration, allowing for timely intervention.
  • Versatile measurement device: Multi-axis load cells are used in various structural testing applications, including complex force distributions and dynamic loading conditions, making them versatile tools for structural and civil engineers.
  • Compact form factor: Interface multi-axis load cells are dimensionally suited for testing structures with limited space constraints.

During the Inventive Multi-Axis and Instrumentation Webinar, our application engineers shared significant technical benefits of multi-axis sensors. Watch the full recorded technical seminar here.

  • Improved understanding of reaction loads at boundary conditions
  • Transmissive loads through DUT
  • Bending and side loads
  • Force vector and center of force
  • Boundary load condition verification
  • Expansion of existing test methods

Applications of Multi-Axis Sensors in Structural Testing

Structural health monitoring: These sensors are used to continuously monitor the condition of structures, identifying early signs of damage or deterioration.

Bridge testing: Multi-axis sensors measure bridges’ load distribution and stress levels during various loading scenarios, ensuring their structural integrity.

Aircraft testing: These sensors measure aircraft structures’ aerodynamic forces and vibration response, ensuring their safety and performance.

Civil engineering testing: Multi-axis sensors are employed in testing a wide range of civil engineering structures, including buildings, dams, and offshore platforms. Visit: Infrastructure Solutions

Multi-axis load cells are an ideal technical solution for structural testing because they can simultaneously measure forces in multiple directions, reduce complexity, and improve accuracy. These versatile sensors can be used in structural testing and ongoing structural monitoring.

ADDITIONAL RESOURCES

Multi-Axis Sensor Application Notes

Interface Solutions for Structural Testing

Structural Testing Overview

Modernizing Infrastructure with Interface Sensor Technologies

Interface and Infrastructure Markets Form a Perfect Partnership

Electric Vehicle Structural Battery Testing

Outlining Force Solutions for Structural Outrigging

Performance Structural Loading

Rocket Structure Testing

 

Fatigue Testing with Interface Load Cells

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Engineers rely on fatigue testing to ensure the safety and reliability of their product designs and structures. By understanding how materials behave under repeated loading, engineers can design components resistant to fatigue failure.

Fatigue testing requires accurate and reliable force measurement. Interface uses ‘fatigue-rated’ as an exact specification that defines a special class of load cell design and construction. Interface fatigue-rated load cells are designed to withstand the rigors of repeated loading, which makes them ideal for even the most demanding high cycle count fatigue testing applications.

In a typical fatigue testing setup, Interface fatigue-rated load cells are attached to the test specimen or the test machine, and the cyclic loading is applied according to the test protocol. The load cells continuously record the applied forces or stresses, allowing engineers and researchers to monitor how the material responds to repeated loading.

By analyzing the data from Interface load cells, researchers and material engineers can determine the material’s endurance limit, fatigue life, and stress-strain behavior. This information is invaluable for optimizing material selection, design, and manufacturing processes to enhance product performance and reliability while identifying fatigue and potential failure risks.

The use of fatigue-rated load cells and data logging instrumentation is necessary for most test and measurement applications, particularly when materials, parts, or assemblies are tested for destruction. This is true because an accurate record of the forces at every moment of the tests is the only way an engineer can analyze the stresses that occurred in the moments just before the ultimate failure. Read more about fatigue testing in our Interface’s Technical Library.

Interface Fatigue-Rated Load Cells

1000 Fatigue-Rated LowProfile® Load Cell

1000 High Capacity Fatigue-Rated LowProfile® Load Cell

1500 Low Capacity LowProfile® Load Cell

1208 Flange Standard Precision LowProfile® Load Cell

Profile of a Fatigue-Rated Load Cell

  • Design stress levels in the flexures are about one-half as high as in a standard LowProfile load cell.
  • Internal high-stress points, such as sharp corners and edges, are specially polished to avoid crack propagation.
  • Extraneous load sensitivity is specified and adjusted to a lower level than in a standard LowProfile load cell.
  • All Interface fatigue-rated load cells have a specified service life of 100 million fully reversed, full-capacity loading cycles.

No one can accurately predict exactly when the failure will occur, nor which part of an assembly will be the weakest link that eventually will fail. This is why high cycle count testing is the best way to measure fatigue life. To read more about fatigue testing and fatigue theory, consult Interface’s Load Cell Field Guide.

Fatigue Testing Applications

Interface fatigue-rated load cells are used in various industries, including aerospace, automotive, civil engineering, and manufacturing. They are used to test various products, from aircraft wings and landing gear to furniture and industrial machinery.

How Interface fatigue-rated load cells are used in fatigue testing:

  • Aerospace: Interface fatigue-rated load cells test the durability of aircraft wings, landing gear, and other aerospace components. This helps to ensure that aircraft can withstand the rigors of repeated takeoffs, landings, and flights. These load cells test the materials used for structures and even rockets.
  • Automotive: Interface fatigue-rated load cells test the fatigue life of engine components, chassis, and suspension systems. This helps to ensure that vehicles are safe and reliable and that they can withstand the stresses of everyday driving.
  • Civil engineering: Interface fatigue-rated load cells test the fatigue resistance of bridges, buildings, and critical infrastructure. This helps to ensure that these structures can withstand the loads they are designed to carry and are safe for the public.
  • Manufacturing: Interface fatigue-rated load cells test the fatigue life of industrial machinery, tools, and consumer products. This helps to ensure that these products are reliable and can withstand the demands of everyday use.

Watch how Interface load cells are used in this bike frame testing application.

Interface has specialized in fatigue-rated load cells and their applications since our founding in 1968. Our LowProfile® fatigue-rated load cells provide up to 100 million duty cycles, and the gaged sensors in every load cell are individually inspected, tested, and certified to meet our rigid performance standards.

It is imperative to choose the right load cell for your fatigue testing application. Load cells come in various sizes and capacities, so it is vital to choose one that is right for your fatigue testing application. Ensure you know the maximum load that will be applied to the load cell, the type of loading, the accuracy requirement, and the environmental conditions for testing. Consult with Interface application engineers to find the suitable load cell for your testing requirements.

ADDITIONAL APPLICATIONS AND RESOURCES

CPG Bike Handlebar Fatigue Testing

Interface Specializes in Fatigue-Rated Load Cells

Prosthetics Load and Fatigue Testing App Note

Furniture Fatigue Cycle Testing App Note

Aircraft Wing Fatigue App Note

 

The Criticality of Thrust Measurement Testing in Aerospace

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Interface is a force measurement solutions provider for many of the largest and most innovative aerospace and space systems organizations. Our measurement devices are utilized to test various aircraft and space vehicle components, including thrust testing for jet engines, gas turbines, and propulsion systems.

Thrust measurement is critical when designing and developing aircraft and spacecraft. These critical measurements are used to build and test rocket engines for launch vehicles and missiles. Thrust testing is also vital for maintenance and quality inspections of vehicle engines and systems. By measuring thrust over time, engineers can identify any potential engine problems and take corrective action before they cause a failure.

Thrust measurements ensure rocket and airplane engines produce enough thrust to safely launch, fly, and land. If an engine is not producing enough thrust, it could lead to a catastrophic failure. Trust testing also helps to improve fuel efficiency and reduce emissions.

The force emitted by a thrust engine dictates the size and speed at which a payload can be lifted off the ground. Enormous amounts of thrust are needed to get a spaceship out of the Earth’s atmosphere or propel a jet engine to move faster than the speed of sound. Thrust must be measured precisely because applying too much thrust to an aircraft may damage it, or using too much thrust at a rocket’s liftoff can use too much fuel.

Interface force sensors provide extremely accurate data to assess the amount of force, helping engineers tune thrusters to provide the right amount of force for the size and speed needed to launch or lift their vehicle.

Thrust is measured by placing the thrust engine on a test stand. Then, as the rocket engine burns fuel and creates thrust, the force of the thrust creates compression force on the load cell sensor. As this happens, a mechanical signal is converted to a digital signal, and this data is sent back to the engineer through a data acquisition device, who can then assess, monitor, and record that data.

A load cell used to measure thrust force must be rated for extreme heat. A typical load cell could not provide an accurate measurement when placed in a temperature environment that the sensor’s materials could not handle. Interface offers a wide range of load cells rated explicitly for this type of testing.

To give you a sense of the power and environment of thrust testing, you can see the thrust test of a jet engine in action posted on the U.S. Defense News YouTube channel.

Jet Engine Thrust Testing Application

A customer wanted to conduct a static jet engine thrust test that could accurately determine the engine’s thrust, burn time, chamber pressure, and other parameters, providing invaluable data to propellant chemists and engineers. They needed a high-accuracy load cell with excellent repeatability to withstand thrust forces in very harsh environments. From ignition to burn-out, Interface’s 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell was ideally suited based on their performance for this application.

The load cell reacted to the thrust forces produced by the jet engine, and the signals were collected and recorded to create a “thrust curve” of the engine. The performance of an Interface LowProfile™ Load Cell allowed engineers to be confident in the data acquired from the static testing. Additionally, the repeatability of the load cell resulted in reduced time between tests, making static jet engine thrust testing more efficient. The 9330 battery-powered high-speed data logging indicator captured the data for analysis.

Thrust measurement ensures safety, reliability, and performance.

Interface is a long-time provider of  Aerospace and Defense Industry Solutions.  Here is another video to watch to learn more about Interface’s role in aerospace innovation.

Go here to learn more about thrust and other force test examples in the aerospace industry.

ADDITIONAL RESOURCES

Taking Flight with Interface Solutions for Aircraft Testing

Enabling A Look Way Beyond Yonder

Aerospace Solutions

Interface Space Economy Solutions

The Aviation Industry Soars Using Interface Solutions

Solutions Provider for Aerospace & Defense

Interface Engineered Solutions for Lifting Webinar Recap

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Everything from mechanical engineering designs, equipment materials, and the sensors used in lifting machinery is changing the concept of lifting today. Interface experts Keith Skidmore and Ken Bishop explore types of measurement products, applications, technical considerations, and tips for lifting use cases in the Interface recorded webinar Engineered Solutions for Lifting.

Sensors are central in lifting equipment to maintain safety, quality, compliance, and efficiency. Interface provides a useful product selection online resource for lifting applications. Go to the Lifting Solutions Guide.

Interface load cells can help prevent accidents by providing real-time feedback on the weight of the lifted load. The measurement data helps ensure the lifting machinery is not overloaded or unbalanced, leading to structural failure, tipping over, or injury. Sensor technologies improve quality control by ensuring products are lifted to the correct specifications.

Interface LowProfile Load Cells, Load Pins, Load Shackles, and Tension Links improve efficiency by automating the lifting process. For example, load cells can control the speed and movement of a lifting mechanism, ensuring that the load is lifted safely and efficiently. These measurement sensors can reduce costs by minimizing damage to equipment and products. By preventing overloads and ensuring that loads are lifted safely, load cell devices can extend the lifespan of equipment and prevent costly accidents.

In many industries, regulations require load cells for lifting applications to ensure compliance and overload protection. For example, the Occupational Safety and Health Administration (OSHA) requires the use of load cells in many lifting applications for monitoring and reporting.

Automation of lifting is on the rise. Using robotics and component activation is commonly designed into new equipment and retrofitting existing hardware. These features also provide valuable operating safety and alarm systems based on key measurements. Modernizing equipment to meet today’s and future use cases is important to operators and manufacturers of lifting equipment. This includes utilizing wireless components and using cloud-based data (IoT).

Lifting sensors are more commonly found in settings with high-temperature variances and exposure to extreme environmental conditions. The measurement solutions must withstand these variances while providing continuous monitoring capabilities. Today’s use cases require smaller load cells, like our beam load cells, while not sacrificing precision measurement.

Interface products are used for all types of lifting equipment, apparatus, and machines, including:

  • All Purpose Cranes
  • Patient Lifts and Medical Equipment
  • Drones with Lift and Carry Capabilities
  • Aircraft Lifts and Rigging
  • Lifting Gantry Systems and Mobile Gantry Cranes
  • Jib Cranes
  • Engine and Floor Cranes
  • Scaffold Runway Systems
  • Venue and Entertainment AV Equipment
  • Rigging Equipment
  • Pallet Movers
  • Elevators
  • Loaders and Bulldozers

During the webinar, Interface experts shared tips and best practices. Here is a quick summary of tips for lifting use cases.

Top Measurement Tips for Lifting Use Cases

TIP #1 Select the right force sensor. Factors to consider when selecting a force sensor include the maximum force it can measure, accuracy, weight, dimensions, and environmental conditions for use.

TIP #2 Proper installation will define your application’s success. It is important to install the force sensor correctly to ensure accurate measurements.

TIP #3 Calibrate the force sensor regularly, preferably once a year. Regularly run calibration-grade tests if the load cell is embedded into the lifting device.

TIP #4 Based on each use case, instrumentation can make all the difference in your program. For example, a data acquisition system collects force data to monitor the lifting process, identify potential problems, and generate reports.

TIP #5 Design the lifting system with safety in mind. Force measurement can improve the safety of lifting systems by preventing overloading, detecting imbalances in the load, and monitoring the condition of the lifting equipment.

Tune into the webinar to hear Keith Skidmore and Ken Bishop detail best practices, key considerations to identify stable and unstable lifting, and a thorough review of industry applications using Interface products.

Lifting Applications

Crane Capacity Verification

A customer wants to verify that their crane is strong enough to safely lift a heavy load at its rated maximum load capacity. A wireless solution is needed to avoid long cables and to have a faster installation time. Interface’s Model WTSATL Lightweight Wireless Tension Link Load Cell can measure the load’s maximum capacity. The WTS-RM1 Wireless Relay Output Receiver Modules can also trigger an alarm that can be set when the maximum capacity of weight/force has been reached. The data is transmitted and can be reviewed with the WTS-BS-1-HS Wireless Handheld Display or on the customer’s PC.

gantry crane lifting a heavy container

Gantry Crane Wireless Lifting for Heavy Containers

Gantry cranes are used for mobile and lifting applications in industrial and construction. A weighing system is needed to see if the gantry crane can lift heavy containers or loads, preventing crane failure or accidents. Interface’s WTSLP Wireless Stainless Steel Load Pins can be installed into the corners of the lifting mechanism of the gantry crane, where heavy-loaded containers are lifted and moved. The force results are then transmitted to the WTS-BS-1-HS Wireless Handheld Display for Single Transmitters and a connected computer using the WTS-BS-6 Wireless Telemetry Dongle Base Station.

Patient Lifting Device

In the medical field, sometimes it is necessary to weigh or transfer patients who are disabled and cannot walk. A Hoyer lift is used to move patients around. A manufacturer would like a force system to weigh disabled patients and see the maximum weight it can hold. Interface’s WTS 1200 Standard Precision LowProfile® Wireless Load Cell is attached to the top of the Hoyer lift. The force results are wirelessly transmitted to the medical laptop through the WTS-BS-6 Wireless Telemetry Dongle Base Station.

Find additional productions and solutions in our Lifting Solutions Overview.

Lifting Solutions Brochure

Force Measurement Sensors are Essential to Modern Industrial Machinery

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Industrial machinery plays a vital role in the global economy. It helps to improve productivity and efficiency, and it is essential to produce many of the goods we rely on daily.

Industrial machinery use cases range from equipment used in manufacturing and construction to transportation and robotics. Force measurement sensors and instrumentation play a critical role in ensuring industrial machinery’s safe and efficient operation.

Interface sensor technologies, including our load cells and multi-axis sensors, provide critical data for various machinery designs and functions. Interface analog and digital instrumentation products are available to amplify, condition, and display the signals from force measurement sensors.

The accuracy of force, torque, and weight measurements guide industrial machinery’s design and performance mechanisms.

What types of industrial machinery are using Interface measurement products today?

  • Machine tools used for grinding, drills, and lathes
  • Fabrication apparatus used for bending, shearing, and welding
  • Assembly equipment for production environments that include conveyor belts, robotic arms, and picking devices
  • Testing, quality control, and safety inspection equipment
  • Heavy equipment operational controllers for forklifts, cranes, and hoisting gear
  • Construction machinery such as loaders, bulldozers, and lifts

Industrial machinery is prevalent in manufacturing vehicles, aircraft, consumer goods, medical devices, and pharmaceuticals. Heavy-duty machinery is standard in energy production, mining, forestry, agriculture, and transportation.

The machines’ quality heavily depends on the accuracy of measurements used in the initial design, retrofitting, production, and practice. Interface products provide the products that enable machines to operate at peak performance safely and efficiently. Learn more in our new Interface Industrial Machinery Solutions, a part of Industrial Automation market offerings.

How Interface Measurement Solutions Used in Industrial Machinery

Machine Safety Monitoring

Interface products are used for monitoring the performance of machines and for management in sensing potential problems before they cause a failure. Interface measurement technologies are used in construction machinery to enable operators to gauge the force applied to materials, preventing overexertion and potential damage. Read Interface Solutions for Safety and Regulation Testing and Monitoring

Heavy Machinery and Lifting Equipment

In material handling equipment, force sensors help prevent accidents and injuries. Interface load cells, including load pins and shackles, monitor loads, weight, and distribution. Learn more about lifting solutions in our Engineered Solutions for Lifting Webinar.

Manufacturing and Production Machines

Manufacturers rely on Interface sensor solutions in industrial machines such as injection molding machines to monitor the force applied to the mold or how they are used in machines to ensure correct product packaging. The efficiency of machines is enhanced by correctly measuring the forces applied during different operations. Force sensors help ensure products are assembled correctly and within tolerance on production lines.

Industrial Automation Machines and Robotics

Interface sensors in industrial machines such as robots allow for more precise and delicate tasks that measure force at touch and throughout the entire operation. In machine tools, load cells assist in monitoring cutting forces and prevent damage to tools and workpieces. In robotic arms and automated assembly lines, force sensors provide precise force application during welding, riveting, and material handling.

Benefits of Using Interface Products in Industrial Machinery

  • Improved safety: Load cells can help prevent accidents and injuries by monitoring the weight and distribution of loads and ensuring that machines operate correctly.
  • Increased productivity: Force measurement sensors can help improve machines’ efficiency by optimizing the force applied during different operations. Force measurement sensors can help reduce machine downtime and enhance the quality of products with accurate data, helping to make intelligent decisions.
  • Reduced waste and operating costs: Measurement devices can help to reduce costs by preventing machine failures and improving the quality of products.

Force measurement sensors and instrumentation are essential components of modern industrial machinery. They ensure the safe, efficient, and productive operation of these machines. Contact Interface application engineers to evaluate the best sensor technologies for your specific test and measurement pe failures and improving the quality of products.

ADDITIONAL RESOURCES

Hydraulic Press Machines and Load Cells

Sanding Machine Force Monitoring

Interface Solutions for Machine Builders

Metal Press Cutting Machine

Laser Machine Cutting Force App Note

Ice Machine Weighing

Force Measurement Testing Improves Products and Consumer Safety

Cobot Safety Programming

Crane Capacity Verification App Note

The Aviation Industry Soars Using Interface Solutions

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Interface is proud to offer a diverse range of force, torque, and weight measurement solutions to the aviation industry.

A sector within the aerospace industry, Interface aviation solutions are products we supply for use in the design, engineering and operation of aircraft.

The quality of our products, including the reliable form factor design, proprietary strain gages, and rugged materials, are built to withstand the rigorous performance standards and environments that aircraft safety demands. It is why Interface is a provider of choice for test and measurement solutions in the aviation industry. Check out our new Aircraft Solutions overview here.

The aircraft and aviation industries are vast and complex with many different sectors. Our products are currently used in commercial, general and military aviation, aviation infrastructure, equipment and systems. In addition to the mechanical component testing, Interface often supplies load cells, torque transducers and instrumentation for use in aviation training, education, research and development.

While aviation systems embody an extensive collection of interconnected components and technologies, this complexity does not lessen the requirements for rigorous sensor-based test and measurement programs for every part. Interface products help to collect critical data on the performance of aircraft components and systems. These aviation systems include aircraft, air traffic control, navigation and communication systems, infrastructure, ground support equipment, airport transport vehicles, aircraft testing labs, and tools.

We work with aeronautical and mechanical engineers who are involved in designing, developing, and maintaining aircraft, propulsion systems, avionics, and air traffic management technologies. Interface load cells and transducers provide accurate and reliable measurements of forces, weights and torques of aviation components and systems.

How does the aviation industry use Interface measurement solutions?

  • Aircraft engine manufacturers use our load cells and torque transducers to measure the operating performance within their design limits and for diagnostics and troubleshooting. Read: Aircraft Engine Hoist
  • Aviation system developers integrate our sensors into equipment and parts to provide continuous force monitoring and to trigger alarms for maintenance.
  • Rotorcraft part makers need to assess the loads and torques on blades and other components to the aircraft is safe to fly and to identify any weaknesses based on accurate measurements. Read:Propeller Testing
  • Landing gear experts use our load cells to confirm that the gear can withstand the forces encountered during takeoff, landing, and taxiing. Read: Landing Gear Joint Testing
  • Aircraft structures must be strong enough to withstand the forces encountered in flight. Testing is standard for cycle counts, environmental tests and assessment of materials. Interface products are used for assessing structural like wings and fuselages in wind tunnel tests. Read: Interface Solutions for Structural Testing and Aircraft Wing Fatigue App Note
  • Flight control systems are using measurement sensors to test and monitor the components used for various controls. Read: Aircraft Yoke Torque Measurement
  • In-flight systems and simulators utilize precision measurement devices to provide vital data that monitors aviation and aircraft health. This is important for real-time assessments and for training purposes. It is essential for the long-term growth of the industry to provide the best tools and equipment to learn the values of accurate measurement and how it impacts performance and safety.

Beyond the essential manufacturers of aircraft parts, aviation systems, and equipment, Interface supplies many of the leading aviation testing labs with load cells, load pins, torque transducers, wireless devices and instrumentation. The quality of our products is built to withstand the rigorous performance standards and environments that aircraft safety demands.

Our products are used for static testing, material testing, torque testing, fatigue testing, stress and tension tests, dynamic testing, environmental and wind tunnel testing, structural tests and compression testing. We also supply the aviation industry with measurement solutions for rigging, lifting, weighing and monitoring of equipment in use. Check out our Aircraft Lifting Equipment App Note.

Learn more about our range of solutions in this Airplane Jacking System solution.

The aviation industry is a dynamic and ever-changing industry, and the sectors within it are constantly evolving. New innovations in the aviation require extensive testing and accurate measurement. The aviation industry is a complex and demanding industry, and the development of new technologies requires a rigorous testing process.

The fact that Interface offers an extensive array of force measure devices in different models, capacities, configurations and capabilities helps aviation system suppliers and manufacturers. Our load cells and sensor technologies are used to measure a wide range of factors, such as tensions, weights, forces, and torques. This information can be used to ensure the safety and reliability of aircraft and their components.

With a surplus of options that can meet the specifications of each use case and testing application, Interface is an experience and preferred provider to the aviation industry.

ADDITIONAL RESOURCES

Interface Supports Wind Tunnel Testing

LIFTING: Airplane Jacking System

LIFTING: Aircraft Engine Hoist

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Wing Fatigue App Note

Aircraft Screwdriver Fastening Control App Note

Airplane Static Testing Case Study

Interface Supports Wind Tunnel Testing

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In the development of an airborne vehicle, like a plane or helicopter, wind tunnel systems are used to gather data across a variety of tests related to the aerodynamics of the vehicle’s design. Whether an object is stationary or mobile, wind tunnels provide insight into the effects of air as it moves over or around the test model. Interface is a supplier of measurement solutions used for aircraft and wind tunnel testing.

Wind tunnels are chambers that test small scale model versions of full systems, or in some cases, parts and components, depending on the size and capabilities of the wind tunnel. They work by allowing the engineers to control airflow within the tunnel and simulate the types of wind force that airplanes and other aircraft will experience in flight. Wind tunnels are also used for testing automobiles, bicycles, drones and space vehicles.

By taking careful measurements of the forces on the model, the engineer can predict the forces on the full-scale aircraft. And by using special diagnostic techniques, the engineer can better understand and improve the performance of the aircraft.

The process for measuring the force and how it reacts to this force works by mounting the model in the wind tunnel on a force balance or test stand. The output is a signal that is related to the forces and moments on the model. Balances can be used to measure both the lift and drag forces. The balance must be calibrated against a known value of the force before, and sometimes during, the test.

Interface’s strain gage load cells are commonly used in wind tunnel testing due to their quality, accuracy and reliability. The instrumentation requirements often depend on the application and type of test. The range of options for both load cells and instrumentation vary based on scale, use, cycle counts, and data requirements.

Instrumentation used in wind tunnel testing can be as simple as our 9325 Portable Sensor Display to a multi-channel data acquisition system. Interface analog, digital and wireless instrumentation solutions provide a range of possibilities. As is the case, wind tunnel testing is typically very sensitive. It is important to calibrate the instrumentation before each test to measurement accuracy.

Types of Wind Tunnel Tests Using Force Measurement Solutions

  • Lift and drag: Load cells are used to measure the two most significant forces that impact aircraft design. Lift is the force that acts perpendicular to the direction of airflow and keeps the craft airborne. Drag is the force that acts parallel to the direction of airflow and opposes forward motion.
  • Side force: This force acts perpendicular to both the direction of airflow and the lift force. It is caused by the difference in pressure between the upper and lower surfaces of the aircraft.
  • Moments: Moments are the forces that act around a point. The most common moments measured in wind tunnels are the pitching moment, the yawing moment, and the rolling moment.
  • Stability and control: Tests conducted to measure the stability and controllability of an aircraft are commonly using force measurement solutions for aircraft design changes or integrating new parts into an existing model.
  • Performance: Particularly important with new designs, engineers use these tests to measure the simulated flight performance under maximum speed, range and fuel efficiency.

The specific tests that are conducted in a wind tunnel depend on the project requirements.

Multi-Axis Sensors for Wind Tunnel Testing Applications

In measuring the forces of a wind tunnel test, multi-axis sensors offer the perfect solution for collecting as much data as possible across every axis, giving the engineer a more complete picture on the aerodynamics of the plane. In fact, Interface has supplied multi-axis load cells for use in several wind tunnel testing applications, for OEMs, testing facilities and part makers.

We offer a variety of multi-axis options including 2, 3 and 6-axis standard and high-capacity configurations depending on testing and data requirements of the user. These sensors can precisely measure the applied force from one direction with little or no crosstalk from the force or moment. Interface products provide excellent performance and accuracy in force and torque measurement.

To match the demands of the volumes of data available using multi-axis sensors in wind tunnel testing, Interface often provides several data acquisition instrumentation solution along with our BlueDAQ software.

Wind Tunnel Test Application

A major aerospace company was developing a new airplane and needed to test their scaled model for aerodynamics in a wind tunnel, by measuring loads created by lift and drag. Interface Model 6A154 6-Axis Load Cell was mounted in the floor of the wind tunnel and connected to the scaled model by a stalk. The wind tunnel blew air over the scaled model creating lift and drag, which was measured and compared to the theoretical airplane models. The output of the 6-axis sensor was connected to the BX8-AS Interface BlueDAQ Series Data Acquisition System, which was connected via USB cable to a computer. Using this solution, the company was able to analyze the collected data and made the necessary adjustments in their design to improve the aerodynamics of their theoretical airplane models.

Interface supports wind tunnel testing and all uses of force measurement in the advancements in aeropspace.

Wind tunnel testing is critical to the aircraft industry, as well as other industries like automotive and space. Interface has been providing multi-axis sensors and strain gage load cells to industry leaders and wind tunnel operators. We understand the unique needs of this type of testing and the instrumentation options that work best with our high-accuracy sensors. We also can work to provide custom solutions, load cells for use in extreme environmental conditions. Contact us to get the right solution for your specific testing program.

Additional Resources

Aircraft Wing Fatigue App Note

Airplane Jacking System

Interface Airplane Static Testing Case Study

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Yoke Torque Measurement

Aircraft Screwdriver Fastening Control App Note

Interface’s Crucial Role in Vehicle and Urban Mobility Markets

Rigging Engineers Choose Interface Measurement Solutions

 

Interface Airplane Static Testing Case Study

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Interface is a preferred supplier of precision force measurement solutions for the aerospace industry and our products are frequently used to help perform critical testing on all types of commercial, industrial, and military aeronautical vehicles.

During the engineering and manufacturing of all types of aircraft, static testing is commonly used to validate designs and components, measure assembly and affirm performance and regulatory requirements. Accuracy and reliability of any type of sensor and instrumentation used during these tests is vital to the testing programs and ensures the safety for pilots, passengers and the public at large when these vehicles take flight.

What is a static test?

Static testing is a type of structural test which allows engineers to analyze an aircraft’s structural integrity while grounded. This is a useful part of the testing process before taking flight, which helps speed up the certification process as it does not require a completed and fully functional aircraft through the entire manufacturing process for aerospace vehicles.

How does Interface place a role in static testing for aircraft?

Our force measurement solutions such as precision load cells and torque transducers play an important role in static testing as force analysis results are used in nearly all structural tests. Interface manufacturers both off-the-shelf and custom solutions that are used by leading part and aircraft manufacturers. These sensor products are used on a static test stand to test frame structure integrity, endurance, and life cycles, with the goal generally being to validate aircraft design and ensure specified criteria are met. The strict accuracy is necessary because in aerospace, every micrometer and gram make a difference in both the performance and safety of an aircraft design.

Static Testing Applications for Airplane Jacking System and Jet Engine Thrust Tests

In the new Airplane Static Testing case study, we have detailed two application examples and how Interface products are specifically used in in static testing of aircraft. These examples demonstrate how our products are applied and utilized for testing an airplane jacking system and provide a solution for a jet engine thrust test.

In the airplane jacking system static testing application, our WTS 1200 LowProfile® Wireless Load Cells are placed on jack points measuring weights and forces on an aircraft. Our advanced Wireless Telemetry System provided instrumentation to capture real-time data, such as the individual load cells attached to each jack point, or any set alarms that may go off if it has exceeded a certain amount of force.

For the jet engine thrust static testing, Interface’s 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell was best suited for this static testing. The load cell reacted to the thrust forces produced by the jet engine and the signals were collected and recorded to create a “thrust curve” of the engine.

To read the Airplane Static Test case study it in full, go here.

To learn more about the many ways Interface can serve the aerospace industry with premium force products and total solutions, watch this video to see the types of products we supply for static and other test and measurement programs in this industry.

Additional Resources

Examining Interface Aerospace Industry Solutions

Aerospace Brochure

Solutions Provider for Aerospace & Defense

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Screwdriver Fastening Control

Aerospace and Defense Industry Solutions

Aerospace and Defense Case Study

 

Taking Flight with Interface Solutions for Aircraft Testing

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As a top supplier of premium force measurement solutions for the aerospace industry, one of our critical areas requiring precision accuracy and high-quality products is for testing airplanes. Interface load cells, torque transducers, and instrumentation are used regularly in testing of all types of aerospace apparatus, components, and machines, along with embedding our force sensors in aircraft for ongoing simulation tests and inflight data acquisition.

Aircraft, spacecraft, military, and defense companies such as Boeing, Airbus, Lockheed, Northrop Grumman, Bombardier, Embraer, Gulfstream, NASA, and Cessna and many others in the supply and production lines utilize Interface load cells for thrust, wing, static, and fatigue testing. While structural test applications use many types of LowProfile™ load cells, Interface also offers a wide variety of load washers, load buttons and miniature tension and compression load cells for test, production, and control monitoring applications for aircraft.

Why do aircraft testing professionals prefer Interface solutions?  One reason is our moment and temperature compensated load cells use proprietary alloy strain gages for extreme accuracy and reliability that is unmatched by other brands. Using eight proprietary strain gages per sensor, our 4mV/V output well exceeds the performance requirements for testing these specialized aerospace vehicles.

In addition, before the airplanes are even assembled, every manufactured part and components must go through rigorous testing. There are hundreds of machines that are used on the production line for the hundreds of thousands of components needed to complete these specialized craft. Interface load cells and torque transducers are found on many of these production and test machines. Our products are used to provide a wealth of insight to guide manufacturers through research, development and final build. Because testing is so inherent for any of these parts, Interface products provide reliability and accuracy when there are no exceptions.

We recently developed several new application notes on ways our products are used to test airplanes. Included below is a preview of a few of the latest additions to our application notes catalog.

Jet Engine Thrust Test

A customer wanted to conduct a static jet engine thrust test that can accurately determine the engine’s thrust, burn time, chamber pressure, and other parameters, providing invaluable data to propellant chemists and engineers. They needed a high accuracy load cell with excellent repeatability to withstand thrust forces in very harsh environments. Interface offered a 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell, which is ideally suited based on their performance for this application. The load cell reacts to the thrust forces produced by the jet engine and the signals are collected and recorded to create a “thrust curve” of the engine. The performance of an Interface LowProfile™ Load Cell allowed the engineers to be confident in the data acquired from the static testing. Additionally, the repeatability of the load cell results in reduced time between tests, making static jet engine thrust testing more efficient. Read the new Jet Engine Thrust Test application note here.

Aircraft Yoke Torque Measurement

An aircraft manufacturer wanted to measure the torque of their aircrafts yoke or control wheel. They also wanted to monitor the torque and forces applied to ensure that the aircrafts controls are operating properly. Interface suggested using the AT103 2-Axis Axial Torsion Load Cell to measure both torque and force within this single sensor. It can be installed inside of the yoke, and can measure the rotation of the yoke, and the forward and backwards movements. Data can be measured and paired with the SI-USB4 4-Channel USB Interface Module and displayed with the customer’s laptop. Using this solution, the customer was able to measure and monitor the torque and force of the yoke control. Read the Aircraft Yoke Torque Measurement application note.

Aircraft Engine Hoist

An aerospace company wanted to test their aircraft engine hoist in order to safely lift, remove, or install engines efficiently and safety. Interface’s solution was to install WTSSHKB-HL Wireless Bow Shackles to the aircraft engine hoist. A heavy load was added to the hooks where the aircraft engine would be. Results from the heavy load are then sent wirelessly to both the WTS-BS-4 USB Industrial Base Station attached to the customers computer or laptop, and the WTS-1-HS Handheld display for single transmitters. With these products, the customer was assured that the aircraft engine hoist was strong and secure enough to lift a heavy engine when installing or removing an engine inside of an aircraft. Learn more about the Aircraft Engine Hoist application here.

Our expert application engineers help our customers by providing technologies that provide exceedingly accurate measurement used in all types of testing, including structural, static and fatigue. For more information on Interface and its solutions designed for airplanes and other aerospace applications, please visit https://www.interfaceforce.com/solutions/aerospace.

Additional Aircraft Testing Resources

Aircraft Wing Fatigue App Note

Aircraft Screwdriver Fastening Control App Note

Aircraft Lifting Equipment App Note

Examining Interface Aerospace Industry Solutions

 

Solutions

Enhancing Structural Testing with Multi-Axis Load Cells

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Multiple industries use structural tests for quality control, regulatory requirements, failure analysis, predictive maintenance, design and performance verification, and safety assurance.

Structural tests measure the tension, design proofing, and lifecycle fatigue validation. Load cells provide valuable measurement data in structural testing. These tests apply to assessing the structural components for rockets, aircraft, automobiles, EV batteries, heavy equipment, and infrastructure projects.

There are times when more data is valuable beyond a standard load cell. Multi-axis sensors are essential tools for structural testing, providing valuable insights into the behavior of structures under various loading conditions. These sensors measure forces in multiple directions, enabling engineers to identify potential weaknesses, assess structural integrity, and optimize designs.

Multi-axis sensors offer several technical advantages for structural testing compared to traditional single-axis load cells. Interface’s 2-axis, 3-axis, and 6-axis load cells are all excellent options for structural testing.

TIP:  Use the new Interface Multi-Axis Selection Guide to evaluate the different designs, capacities, and capabilities quickly.

Primary Benefits of Using Multi-Axis Load Cells for Structural Testing

  • Extensive data acquisition: The primary advantage of multi-axis sensors is they can simultaneously measure forces in multiple directions, thoroughly analyzing the force distribution on a structure.
  • Improvements to structural design: The data obtained from multi-axis sensors can be used to refine structural design models, leading to more robust, efficient, and safe structures.
  • Reduction in complexity: Multi-axis load cells can replace multiple single-axis load cells, simplifying test setups and reducing the required data channels. The benefits are saving time during test setup and data analysis.
  • High accuracy: Multi-axis load cells are designed to minimize crosstalk between axes, ensuring accurate measurements even when forces are applied in multiple directions, which is critical in structural test data.
  • Early detection of structural issues: Using multi-axis sensors can help to identify subtle changes in structural behavior that may indicate early signs of damage or deterioration, allowing for timely intervention.
  • Versatile measurement device: Multi-axis load cells are used in various structural testing applications, including complex force distributions and dynamic loading conditions, making them versatile tools for structural and civil engineers.
  • Compact form factor: Interface multi-axis load cells are dimensionally suited for testing structures with limited space constraints.

During the Inventive Multi-Axis and Instrumentation Webinar, our application engineers shared significant technical benefits of multi-axis sensors. Watch the full recorded technical seminar here.

  • Improved understanding of reaction loads at boundary conditions
  • Transmissive loads through DUT
  • Bending and side loads
  • Force vector and center of force
  • Boundary load condition verification
  • Expansion of existing test methods

Applications of Multi-Axis Sensors in Structural Testing

Structural health monitoring: These sensors are used to continuously monitor the condition of structures, identifying early signs of damage or deterioration.

Bridge testing: Multi-axis sensors measure bridges’ load distribution and stress levels during various loading scenarios, ensuring their structural integrity.

Aircraft testing: These sensors measure aircraft structures’ aerodynamic forces and vibration response, ensuring their safety and performance.

Civil engineering testing: Multi-axis sensors are employed in testing a wide range of civil engineering structures, including buildings, dams, and offshore platforms. Visit: Infrastructure Solutions

Multi-axis load cells are an ideal technical solution for structural testing because they can simultaneously measure forces in multiple directions, reduce complexity, and improve accuracy. These versatile sensors can be used in structural testing and ongoing structural monitoring.

ADDITIONAL RESOURCES

Multi-Axis Sensor Application Notes

Interface Solutions for Structural Testing

Structural Testing Overview

Modernizing Infrastructure with Interface Sensor Technologies

Interface and Infrastructure Markets Form a Perfect Partnership

Electric Vehicle Structural Battery Testing

Outlining Force Solutions for Structural Outrigging

Performance Structural Loading

Rocket Structure Testing

 

Fatigue Testing with Interface Load Cells

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Engineers rely on fatigue testing to ensure the safety and reliability of their product designs and structures. By understanding how materials behave under repeated loading, engineers can design components resistant to fatigue failure.

Fatigue testing requires accurate and reliable force measurement. Interface uses ‘fatigue-rated’ as an exact specification that defines a special class of load cell design and construction. Interface fatigue-rated load cells are designed to withstand the rigors of repeated loading, which makes them ideal for even the most demanding high cycle count fatigue testing applications.

In a typical fatigue testing setup, Interface fatigue-rated load cells are attached to the test specimen or the test machine, and the cyclic loading is applied according to the test protocol. The load cells continuously record the applied forces or stresses, allowing engineers and researchers to monitor how the material responds to repeated loading.

By analyzing the data from Interface load cells, researchers and material engineers can determine the material’s endurance limit, fatigue life, and stress-strain behavior. This information is invaluable for optimizing material selection, design, and manufacturing processes to enhance product performance and reliability while identifying fatigue and potential failure risks.

The use of fatigue-rated load cells and data logging instrumentation is necessary for most test and measurement applications, particularly when materials, parts, or assemblies are tested for destruction. This is true because an accurate record of the forces at every moment of the tests is the only way an engineer can analyze the stresses that occurred in the moments just before the ultimate failure. Read more about fatigue testing in our Interface’s Technical Library.

Interface Fatigue-Rated Load Cells

1000 Fatigue-Rated LowProfile® Load Cell

1000 High Capacity Fatigue-Rated LowProfile® Load Cell

1500 Low Capacity LowProfile® Load Cell

1208 Flange Standard Precision LowProfile® Load Cell

Profile of a Fatigue-Rated Load Cell

  • Design stress levels in the flexures are about one-half as high as in a standard LowProfile load cell.
  • Internal high-stress points, such as sharp corners and edges, are specially polished to avoid crack propagation.
  • Extraneous load sensitivity is specified and adjusted to a lower level than in a standard LowProfile load cell.
  • All Interface fatigue-rated load cells have a specified service life of 100 million fully reversed, full-capacity loading cycles.

No one can accurately predict exactly when the failure will occur, nor which part of an assembly will be the weakest link that eventually will fail. This is why high cycle count testing is the best way to measure fatigue life. To read more about fatigue testing and fatigue theory, consult Interface’s Load Cell Field Guide.

Fatigue Testing Applications

Interface fatigue-rated load cells are used in various industries, including aerospace, automotive, civil engineering, and manufacturing. They are used to test various products, from aircraft wings and landing gear to furniture and industrial machinery.

How Interface fatigue-rated load cells are used in fatigue testing:

  • Aerospace: Interface fatigue-rated load cells test the durability of aircraft wings, landing gear, and other aerospace components. This helps to ensure that aircraft can withstand the rigors of repeated takeoffs, landings, and flights. These load cells test the materials used for structures and even rockets.
  • Automotive: Interface fatigue-rated load cells test the fatigue life of engine components, chassis, and suspension systems. This helps to ensure that vehicles are safe and reliable and that they can withstand the stresses of everyday driving.
  • Civil engineering: Interface fatigue-rated load cells test the fatigue resistance of bridges, buildings, and critical infrastructure. This helps to ensure that these structures can withstand the loads they are designed to carry and are safe for the public.
  • Manufacturing: Interface fatigue-rated load cells test the fatigue life of industrial machinery, tools, and consumer products. This helps to ensure that these products are reliable and can withstand the demands of everyday use.

Watch how Interface load cells are used in this bike frame testing application.

Interface has specialized in fatigue-rated load cells and their applications since our founding in 1968. Our LowProfile® fatigue-rated load cells provide up to 100 million duty cycles, and the gaged sensors in every load cell are individually inspected, tested, and certified to meet our rigid performance standards.

It is imperative to choose the right load cell for your fatigue testing application. Load cells come in various sizes and capacities, so it is vital to choose one that is right for your fatigue testing application. Ensure you know the maximum load that will be applied to the load cell, the type of loading, the accuracy requirement, and the environmental conditions for testing. Consult with Interface application engineers to find the suitable load cell for your testing requirements.

ADDITIONAL APPLICATIONS AND RESOURCES

CPG Bike Handlebar Fatigue Testing

Interface Specializes in Fatigue-Rated Load Cells

Prosthetics Load and Fatigue Testing App Note

Furniture Fatigue Cycle Testing App Note

Aircraft Wing Fatigue App Note

 

The Criticality of Thrust Measurement Testing in Aerospace

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Interface is a force measurement solutions provider for many of the largest and most innovative aerospace and space systems organizations. Our measurement devices are utilized to test various aircraft and space vehicle components, including thrust testing for jet engines, gas turbines, and propulsion systems.

Thrust measurement is critical when designing and developing aircraft and spacecraft. These critical measurements are used to build and test rocket engines for launch vehicles and missiles. Thrust testing is also vital for maintenance and quality inspections of vehicle engines and systems. By measuring thrust over time, engineers can identify any potential engine problems and take corrective action before they cause a failure.

Thrust measurements ensure rocket and airplane engines produce enough thrust to safely launch, fly, and land. If an engine is not producing enough thrust, it could lead to a catastrophic failure. Trust testing also helps to improve fuel efficiency and reduce emissions.

The force emitted by a thrust engine dictates the size and speed at which a payload can be lifted off the ground. Enormous amounts of thrust are needed to get a spaceship out of the Earth’s atmosphere or propel a jet engine to move faster than the speed of sound. Thrust must be measured precisely because applying too much thrust to an aircraft may damage it, or using too much thrust at a rocket’s liftoff can use too much fuel.

Interface force sensors provide extremely accurate data to assess the amount of force, helping engineers tune thrusters to provide the right amount of force for the size and speed needed to launch or lift their vehicle.

Thrust is measured by placing the thrust engine on a test stand. Then, as the rocket engine burns fuel and creates thrust, the force of the thrust creates compression force on the load cell sensor. As this happens, a mechanical signal is converted to a digital signal, and this data is sent back to the engineer through a data acquisition device, who can then assess, monitor, and record that data.

A load cell used to measure thrust force must be rated for extreme heat. A typical load cell could not provide an accurate measurement when placed in a temperature environment that the sensor’s materials could not handle. Interface offers a wide range of load cells rated explicitly for this type of testing.

To give you a sense of the power and environment of thrust testing, you can see the thrust test of a jet engine in action posted on the U.S. Defense News YouTube channel.

Jet Engine Thrust Testing Application

A customer wanted to conduct a static jet engine thrust test that could accurately determine the engine’s thrust, burn time, chamber pressure, and other parameters, providing invaluable data to propellant chemists and engineers. They needed a high-accuracy load cell with excellent repeatability to withstand thrust forces in very harsh environments. From ignition to burn-out, Interface’s 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell was ideally suited based on their performance for this application.

The load cell reacted to the thrust forces produced by the jet engine, and the signals were collected and recorded to create a “thrust curve” of the engine. The performance of an Interface LowProfile™ Load Cell allowed engineers to be confident in the data acquired from the static testing. Additionally, the repeatability of the load cell resulted in reduced time between tests, making static jet engine thrust testing more efficient. The 9330 battery-powered high-speed data logging indicator captured the data for analysis.

Thrust measurement ensures safety, reliability, and performance.

Interface is a long-time provider of  Aerospace and Defense Industry Solutions.  Here is another video to watch to learn more about Interface’s role in aerospace innovation.

Go here to learn more about thrust and other force test examples in the aerospace industry.

ADDITIONAL RESOURCES

Taking Flight with Interface Solutions for Aircraft Testing

Enabling A Look Way Beyond Yonder

Aerospace Solutions

Interface Space Economy Solutions

The Aviation Industry Soars Using Interface Solutions

Solutions Provider for Aerospace & Defense

Interface Engineered Solutions for Lifting Webinar Recap

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Everything from mechanical engineering designs, equipment materials, and the sensors used in lifting machinery is changing the concept of lifting today. Interface experts Keith Skidmore and Ken Bishop explore types of measurement products, applications, technical considerations, and tips for lifting use cases in the Interface recorded webinar Engineered Solutions for Lifting.

Sensors are central in lifting equipment to maintain safety, quality, compliance, and efficiency. Interface provides a useful product selection online resource for lifting applications. Go to the Lifting Solutions Guide.

Interface load cells can help prevent accidents by providing real-time feedback on the weight of the lifted load. The measurement data helps ensure the lifting machinery is not overloaded or unbalanced, leading to structural failure, tipping over, or injury. Sensor technologies improve quality control by ensuring products are lifted to the correct specifications.

Interface LowProfile Load Cells, Load Pins, Load Shackles, and Tension Links improve efficiency by automating the lifting process. For example, load cells can control the speed and movement of a lifting mechanism, ensuring that the load is lifted safely and efficiently. These measurement sensors can reduce costs by minimizing damage to equipment and products. By preventing overloads and ensuring that loads are lifted safely, load cell devices can extend the lifespan of equipment and prevent costly accidents.

In many industries, regulations require load cells for lifting applications to ensure compliance and overload protection. For example, the Occupational Safety and Health Administration (OSHA) requires the use of load cells in many lifting applications for monitoring and reporting.

Automation of lifting is on the rise. Using robotics and component activation is commonly designed into new equipment and retrofitting existing hardware. These features also provide valuable operating safety and alarm systems based on key measurements. Modernizing equipment to meet today’s and future use cases is important to operators and manufacturers of lifting equipment. This includes utilizing wireless components and using cloud-based data (IoT).

Lifting sensors are more commonly found in settings with high-temperature variances and exposure to extreme environmental conditions. The measurement solutions must withstand these variances while providing continuous monitoring capabilities. Today’s use cases require smaller load cells, like our beam load cells, while not sacrificing precision measurement.

Interface products are used for all types of lifting equipment, apparatus, and machines, including:

  • All Purpose Cranes
  • Patient Lifts and Medical Equipment
  • Drones with Lift and Carry Capabilities
  • Aircraft Lifts and Rigging
  • Lifting Gantry Systems and Mobile Gantry Cranes
  • Jib Cranes
  • Engine and Floor Cranes
  • Scaffold Runway Systems
  • Venue and Entertainment AV Equipment
  • Rigging Equipment
  • Pallet Movers
  • Elevators
  • Loaders and Bulldozers

During the webinar, Interface experts shared tips and best practices. Here is a quick summary of tips for lifting use cases.

Top Measurement Tips for Lifting Use Cases

TIP #1 Select the right force sensor. Factors to consider when selecting a force sensor include the maximum force it can measure, accuracy, weight, dimensions, and environmental conditions for use.

TIP #2 Proper installation will define your application’s success. It is important to install the force sensor correctly to ensure accurate measurements.

TIP #3 Calibrate the force sensor regularly, preferably once a year. Regularly run calibration-grade tests if the load cell is embedded into the lifting device.

TIP #4 Based on each use case, instrumentation can make all the difference in your program. For example, a data acquisition system collects force data to monitor the lifting process, identify potential problems, and generate reports.

TIP #5 Design the lifting system with safety in mind. Force measurement can improve the safety of lifting systems by preventing overloading, detecting imbalances in the load, and monitoring the condition of the lifting equipment.

Tune into the webinar to hear Keith Skidmore and Ken Bishop detail best practices, key considerations to identify stable and unstable lifting, and a thorough review of industry applications using Interface products.

Lifting Applications

Crane Capacity Verification

A customer wants to verify that their crane is strong enough to safely lift a heavy load at its rated maximum load capacity. A wireless solution is needed to avoid long cables and to have a faster installation time. Interface’s Model WTSATL Lightweight Wireless Tension Link Load Cell can measure the load’s maximum capacity. The WTS-RM1 Wireless Relay Output Receiver Modules can also trigger an alarm that can be set when the maximum capacity of weight/force has been reached. The data is transmitted and can be reviewed with the WTS-BS-1-HS Wireless Handheld Display or on the customer’s PC.

gantry crane lifting a heavy container

Gantry Crane Wireless Lifting for Heavy Containers

Gantry cranes are used for mobile and lifting applications in industrial and construction. A weighing system is needed to see if the gantry crane can lift heavy containers or loads, preventing crane failure or accidents. Interface’s WTSLP Wireless Stainless Steel Load Pins can be installed into the corners of the lifting mechanism of the gantry crane, where heavy-loaded containers are lifted and moved. The force results are then transmitted to the WTS-BS-1-HS Wireless Handheld Display for Single Transmitters and a connected computer using the WTS-BS-6 Wireless Telemetry Dongle Base Station.

Patient Lifting Device

In the medical field, sometimes it is necessary to weigh or transfer patients who are disabled and cannot walk. A Hoyer lift is used to move patients around. A manufacturer would like a force system to weigh disabled patients and see the maximum weight it can hold. Interface’s WTS 1200 Standard Precision LowProfile® Wireless Load Cell is attached to the top of the Hoyer lift. The force results are wirelessly transmitted to the medical laptop through the WTS-BS-6 Wireless Telemetry Dongle Base Station.

Find additional productions and solutions in our Lifting Solutions Overview.

Lifting Solutions Brochure

Force Measurement Sensors are Essential to Modern Industrial Machinery

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Industrial machinery plays a vital role in the global economy. It helps to improve productivity and efficiency, and it is essential to produce many of the goods we rely on daily.

Industrial machinery use cases range from equipment used in manufacturing and construction to transportation and robotics. Force measurement sensors and instrumentation play a critical role in ensuring industrial machinery’s safe and efficient operation.

Interface sensor technologies, including our load cells and multi-axis sensors, provide critical data for various machinery designs and functions. Interface analog and digital instrumentation products are available to amplify, condition, and display the signals from force measurement sensors.

The accuracy of force, torque, and weight measurements guide industrial machinery’s design and performance mechanisms.

What types of industrial machinery are using Interface measurement products today?

  • Machine tools used for grinding, drills, and lathes
  • Fabrication apparatus used for bending, shearing, and welding
  • Assembly equipment for production environments that include conveyor belts, robotic arms, and picking devices
  • Testing, quality control, and safety inspection equipment
  • Heavy equipment operational controllers for forklifts, cranes, and hoisting gear
  • Construction machinery such as loaders, bulldozers, and lifts

Industrial machinery is prevalent in manufacturing vehicles, aircraft, consumer goods, medical devices, and pharmaceuticals. Heavy-duty machinery is standard in energy production, mining, forestry, agriculture, and transportation.

The machines’ quality heavily depends on the accuracy of measurements used in the initial design, retrofitting, production, and practice. Interface products provide the products that enable machines to operate at peak performance safely and efficiently. Learn more in our new Interface Industrial Machinery Solutions, a part of Industrial Automation market offerings.

How Interface Measurement Solutions Used in Industrial Machinery

Machine Safety Monitoring

Interface products are used for monitoring the performance of machines and for management in sensing potential problems before they cause a failure. Interface measurement technologies are used in construction machinery to enable operators to gauge the force applied to materials, preventing overexertion and potential damage. Read Interface Solutions for Safety and Regulation Testing and Monitoring

Heavy Machinery and Lifting Equipment

In material handling equipment, force sensors help prevent accidents and injuries. Interface load cells, including load pins and shackles, monitor loads, weight, and distribution. Learn more about lifting solutions in our Engineered Solutions for Lifting Webinar.

Manufacturing and Production Machines

Manufacturers rely on Interface sensor solutions in industrial machines such as injection molding machines to monitor the force applied to the mold or how they are used in machines to ensure correct product packaging. The efficiency of machines is enhanced by correctly measuring the forces applied during different operations. Force sensors help ensure products are assembled correctly and within tolerance on production lines.

Industrial Automation Machines and Robotics

Interface sensors in industrial machines such as robots allow for more precise and delicate tasks that measure force at touch and throughout the entire operation. In machine tools, load cells assist in monitoring cutting forces and prevent damage to tools and workpieces. In robotic arms and automated assembly lines, force sensors provide precise force application during welding, riveting, and material handling.

Benefits of Using Interface Products in Industrial Machinery

  • Improved safety: Load cells can help prevent accidents and injuries by monitoring the weight and distribution of loads and ensuring that machines operate correctly.
  • Increased productivity: Force measurement sensors can help improve machines’ efficiency by optimizing the force applied during different operations. Force measurement sensors can help reduce machine downtime and enhance the quality of products with accurate data, helping to make intelligent decisions.
  • Reduced waste and operating costs: Measurement devices can help to reduce costs by preventing machine failures and improving the quality of products.

Force measurement sensors and instrumentation are essential components of modern industrial machinery. They ensure the safe, efficient, and productive operation of these machines. Contact Interface application engineers to evaluate the best sensor technologies for your specific test and measurement pe failures and improving the quality of products.

ADDITIONAL RESOURCES

Hydraulic Press Machines and Load Cells

Sanding Machine Force Monitoring

Interface Solutions for Machine Builders

Metal Press Cutting Machine

Laser Machine Cutting Force App Note

Ice Machine Weighing

Force Measurement Testing Improves Products and Consumer Safety

Cobot Safety Programming

Crane Capacity Verification App Note

The Aviation Industry Soars Using Interface Solutions

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Interface is proud to offer a diverse range of force, torque, and weight measurement solutions to the aviation industry.

A sector within the aerospace industry, Interface aviation solutions are products we supply for use in the design, engineering and operation of aircraft.

The quality of our products, including the reliable form factor design, proprietary strain gages, and rugged materials, are built to withstand the rigorous performance standards and environments that aircraft safety demands. It is why Interface is a provider of choice for test and measurement solutions in the aviation industry. Check out our new Aircraft Solutions overview here.

The aircraft and aviation industries are vast and complex with many different sectors. Our products are currently used in commercial, general and military aviation, aviation infrastructure, equipment and systems. In addition to the mechanical component testing, Interface often supplies load cells, torque transducers and instrumentation for use in aviation training, education, research and development.

While aviation systems embody an extensive collection of interconnected components and technologies, this complexity does not lessen the requirements for rigorous sensor-based test and measurement programs for every part. Interface products help to collect critical data on the performance of aircraft components and systems. These aviation systems include aircraft, air traffic control, navigation and communication systems, infrastructure, ground support equipment, airport transport vehicles, aircraft testing labs, and tools.

We work with aeronautical and mechanical engineers who are involved in designing, developing, and maintaining aircraft, propulsion systems, avionics, and air traffic management technologies. Interface load cells and transducers provide accurate and reliable measurements of forces, weights and torques of aviation components and systems.

How does the aviation industry use Interface measurement solutions?

  • Aircraft engine manufacturers use our load cells and torque transducers to measure the operating performance within their design limits and for diagnostics and troubleshooting. Read: Aircraft Engine Hoist
  • Aviation system developers integrate our sensors into equipment and parts to provide continuous force monitoring and to trigger alarms for maintenance.
  • Rotorcraft part makers need to assess the loads and torques on blades and other components to the aircraft is safe to fly and to identify any weaknesses based on accurate measurements. Read:Propeller Testing
  • Landing gear experts use our load cells to confirm that the gear can withstand the forces encountered during takeoff, landing, and taxiing. Read: Landing Gear Joint Testing
  • Aircraft structures must be strong enough to withstand the forces encountered in flight. Testing is standard for cycle counts, environmental tests and assessment of materials. Interface products are used for assessing structural like wings and fuselages in wind tunnel tests. Read: Interface Solutions for Structural Testing and Aircraft Wing Fatigue App Note
  • Flight control systems are using measurement sensors to test and monitor the components used for various controls. Read: Aircraft Yoke Torque Measurement
  • In-flight systems and simulators utilize precision measurement devices to provide vital data that monitors aviation and aircraft health. This is important for real-time assessments and for training purposes. It is essential for the long-term growth of the industry to provide the best tools and equipment to learn the values of accurate measurement and how it impacts performance and safety.

Beyond the essential manufacturers of aircraft parts, aviation systems, and equipment, Interface supplies many of the leading aviation testing labs with load cells, load pins, torque transducers, wireless devices and instrumentation. The quality of our products is built to withstand the rigorous performance standards and environments that aircraft safety demands.

Our products are used for static testing, material testing, torque testing, fatigue testing, stress and tension tests, dynamic testing, environmental and wind tunnel testing, structural tests and compression testing. We also supply the aviation industry with measurement solutions for rigging, lifting, weighing and monitoring of equipment in use. Check out our Aircraft Lifting Equipment App Note.

Learn more about our range of solutions in this Airplane Jacking System solution.

The aviation industry is a dynamic and ever-changing industry, and the sectors within it are constantly evolving. New innovations in the aviation require extensive testing and accurate measurement. The aviation industry is a complex and demanding industry, and the development of new technologies requires a rigorous testing process.

The fact that Interface offers an extensive array of force measure devices in different models, capacities, configurations and capabilities helps aviation system suppliers and manufacturers. Our load cells and sensor technologies are used to measure a wide range of factors, such as tensions, weights, forces, and torques. This information can be used to ensure the safety and reliability of aircraft and their components.

With a surplus of options that can meet the specifications of each use case and testing application, Interface is an experience and preferred provider to the aviation industry.

ADDITIONAL RESOURCES

Interface Supports Wind Tunnel Testing

LIFTING: Airplane Jacking System

LIFTING: Aircraft Engine Hoist

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Wing Fatigue App Note

Aircraft Screwdriver Fastening Control App Note

Airplane Static Testing Case Study

Interface Supports Wind Tunnel Testing

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In the development of an airborne vehicle, like a plane or helicopter, wind tunnel systems are used to gather data across a variety of tests related to the aerodynamics of the vehicle’s design. Whether an object is stationary or mobile, wind tunnels provide insight into the effects of air as it moves over or around the test model. Interface is a supplier of measurement solutions used for aircraft and wind tunnel testing.

Wind tunnels are chambers that test small scale model versions of full systems, or in some cases, parts and components, depending on the size and capabilities of the wind tunnel. They work by allowing the engineers to control airflow within the tunnel and simulate the types of wind force that airplanes and other aircraft will experience in flight. Wind tunnels are also used for testing automobiles, bicycles, drones and space vehicles.

By taking careful measurements of the forces on the model, the engineer can predict the forces on the full-scale aircraft. And by using special diagnostic techniques, the engineer can better understand and improve the performance of the aircraft.

The process for measuring the force and how it reacts to this force works by mounting the model in the wind tunnel on a force balance or test stand. The output is a signal that is related to the forces and moments on the model. Balances can be used to measure both the lift and drag forces. The balance must be calibrated against a known value of the force before, and sometimes during, the test.

Interface’s strain gage load cells are commonly used in wind tunnel testing due to their quality, accuracy and reliability. The instrumentation requirements often depend on the application and type of test. The range of options for both load cells and instrumentation vary based on scale, use, cycle counts, and data requirements.

Instrumentation used in wind tunnel testing can be as simple as our 9325 Portable Sensor Display to a multi-channel data acquisition system. Interface analog, digital and wireless instrumentation solutions provide a range of possibilities. As is the case, wind tunnel testing is typically very sensitive. It is important to calibrate the instrumentation before each test to measurement accuracy.

Types of Wind Tunnel Tests Using Force Measurement Solutions

  • Lift and drag: Load cells are used to measure the two most significant forces that impact aircraft design. Lift is the force that acts perpendicular to the direction of airflow and keeps the craft airborne. Drag is the force that acts parallel to the direction of airflow and opposes forward motion.
  • Side force: This force acts perpendicular to both the direction of airflow and the lift force. It is caused by the difference in pressure between the upper and lower surfaces of the aircraft.
  • Moments: Moments are the forces that act around a point. The most common moments measured in wind tunnels are the pitching moment, the yawing moment, and the rolling moment.
  • Stability and control: Tests conducted to measure the stability and controllability of an aircraft are commonly using force measurement solutions for aircraft design changes or integrating new parts into an existing model.
  • Performance: Particularly important with new designs, engineers use these tests to measure the simulated flight performance under maximum speed, range and fuel efficiency.

The specific tests that are conducted in a wind tunnel depend on the project requirements.

Multi-Axis Sensors for Wind Tunnel Testing Applications

In measuring the forces of a wind tunnel test, multi-axis sensors offer the perfect solution for collecting as much data as possible across every axis, giving the engineer a more complete picture on the aerodynamics of the plane. In fact, Interface has supplied multi-axis load cells for use in several wind tunnel testing applications, for OEMs, testing facilities and part makers.

We offer a variety of multi-axis options including 2, 3 and 6-axis standard and high-capacity configurations depending on testing and data requirements of the user. These sensors can precisely measure the applied force from one direction with little or no crosstalk from the force or moment. Interface products provide excellent performance and accuracy in force and torque measurement.

To match the demands of the volumes of data available using multi-axis sensors in wind tunnel testing, Interface often provides several data acquisition instrumentation solution along with our BlueDAQ software.

Wind Tunnel Test Application

A major aerospace company was developing a new airplane and needed to test their scaled model for aerodynamics in a wind tunnel, by measuring loads created by lift and drag. Interface Model 6A154 6-Axis Load Cell was mounted in the floor of the wind tunnel and connected to the scaled model by a stalk. The wind tunnel blew air over the scaled model creating lift and drag, which was measured and compared to the theoretical airplane models. The output of the 6-axis sensor was connected to the BX8-AS Interface BlueDAQ Series Data Acquisition System, which was connected via USB cable to a computer. Using this solution, the company was able to analyze the collected data and made the necessary adjustments in their design to improve the aerodynamics of their theoretical airplane models.

Interface supports wind tunnel testing and all uses of force measurement in the advancements in aeropspace.

Wind tunnel testing is critical to the aircraft industry, as well as other industries like automotive and space. Interface has been providing multi-axis sensors and strain gage load cells to industry leaders and wind tunnel operators. We understand the unique needs of this type of testing and the instrumentation options that work best with our high-accuracy sensors. We also can work to provide custom solutions, load cells for use in extreme environmental conditions. Contact us to get the right solution for your specific testing program.

Additional Resources

Aircraft Wing Fatigue App Note

Airplane Jacking System

Interface Airplane Static Testing Case Study

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Yoke Torque Measurement

Aircraft Screwdriver Fastening Control App Note

Interface’s Crucial Role in Vehicle and Urban Mobility Markets

Rigging Engineers Choose Interface Measurement Solutions

 

Interface Airplane Static Testing Case Study

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Interface is a preferred supplier of precision force measurement solutions for the aerospace industry and our products are frequently used to help perform critical testing on all types of commercial, industrial, and military aeronautical vehicles.

During the engineering and manufacturing of all types of aircraft, static testing is commonly used to validate designs and components, measure assembly and affirm performance and regulatory requirements. Accuracy and reliability of any type of sensor and instrumentation used during these tests is vital to the testing programs and ensures the safety for pilots, passengers and the public at large when these vehicles take flight.

What is a static test?

Static testing is a type of structural test which allows engineers to analyze an aircraft’s structural integrity while grounded. This is a useful part of the testing process before taking flight, which helps speed up the certification process as it does not require a completed and fully functional aircraft through the entire manufacturing process for aerospace vehicles.

How does Interface place a role in static testing for aircraft?

Our force measurement solutions such as precision load cells and torque transducers play an important role in static testing as force analysis results are used in nearly all structural tests. Interface manufacturers both off-the-shelf and custom solutions that are used by leading part and aircraft manufacturers. These sensor products are used on a static test stand to test frame structure integrity, endurance, and life cycles, with the goal generally being to validate aircraft design and ensure specified criteria are met. The strict accuracy is necessary because in aerospace, every micrometer and gram make a difference in both the performance and safety of an aircraft design.

Static Testing Applications for Airplane Jacking System and Jet Engine Thrust Tests

In the new Airplane Static Testing case study, we have detailed two application examples and how Interface products are specifically used in in static testing of aircraft. These examples demonstrate how our products are applied and utilized for testing an airplane jacking system and provide a solution for a jet engine thrust test.

In the airplane jacking system static testing application, our WTS 1200 LowProfile® Wireless Load Cells are placed on jack points measuring weights and forces on an aircraft. Our advanced Wireless Telemetry System provided instrumentation to capture real-time data, such as the individual load cells attached to each jack point, or any set alarms that may go off if it has exceeded a certain amount of force.

For the jet engine thrust static testing, Interface’s 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell was best suited for this static testing. The load cell reacted to the thrust forces produced by the jet engine and the signals were collected and recorded to create a “thrust curve” of the engine.

To read the Airplane Static Test case study it in full, go here.

To learn more about the many ways Interface can serve the aerospace industry with premium force products and total solutions, watch this video to see the types of products we supply for static and other test and measurement programs in this industry.

Additional Resources

Examining Interface Aerospace Industry Solutions

Aerospace Brochure

Solutions Provider for Aerospace & Defense

Taking Flight with Interface Solutions for Aircraft Testing

Aircraft Screwdriver Fastening Control

Aerospace and Defense Industry Solutions

Aerospace and Defense Case Study

 

Taking Flight with Interface Solutions for Aircraft Testing

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As a top supplier of premium force measurement solutions for the aerospace industry, one of our critical areas requiring precision accuracy and high-quality products is for testing airplanes. Interface load cells, torque transducers, and instrumentation are used regularly in testing of all types of aerospace apparatus, components, and machines, along with embedding our force sensors in aircraft for ongoing simulation tests and inflight data acquisition.

Aircraft, spacecraft, military, and defense companies such as Boeing, Airbus, Lockheed, Northrop Grumman, Bombardier, Embraer, Gulfstream, NASA, and Cessna and many others in the supply and production lines utilize Interface load cells for thrust, wing, static, and fatigue testing. While structural test applications use many types of LowProfile™ load cells, Interface also offers a wide variety of load washers, load buttons and miniature tension and compression load cells for test, production, and control monitoring applications for aircraft.

Why do aircraft testing professionals prefer Interface solutions?  One reason is our moment and temperature compensated load cells use proprietary alloy strain gages for extreme accuracy and reliability that is unmatched by other brands. Using eight proprietary strain gages per sensor, our 4mV/V output well exceeds the performance requirements for testing these specialized aerospace vehicles.

In addition, before the airplanes are even assembled, every manufactured part and components must go through rigorous testing. There are hundreds of machines that are used on the production line for the hundreds of thousands of components needed to complete these specialized craft. Interface load cells and torque transducers are found on many of these production and test machines. Our products are used to provide a wealth of insight to guide manufacturers through research, development and final build. Because testing is so inherent for any of these parts, Interface products provide reliability and accuracy when there are no exceptions.

We recently developed several new application notes on ways our products are used to test airplanes. Included below is a preview of a few of the latest additions to our application notes catalog.

Jet Engine Thrust Test

A customer wanted to conduct a static jet engine thrust test that can accurately determine the engine’s thrust, burn time, chamber pressure, and other parameters, providing invaluable data to propellant chemists and engineers. They needed a high accuracy load cell with excellent repeatability to withstand thrust forces in very harsh environments. Interface offered a 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell, which is ideally suited based on their performance for this application. The load cell reacts to the thrust forces produced by the jet engine and the signals are collected and recorded to create a “thrust curve” of the engine. The performance of an Interface LowProfile™ Load Cell allowed the engineers to be confident in the data acquired from the static testing. Additionally, the repeatability of the load cell results in reduced time between tests, making static jet engine thrust testing more efficient. Read the new Jet Engine Thrust Test application note here.

Aircraft Yoke Torque Measurement

An aircraft manufacturer wanted to measure the torque of their aircrafts yoke or control wheel. They also wanted to monitor the torque and forces applied to ensure that the aircrafts controls are operating properly. Interface suggested using the AT103 2-Axis Axial Torsion Load Cell to measure both torque and force within this single sensor. It can be installed inside of the yoke, and can measure the rotation of the yoke, and the forward and backwards movements. Data can be measured and paired with the SI-USB4 4-Channel USB Interface Module and displayed with the customer’s laptop. Using this solution, the customer was able to measure and monitor the torque and force of the yoke control. Read the Aircraft Yoke Torque Measurement application note.

Aircraft Engine Hoist

An aerospace company wanted to test their aircraft engine hoist in order to safely lift, remove, or install engines efficiently and safety. Interface’s solution was to install WTSSHKB-HL Wireless Bow Shackles to the aircraft engine hoist. A heavy load was added to the hooks where the aircraft engine would be. Results from the heavy load are then sent wirelessly to both the WTS-BS-4 USB Industrial Base Station attached to the customers computer or laptop, and the WTS-1-HS Handheld display for single transmitters. With these products, the customer was assured that the aircraft engine hoist was strong and secure enough to lift a heavy engine when installing or removing an engine inside of an aircraft. Learn more about the Aircraft Engine Hoist application here.

Our expert application engineers help our customers by providing technologies that provide exceedingly accurate measurement used in all types of testing, including structural, static and fatigue. For more information on Interface and its solutions designed for airplanes and other aerospace applications, please visit https://www.interfaceforce.com/solutions/aerospace.

Additional Aircraft Testing Resources

Aircraft Wing Fatigue App Note

Aircraft Screwdriver Fastening Control App Note

Aircraft Lifting Equipment App Note

Examining Interface Aerospace Industry Solutions