Posts

Interface Solutions for Machine Builders

/0 Comments/in /by

No matter the industry, if products are being made chances are industrial machines are involved in some part of R&D, testing, production, and distribution.

Engineers involved in the design and manufacturing of these machines require the highest quality sensors, tools and equipment. In addition, humans often lean on machines for very precise or repetitive tasks, this means that precision and reliability is key for every aspect of these machines.

Machine builders are the backbone of product development and production. They are responsible for building, assembling, and integrating components for stand-alone and multi-station automated machine tools and systems. These automated machine-tool systems are used in all sectors of manufacturing, including assembly, processing, and fabricating systems.

Interface plays a critical role for machine builders, for those that design one machine or manufacture machines at scale for users around the world. We supply machine builders with precision load cells, torque transducers, instrumentation, data acquisition devices and accessories. They lean on Interface because of our experience in supplying the world solutions utilized for industrial product testing and production across all kinds of industries from agricultural machinery to medical testing machines.

The accuracy and quality of our products is why machine builders rely on Interface. In addition, our experience and diversity of product has led machine builders and engineers to choose Interface force measurement sensors throughout their careers. In fact, Interface has served machine builders for more than 50 years. It is a relationship and role we know very well.

The world of machine building has also changed over the years. In the past, machine builders used force sensors primarily to test products before going out to the market. This is still a prominent use case amongst product engineers. The fast-rising use cases over the past decade comes from the demand for smarter machines, automation and miniaturization of products.

Today, more machines builders and OEMs are designing force sensors directly into machines to allow users to activate components, monitor data on the machines in use for real-time feedback and adjustments. This type of innovation using sensors has opened opportunities for Industry 4.0 connectivity between machines.

To get a better idea of how machine builders are using force sensors, Interface has developed a wide range of applications notes to provide real world examples of force measurement in action in the machine building world. We have included a few of those examples below.

Metal Press Cutting Machine

A customer wanted to test the amount of force it takes to cut through different thicknesses of metal on their metal press cutting machine. They also wanted to ensure their metal press cutting machine is working properly and understand its maximum limitation. Interface suggested installing their 3AXX 3-Axis Force Load Cell underneath the plate where pieces of metal are placed to be cut, or punched holes in. When connected to the BX8-HD44 BlueDAQ Series Data Acquisition System, the force results of different metals being cut will be displayed, graphed, and recorded on the customer’s PC. It also has an analog output that can connect to the machines PLC in case of an overload. Using this solution, the customer was able to determine the different number of forces it took for their metal press cutting machine to cut through different types and thicknesses of metal. Read more here.

Snack Weighing and Packaging Machine

A snack manufacturing brand wanted to weigh the amount of their snacks that is automatically dispersed into the bags during the packaging process. In this case, they wanted to weigh their potato chips being packaged and ensure the potato chips are at the exact weight needed due to regulatory standards. Interface’s solution was to use multiple SPI Platform Scale Load Cells and install it to the potato multi-head weigher and packaging machine. The SPI Platform Scale Load cells were installed inside of the mount that attaches the head weigher to the packaging machine. Force results from the potato chips are read by the load cells and sent to the ISG Isolated DIN Rail Mount Signal Conditioner, where the customer is able to control the automated production from their command center. Using this solution, the customer was able to determine the weight of the potato chips being distributed into their bags with highly accurate results. They also were able to control the automated production process with the provided instrumentation. They will use this same weighing method for other snacks that need to be packaged. Read about this application here.

Tablet Forming Machine

A pharmaceutical company needs to precisely monitor the forces applied by the tablet (pill) forming machine to understand the relationship between raw material, die set, forming force, and motor cycle speed. Optimizing the equipment will improve productivity and efficiency of the tablet forming process, while reducing losses. For maximizing production and monitoring the process, Interface suggested a WMC Sealed Stainless Steel Mini Load Cell (10K lbf Capacity) be mounted in the section of the downward press bar. The load cell was then connected to a 9320 Portable Load Cell Indicator to collect the needed data. Read more here.

Machine builders require the best test and monitoring equipment. Interface has backed professional machine builders, machine design engineers, machine manufacturers and those that utilize the equipment for many years with top-of-the-line force sensing solutions.  Whether you are looking to build a machine, design machine tools and equipment or embed sensors into machines, we are here to help.

ADDITIONAL RESOURCES

Proving Theoretical Cutting Forces of Rotary Ultrasonic Machinery App Note

Force Solutions for Testing Machines

Interface Sensors Used for Internet of Things

OEM: Industrial Robotic Arm

Fitness Equipment and Machines

Ice Machine Weighing

GS-SYS04 Gold Standard® Portable E4 Machine Calibration System

Laser Machine Cutting Force App Note

Interface Solutions for Testing Tools

/0 Comments/in /by

Interface load cells, torque transducers and instrumentation are commonly used in the test and measurement of different tools and fasteners used in testing products and actual production of various machines and components. The sensor data received in measuring assembly tools and fixtures used in securing nuts, bolts, and screws, is critical in making safe and reliable products.

For example, the ability to measure torque on screws and the force output of a screwdriver or wrench is very important when there are tight tolerances involved like in engineering and build of automotive or aerospace and defense machines and parts.

As we did for the machine testing blog, we’ve detailed a few examples of how Interface force and torque solutions are used in measuring tools performance for both design and assembly.  You can find additional application notes on these examples and more by visiting our industry solutions.

Bolt Fastening Force and Torque

An aerospace company was working on a test plan that involved taking torque and compression measurements on fasteners with varying joint materials. The system required both high and low sampling rates, in addition to the capability of precisely measuring force and torque simultaneously. They required reliable accuracy and long-term stability. The test plan intended to provide verification of required force and torque specifications for fasteners, to ensure safety without compromising installation. Interface suggested a LW or LWCF Load Washer in conjunction with a  T12 Square Drive Rotary Torque Transducer. With this solution, the customer was able to align force and torque measurements to desired levels. This was accomplished by combining the sensors with the high sample rate of the data logging and graphing capabilities of the SI-USB, capturing real-time force and torque levels for examination. The fasteners were tightened to the specified force and torque requirements and were safely installed without impairment to themselves or the joint material. The customer was able to measure the rapid event effectively and accurately. Read more about this bolt fastening solution here.

Aircraft Screwdriver Fastening Control

An airplane manufacturer needed a solution where they can control the torque when fastening screws on their airplane models. They didn’t want to create any damage to materials or apply too much torque when plane components are being fastened together. Interface suggested a T15 Hex Drive Rotary Torque Transducer, which can be attached to the fastening work bench, measuring and recording torque, rotational speed, and angle of the screwdriver. The LWCF Clamping Force Load Cell is installed, measuring the forces applied on the screw being fastened. Results are sent to the SI-USB4 4-channel USB Interface Module, which is connected to the customer’s PC or laptop where data is logged, graphed, and displayed. This solution allowed the airplane manufacturer to calibrate their screwdriver by measuring its torque, rotational speed, and angle, when attaching materials together for their airplane. They were also able to measure the forces being applied to the screw, to ensure it was not applying too much torque to the components. You can learn more about the aircraft screwdriver application here.

Ratchet Wrench Torque Verification

A customer wanted to perform regular torque testing on his ratchet-type torque wrench while recording these values for future examination. Interface supplied a model TS15 Square to Flange Reaction Torque Transducer with the INF-USB3 PC Interface Module for the customer to use. The customer mounted TS15 to work bench through flange and inserted the ratchet-type torque transducer into the TS15. Using this product, the customer was able to accurately perform their calibration checks and view the results while logging them to their PC Computer.  Learn more about this wrench torque verification testing here.

While not nearly as complex as machine testing applications, tools testing is equally important to the outcome of a project. The tools and fasteners used, even those as simple as a bolt and wrench, need to be accurately measured and assembled to avoid loose connection or overtightening that can damage the product. Interface provides a host of tool testing solutions for nearly anything that outputs force or torque. To learn more about our tool testing solutions, visit us at www.interfaceforce.com.

Additional Resources

Force Measurement Solutions for Bolt and Screw Fastening

Bolt Fastening- Force

Fastening Work Bench

Engine Head Bolt Tightening

New Interface White Paper Highlights Turning an Active Component into a Sensor

/0 Comments/in /by

The most common uses of force measurement in OEM (original equipment manufacturer) applications are when a force sensor is designed into a product that will be produced at mid to high volumes and provides real-time force feedback on certain product functions in use. Utilizing sensors as a feature enables data acquisition over time to monitor forces and understand how those forces effect product efficiency, safety, quality or all of these performance metrics. This ultimately is used to design a better product, in the current state and for future enhancements or to know when a product is performing best or risks breaking down.

Did you know that there is another application of force sensors in OEM applications that is playing a large role in the factory of the future? This is when we turn an active component into a sensor and use that data to create automated actions. This solution is used when there is a desire to take a moving component within a system and make it smarter, ultimately allowing it to make data-based decisions on its own.

For example, the manufacturing industry is using force sensors on machines within a production line that are responsible for picking components up for visual inspection. The sensor is integrated into the grabbing component and can tell the machine the exact force to use when picking up the component as not to damage it. This is a critical capability when dealing with expensive and delicate components that can break under too much force. In the past, a force measurement sensor would have been used only to test this functionality. When the sensor is designed directly into the machine, the user can both test beforehand and monitor and automate processes in real-time.

The need for this type of capability is growing rapidly amongst manufacturers across a wide variety of industry including aerospace and defense, industrial, medical, automotive, industrial automation, assembly and more. To further outline the potential for these types of solutions, Interface developed a new white paper that details  how sensor solutions for OEMs work with specific examples of the benefit of turning an active component into a sensor.

Included below is a brief intro to the recently released white paper. Get your copy by clicking on the link here. Additionally, if you’re interested in learning more about Interface solutions for OEM applications go here, or call us to speak to our OEM application experts at 480-948-5555. Ready to get started, let us know how we can help here.

WHITE PAPER EXCERPT

OEM SOLUTIONS: TURNING AN ACTIVE COMPONENT INTO A SENSOR

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

Get your copy of the white paper to read more.

Special note, contributors to the white paper are Interface and sensor engineering experts, Brian Peters and Rob Fuge.

Additional Resources for OEM

Interface is a Critical Solutions Provider for OEMs

Making the Case for Custom Solutions Webinar Recap

 

Force Measurement Solutions for Bolt and Screw Fastening

/0 Comments/in /by

Among the many applications of force measurement devices, one that appears to be a simple application can have a big impact on worker safety, productivity, waste reduction, assembly and product performance. In this new animated application note highlight, we take a look at the tools used for bolt fastening measurement.

Bolts and screws are used to secure different pieces or components together for nearly every product imaginable, especially when it comes to large machinery and even automobiles. The success of these products and the manufacturing of these components requires a strict level of detail that goes into the tightness of a bolt. It’s not like your typical “do it yourself” furniture where you just tighten a screw or bolt until you can’t anymore. The precision needed for certain objects to be tightened to the exact measurement is mandatory.

Interface provides measurement solutions for all types of industrial automation and toolset testing used in thousands of applications that ultimately are utilized in the building of products. In the example below, we provided devices that are used to determine the exact bolt force and tightness necessary. The goal of measuring the tightness is to avoid under or overtightening. As you can imagine, under tightening can cause components to come apart. However, over tightness can also cause significant damage to the pieces being bolted together.

Bolt Fastening Application

To show the process of measuring bolt tightness, check out this latest use case video demonstration.

For this bolt fastening application, the customer used an Interface Model LWCF Load Washer along with an Interface Model INF-USB3 Single Channel PC Interface Module to monitor force being applied during bolt tightening. The data transferred from the bolt clamping force load cell load washer with a thru-hole, to the instrumentation is displayed, logged and graphed directly onto a computer for analysis and performance testing.

This is a basic example of the test and measurement process, however, Interface also contributed to a number of real-world projects and created applications notes to provide an illustration. One of our favorites is when an industrial automation company was building an automated assembly machine for an automotive manufactur­ing plant.

The product engineers and testing team needed to tighten all of the head bolts on an engine on their assembly line to a specific torque value. Having the head bolts precisely and consistently tightened to the engine block is critical to the operation of the engine.

To measure this force, several Interface Model T33 Spindle Torque Transducers were installed in their new machine to control torque and angle and ensure the head bolt was properly tight­ened. The square drive of the T33 allowed the customer to fix their tool directly to the end of the torque sensor, streamlining the installation.

Using this solution, the head bolts were correctly installed according to manufacturer specifications, producing an engine that meets performance and reliability expectations of the auto manufacturing plant.

Here are additional solutions that showcase how Interface load cells, torque transducers, instrumentation and custom solutions are used for various tools and manufacturing processes across various industries.

Aircraft Screwdriver Fastening Control

Fastening Work Bench

Bolt Fastening Force and Torque

Interface Solutions for Robotics and Industrial Automation

Contact us to learn more how we can help you ensure the right fastening and machine control for your next projects.