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Interface Validates Trends in Automotive Test and Measurement

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As a trusted supplier to automotive testing labs and automakers of precision sensor technologies for force, torque, and weighing applications, the depth of our product line is vital to support research, testing, and innovation in the industry. In particular, there is a high increase in the use of Interface torque transducers for automotive test and measurement use cases.

We strive to provide the latest sensor technology to help our customers move at the pace of automotive innovation. Over the years, we have developed new products for testing and monitoring advancements in all vehicles and supporting R&D into new automotive types like electric vehicles (EVs) and autonomous vehicles. Learn more in the case study: Accelerating Automotive Excellence with Interface Testing Lab Solutions.

Growing Demands for Torque Transducers in Auto Testing

Based on current demands for Interface measurement solutions, the auto industry is experiencing a high upsurge in using torque transducers. Specifically, EV manufacturers and parts makers are using torque measurement in testing the performance of electric motors and powertrains.

EVs have become a significant force and torque measurement sensor technology user, including our popular AxialTQ™ Rotary Torque Transducer product line. Many of our transducer models are also being used to test EV battery technology, including storage, capacity, and more.

Another growing use case requiring cutting-edge torque transducers is testing advanced driver assistance systems (ADAS) performance. ADAS systems rely on various sensors, including our torque transducers, to measure and control the vehicle’s dynamics. In these use cases, automotive engineers rely on supreme accuracy due to the critical nature of this safety feature. These types of use cases are pushing the requirement for accuracy further.

Finally, our torque transducers are being used in experiential automotive technologies such as fully autonomous and driver-assisted vehicle innovations. The accuracy of measurement is instrumental in bringing these inventions to market. Size, weight, and power (SWaP) is also a premium factor in these types of sensors. As more and more sensor technology is added to autonomous vehicles, the sensors must become more compact and efficient.

Specific products that Interface is supplying for these types of testing programs include high-accuracy reaction and rotary torque transducer technologies. This includes more miniature lightweight torque transducers to make integrating into test machines, production lines, and vehicles easier. Our expansion of Interface Mini Torque Transducers is helping with this requirement. We also provide more wireless torque transducer capabilities, eliminating the need for cables and wires and making testing more convenient and efficient.

Use Interface’s Torque Transducer Selection Guide to find the right product for your application requirements. Join Interface at the next Automotive Testing Expo to see live demonstrations of Interface measurement solutions.

Automotive Industry Applications Using Torque Transducers

Tire Force And Moment Using Contactless Force and Torque Transducer

A tire production company wants to put their tires under a stress test. They want to research the dynamic control capabilities of their tires. They want to measure both the torque and lateral force of the tire. Interface suggests using the AT105 Contactless Force and Torque Transducer to measure the tire lateral force and torque. Torque and force results can be displayed and graphed when connected to the SI-USB4 4-Channel USB Interface Module. After conducting a stress test on their tires, the tire production company could record and log the measurements of the torque and lateral forces implemented on their tires. Read Tire Force and Moment App Note

Vacuum Testing Using Rotary Torque Testing to Optimize Automotive Performance

The vacuum pump in a car plays an integral part in several systems, such as power brakes, HVAC, and sometimes even in the turbocharger or emissions control systems. Its primary function is to create a vacuum or negative pressure within a specific system. A torque test needs to be performed to ensure it is performing correctly. Interface’s T2 Ultra Precision Shaft Style Rotary Torque Transducer with torque couplings can be attached to the vacuum pump during performance testing. It will measure the amount of torque that is being used on the pump’s motor or drive system. When connected to the customer’s computer, results can be displayed, recorded, and logged using the SI-USB4 4-Channel USB Interface Module. Read Vacuum Testing for Automotive Performance

Torque Measurement For Electric Vehicles

Electric vehicle manufacturers need a torque measurement system for motor testing. These motors run at significantly higher rotational speeds than their internal combustion engine (ICE) counterparts and have much higher power densities due to their small size and lightweight. The system would be used to test the torque and speed of their electric motors to achieve and ensure optimum instant peak torque performance. Interface’s AxialTQ™ Wireless Rotary Torque Transducer is highly accurate with the highest quality torque measurement. This product comes with the AxialTQ™ Output Module and the provided AxialTQ™ Assistant software that can be installed on a test bench. Data results are calculated and collected in real time. Read Torque Measurement for Electric Vehicles App Note

Motor Test Stand Using Torque Transducer

In the quality control lab at a major automotive manufacturing company, a test engineer needed to test, record, and audit the torque produced by a new motor design under start load. Interface supplied our AAxialTQ™ Wireless Rotary Torque Transducer connected between the motor and the differential on the drive shaft that could measure and record these torque values. Based on the data collected using the AxialTQ, AxialTQ Output Module, and customer laptop, the Test Engineer recommended optimizing the torque of the new motor design.

ADDITIONAL RESOURCES

Anniversary of Interface Miniature Torque Transducers

Fuel Pump Optimization and Rotary Torque

Choosing the Right Torque Transducer

A Comparison of Torque Measurement Systems White Paper

Advancing Auto Testing with Interface Measurement Solutions

Automotive Window Pinch Force Testing

Automotive Head Rest Testing

Trends in Torque Transducer Applications in the Auto Industry

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Torque transducers are crucial in force measurement testing, especially in the automotive industry. A torque sensor is a transducer that converts a torsional mechanical input into an electrical output signal.

Interface’s experience suggests the automotive industry’s most frequently used torque transducers are rotary torque transducers, like our AxialTQ, which measure dynamic force. These transducers are necessary for applications where the torque transducer must rotate when attached to a spinning shaft. A rotary torque transducer provides a method of getting the signal off the rotating element without an attached cable.

Automotive testing labs also commonly use a fixed-style mount instead of a floating style. This is because fixed types are ideal for high-speed applications. Fixed and supportive mounting is often mandatory. Fixed mounts apply only to sensors with bearings, which involves attaching the sensor housing to fixed support for added stability.

Torque plays a critical role in automotive testing, and Interface has more than 50 transducer models with multiple capacities and sizes. Use our Torque Transducer Selection Guide to help define the suitable model for your specific application.

Interface will demonstrate the range of torque transducer solutions at the upcoming Auto Test Expo. You can get your free pass online.

Top Trends in Torque Transducer Applications

Torque transducers create faster, more efficient, and safer vehicles. Interface transducers are designed to meet the growing demands of the auto industry.

  • Interface recognizes the growing use of torque transducers to measure the performance of electric vehicles (EVs). Torque transducers are essential for testing the performance of their electric motors and powertrains. Torque transducers are used to measure the torque output of electric motors, which is critical for ensuring that they meet their performance specifications. Read Torque Measurement for Electric Vehicles.
  • Interface torque transducers are helping to assess advanced driver assistance systems (ADAS) performance. ADAS systems rely on numerous sensors, including torque transducers, to measure and control the vehicle’s dynamics. Torque transducers measure the torque applied to the steering wheel and brakes, which ensures that ADAS systems function correctly.
  • Torque transducers measure the torque applied to the wheels, which ensures that autonomous vehicles can safely navigate their environment.

Torque transducers are essential research, design, testing, and manufacturing tools. As emerging automotive technologies evaluate new components, materials, and vehicle capabilities, torque transducers provide vital measurement data to assess performance. We see this in the use cases for torque transducers in all phases of developing autonomous and self-driving vehicles, including the transition to flying cars.

Automotive Applications Using Interface Torque Transducers

AxialTQ™ Engine Dynamometer

One of our customers needed to measure the torque and the speed (RPM) produced by an engine and calculate it simultaneously. Using the Interface AxialTQ Wireless Rotary Torque Measurement System, which was developed in direct collaboration with over 30 end-users who shared their wish lists for operational priorities, user interface, design, features, real-world field issues, and more, the customer was able to measure and calculate the torque and rotational speed (RPM) of the engine in real-time while collecting the data accurately and simultaneously.

Lug Nut Assembly

Proper lug nut assembly is critical to a quality vehicle and meeting strict quality and safety requirements. Interface’s customer wants to increase productivity for automobile wheel installation while ensuring the lug nuts are installed to the proper torque values for safety. Interface supplied five T33 Spindle Torque Transducers for use in the customer’s wheel installation assembly machine, which comes standard with +/-5VDC analog output for torque measurements and a 360 pulse, 2-track encoder for speed/angle measurement. The customer could perform five simultaneous torque measurements during wheel installation in seconds using this solution.  The T33 Spindle Torque Transducer provided a +/-5VDC signal for torque and a TTL signal for angle measurement to the customer’s control system for logging, evaluating, and recording the results.

Another important consideration for testing torque with these sensors is the coupling. Couplings are a critical component of the torque transducer that ensures the isolation of torque loads. Couplings should be used in all applications, and the selection of the coupling type is based on the speed of the application. For higher-speed applications, you will want to look for high-quality couplings. The coupling helps to prevent error and damage from extraneous loads. You can learn more about selecting the proper coupling in our new blog, Torque Transducers and Couplings are the Perfect Pairing.

Every industry segment has numerous priorities as they compete to design, engineer, build, and supply new and innovative vehicles. From the focus on the extreme performance of racing vehicles to the safety focus of consumer automobiles, Interface can provide force and torque measurement solutions to help you today and in the future.

ADDITIONAL RESOURCES

Tire Force and Measurement

Fuel Pump Optimization & Rotary Torque

Engine Head Bolt Tightening

Dual Motor Dynamometer

Accelerating Automotive Excellence in the Test Lab

Force Measurement Solutions Demonstrations at Automotive Testing Expo

 

Faces of Interface Featuring Ryan Roden

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Ryan Roden, one of our outstanding engineers, is our feature in today’s Faces of Interface. Ryan has been a team member at Interface for more than two years. He is instrumental in leading one of our most important product lines, the revolutionary AxialTQ wireless rotary torque transducer.

Like many of Interface’s talented engineers, Ryan’s interest in the world of electronics and design started at an early age. He remembers working on cars, building, and fixing things around the house constantly as a kid. In addition, his father owned a machine shop, so he always had the tools around, as well as the mentorship of his father.

This early interest led Ryan to pursue an educational foundation in electrical engineering at LeTourneau University in Texas. During his time in school, he also had the opportunity to join Colorado Engineering as an intern, which eventually led to his very first role in the industry as an associate electrical engineer with the same company.

In this role, Ryan worked with a wide variety of different applications, most notable military grade products involving radar. As an associate engineer, he worked on digital design, board layout, testing and troubleshooting across military and commercial applications. He worked with Colorado Engineering, Inc., for two years before moving back to Arizona.

When he came back, Ryan worked for his dad for a few months while looking for a job in the area. He found Interface had an opening and immediately saw that his skillset fit the types of things we’re doing in the area of electrical engineering, and he was excited to have a diverse set of industries and applications that can utilize his experience.

Ryan was hired and he has been an excellent member of the team. He notes that his day-to-day is always different, but typically he can be found troubleshooting electrical challenges, designing PCBs, dealing with the supply chain to source parts and materials, and working with the engineering lab on new products.

What he enjoys most about working at Interface is that it is a diverse mix of different fields of engineering including electrical and mechanical. He also enjoys the deep level of problem solving required to serve customers. He says the work keeps him on his toes and constantly shifting gears to solve different challenges.

In his free time, Ryan is an outdoors person. He enjoys boating in the summer and hunting as much as possible throughout Arizona, as well as spending time with his family. He also still enjoys being around and working on cars, a passion that never left him since he was a kid.

Ryan has proven his abilities as an engineer repeatedly over the last two years with Interface and we are proud to have him on the team!

We hope you enjoyed learning more about Ryan, and if you’re interested in getting to know the rest of our outstanding Interface team members, tune in monthly to the Interface blog for more ForceLeaders features.

Additional Resources

Interface Celebrates Engineers

Electrical Engineers Choose Interface Sensor Technologies

AxialTQ Technical White Paper Details Comparative Testing

Recap of Latest Spin on AxialTQ Webinar

Interface Solutions for Production Line Engineers

Quality Engineers Require Accurate Force Measurement Solutions

 

Force Measurement Solutions Demonstrations at Automotive Testing Expo

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Interface experts are returning to Novi, Michigan, to demonstrate new and popular force measurement solutions at the Automotive Testing Expo.  The focus of this year includes our multi-axis sensors, axial torsion and torque transducers, miniature load cells, wireless and testing rig solutions, instrumentation, along with our precision load cell technologies for all types of automotive testing and equipment used in the industry.

New SuperSC for Automotive Industry

One of the demonstrations will be Interface’s new SuperSC S-Type Miniature Load Cell. This new product is an economical general purpose load cell with a compact design that measures tension and compression in one unit. It offers high performance capacities in a form factor 80% smaller and 50% lighter than other models of s-type shear beam load cells.

The SuperSC is an ideal product in end of line validation testing for automotive, individual automotive component testing, and fatigue or life cycle testing. It is versatile for machines, component tests, integration into a manufacturing or assembly line for real-time force monitoring.

Many automotive testing labs rely on an actuator for fatigue or lifetime expectancy testing. Without force measurement, testers can only tell when the product reaches failure. The SuperSC can provide early warnings on component performance and life degradation.

SuperSC comes in 12 capacities ranging from 25 to 1K lbf and 100 N to 5 kN. Six designs for international standards of measurement (metric) and six for imperial standards. They are environmentally sealed with an IP66 rating and offer high stiffness with low detection and is insensitive to off-axis loading.

AxialTQ Demonstration

Another product that will be a focus is the revolutionary AxialTQ™ Wireless Rotary Torque Transducer. Designed for the automotive industry, this transducer is common for advanced torque tests and in the electric vehicle markets. Interface presented a new white paper that provides comparative research related to the AxialTQ product, demonstrating its performance related to other offerings. Read AxialTQ Technical White Paper Details Comparative Testing.

To learn more about AxialTQ, watch this video demonstration.

Automotive Testing Applications

Interface will also be showcasing brake pedal load cells, our robot using multi-axis sensors, digital and portable instrumentation and custom solutions designed specifically for auto test engineers. One of these solutions that we will be sharing is our Electric Vehicle Structural Battery Testing application.

EV Battery Structural Testing

Structural EV battery testing is core to optimization as innovation drives electric vehicle battery design and sustainability. Automotive manufacturers and component testing engineers need to validate structural battery pack design for life expectancy against design targets, as well as crash test compliance and survivability. Working with the EV battery maker, Interface’s recommendation is our 1100 Ultra-Precision LowProfile Load Cells for use in-line with hydraulic or electromechanical actuators within the test stand. Interface’s 6A Series 6-Axis Load Cells are also used to capture reactive forces transmitting through pack structure. Multi-axis measurement brings greater system level insight and improved product success.

Bluetooth® Brake Pedal Animated Application Note

Additional Automotive Solutions and Resources

EV Battery Testing Solutions Utilize Interface Mini Load Cells

Electric Vehicle Battery Monitoring App Note

Torque Measurement for Electric Vehicles

Automotive Head Rest Testing App Note

Fine-Tuning Testing Solutions for Championship Racing Vehicles

Automotive Window Pinch Force Testing

Automotive Head Rest Testing Animated Application Note

Automotive + Vehicle Brochure

 

AxialTQ Technical White Paper Details Comparative Testing

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Recently, Interface put together a full comparison of our AxialTQ™ Torque Transducer measurement systems versus a competitor’s system that offers a DIN120, 1kNm capacity transducer. To view the complete details, read the new Interface technical white paper A Comparison of Torque Measurement Systems, authored by Jay Bradley, Interface Electrical Engineering Manager.

Here is a brief overview covering the crucial results of the comparison testing.

About AxialTQ Torque Transducer

Since 2018, the AxialTQ has redefined the category of torque measurement systems in terms of function, accuracy, and customizable compatibility. It’s a must have torque transducer for anyone working to minimize uncertainty when measuring anything that turns. It is specifically designed for the expanding torque measurement needs in fields that include the automotive industry, as well as the aerospace and industrial automation sectors.

At the heart of AxialTQ’s innovation is the rotor and high-precision sensing element technology, which when combined with the electronics component, produces industry-leading accuracy. This product is also fully customizable due to its ability to use simultaneous analog and digital outputs. This is key, as it enables real-time control and data collection. The flexible capability of the stator and output module mounting offers an infinite number of configurations to meet any application needs.

AxialTQ was designed and engineered by Interface in direct collaboration with end-users who shared their wish-lists for operational priorities, user profiles, design specifications, feature preferences, and real-world field challenges they wanted a solution to resolve.

The unique decision to implement an axial gap, as opposed to the industry standard radial gap, means there is minimized concern that the shaft, rotor and stator will make contact, significantly reducing the possibility of damaging the system.

Installation Overview

AxialTQ features a 120° stator coil giving it the ability to be mounted in several different orientations. While the full stator loop of the competing system must be carefully aligned with the rotor. AxialTQ’s large axial gap of up to 6mm and radial gap of up to 12mm also allows for small misalignments or rotor movement. The competing system has a small radial gap of 1mm and ±2mm when installed, providing less flexibility and durability. The stators of both the AxialTQ and the competing system have multicolor status LEDs that indicate proper alignment and data transmission.

Performance Testing and Validation

The tests found that both systems performed well and met their respective operating specifications. Some of the dynamic testing was performed only once due to time constraints. This testing also has a greater uncertainty of measurement because of the test setup.

In this comparison we tested the installation process, as well as performance for the following specifications:

  • Zero balance stability
  • Shunt calibration stability and repeatability
  • Measurement repeatability
  • Measurement non-linearity
  • Measurement hysteresis
  • Axial force crosstalk
  • Zero balance over operating temperature
  • Axial gradient temperature performance

Overall, both systems performed in line with specifications. Areas in which the AxialTQ stood out included change in zero-balance readings, performance in operating temperature ranges, and in the in-house spin testing cycles.

Configuration Advantages

Unlike the competing system, the AxialTQ has one analog voltage or current output, two analog frequency outputs, and a digital serial output which are all active and independently scalable and filtered. This means that by applying different scaling to two different outputs, the AxialTQ can operate like a dual range sensor.

Durability

AxialTQ also has a significant advantage in durability. The large axial (up to 6mm) and radial (typically 12 mm) gaps between the rotor and stator make it highly unlikely that the rotor will contact the stator because of harmonic vibration, torque pulse or some other event. Both the rotor and stator coils of the AxialTQ are fabricated from 0.125in (3.18mm) thick FR4, with any conductors located at least 0.05in (1.27mm) from the edge. If damaged, these coils are easily replaced in the factory.

AxialTQ is innovative alternative to current systems and includes creative solutions to overcome some of the challenges that diminish performance in these systems as well. To learn more about go to our AxialTQ product page.

Additional Resources

Recap of Latest Spin on AxialTQ Webinar

AxialTQ Engine Dynamometer Application Note

The AxialTQ Dynamometer

AxialTQ for Anything That Turns and Needs Testing

Fine-Tuning Testing Solutions for Championship Racing Vehicles

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As every championship race car team looks to find its competitive advantage, measured in seconds, Interface continues to play a pivotal role in ensuring accurate force measurement solutions are used to test the limits of every component used in motorsports.

The automotive industry has long depended on the quality and accuracy of Interface load cells, torque transducers, instrumentation, and multi-axis sensors.  Did you know it is also used in the competitive arena of auto racing?  Performance demands are constantly being pushed for all types of racing machines, whether it’s for NASCAR, IndyCar, or even the amateur level racing. What is known in the racing community is that engineers and manufacturers of equipment and parts used in these high-performance vehicles rely on Interface for precision testing solutions.

In our new case study, Building a Championship Race Car, we detail some of the specific sensor technologies used in the racing arena for high performance testing. We highlight how Interface’s TXY 2-Axis Load Cell is used in testing tires. Leading tire manufacturers, including SCCA sponsors, utilize these sensors to get precise test data on tire uniformity. The TXY has minimal cross talk across its strain gage bridges, ideal for this type of testing.

We also detail how our top load cell, the LowProfile, is frequently used in testing shocks, springs, and struts.  With any racing vehicle, control is fundamental, and the equipment used to maintain that control must be proven to meet the exceptionalism and requirements of racing professionals and their teams.

In this technical article, learn how the popular AxialTQ Torque Transducer, a bearing-less, compact wireless design, affords the test engineer suitable data collection for engine analysis, as well as brake HP calculations for active performance testing.

A competitive spirit runs deep within our Interface team, it’s what we do. We like to ensure our products are top class and help our customers win!  We also have first-hand experience in how our products are used in the racing arena. That experience affirms the positive performance effects of force measurement in auto racing.

Did you know that Interface’s Vice President of Sales, Brian Peters, has accomplished eight National Championships in Sports Car Club of America (SCCA) solo racing, and also competes in the One Lap of America cross-country, weeklong multi-competition racing event?

The annual SCCA National Championships draws more than 1,000 drivers from across North America to compete over two days. Wins are decided by mere thousandths of a second. Knowing how our products are used in high-performance racing environments, only fuels us more.

Performance and precision are critical and Interface force measurement solutions help to fine-tune critical racing vehicles, parts, and apparatus used to test different components in motorsports. We also like to say, it’s a competitive advantage. Read our case study to learn more.

Additional Resources

Powered by Interface Race Update from Brian Peters

Race Car Suspension Testing

Driving Force in Automotive Applications

Automotive and Vehicle

Interface Helps to Power the Electric Vehicle Market Forward

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Any time innovation is introduced into the market, it takes many years to iterate and realize the full potential of the technology. In today’s automotive marketplace, electric vehicles (EV) are reaching a point where the technology and capabilities are fully realized and is primed for an outbreak on mass scale. In fact, a recent IEA report found that more than 10 million cars on the road in 2020 were electric, estimated to be 2% of the market.

There are currently 370 models of electric vehicles sold today, with the number growing. To facilitate the further growth of the EV market, Interface continues to play a pivotal role in supplying force and torque test and measurement systems that meet the demands for superior testing requirements of all components used to make these vehicles. The automotive market, and especially EVs, are subjected to extremely strict regulations. Therefore, test and measurement are critical for every part for safety, reliability, durability, and overall vehicle performance.

Interface saw the rise in the electric vehicle market long before is the exponential adoption and growth and started early in investing in the development of force measurement technologies designed specifically to support testing of EVs. Our products we’re already well-known within the automotive industry because of our ability to deliver superior quality and high accuracy solutions that auto manufacturers and testing labs rely upon.

One of the most important developments in our lineup of EV compatible testing equipment was the introduction of AxialTQ™ torque transducer system in 2018. The AxialTQ system was engineered in direct collaboration with end-users who shared operational priorities, user interface, design, features, real-world field issues and more. The AxialTQ torque measurement system redefines the torque transducer category in terms a crash-proof design for maximum reliability, versatile model for application flexibility, simultaneous analog and digital outputs, real-time control and data collection and interchangeable stators and output modules that minimize parts inventory. You can see it in action in this video, AxialTQ Engine Dynamometer Application Note.

The rotor sensing element and electronics are the heart of the system which will be offered in 8 torque capacities in 5 DIN sizes. With the flexible capability of stator and output module mounting, the AxialTQ system offers vast configurations capabilities to meet any application need, especially for testing of EV motors. Watch the latest webinar, The Latest Spin on AxialTQ, to learn more about this dynamic auto testing transducer.

Torque Measurement for Electric Vehicles

When an electric vehicle manufacturer needed a torque measurement system for their electric vehicle, they contacted us to inquire about a solution designed for the unique needs of EV motors. These motors run at significantly higher rotational speeds than their internal combustion engine (ICE) counterparts and have much higher power densities due to the small size and light weight. The preferred system would be used to test the torque and speed of their electric motors to achieve and ensure optimum instant peak torque performance.

Interface provided its AxialTQ Wireless Rotary Torque Transducer to provide the highest quality torque measurement. This product was delivered with the AxialTQ Output Module and the provided AxialTQ Assistant Software, that is installed on a test bench. This allows data results to be calculated and collected in real-time. Using AxialTQ, the customer ran tests to sense the electric vehicle’s motor with high accuracy. It both measured and calculated the electric vehicles torque and rotational speed (RPM), while collecting data. Results are then be reviewed on the customer’s PC or laptop with the included AxialTQ Assistant Software. Using this solution, the customer was able to achieve their required instant peak torque.

This is just one of the many test and measurement solutions Interface provides to automotive manufacturers and makers of electric vehicles components.  Interface will be showcasing additional products used for auto testing at the next Automotive Test Expo.  You can see a highlight of some of these products in this highlight video of popular Interface automotive testing products.

ADDITIONAL RESOURCES

Advancing Auto Testing with Interface Measurement Solutions

Driving Force in Automotive Applications

Auto Industry Applications

Automotive and Vehicle

Torque Measurement for Electric Vehicles

Test and Measurement for Electric Vehicles

Recap of Latest Spin on AxialTQ Webinar

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Interface recently hosted a new webinar in our ForceLeaders series that highlighted the revolutionary AxialTQ product.  The event reviewed the bearingless wireless rotary torque transducer design and detailed component specifications, why test engineers prefer the AxialTQ, and use cases for this precision measurement system.

If you were not able to attend the Latest Spin on AxialTQ event, you can watch the entire recording online here.

The revolutionary AxialTQ was first introduced in 2018. The design originated from the popular HRDT product that utilized a rotor stator gap design as a single component. After hundreds of users, we started the product engineering exercise to see how we could advance the soon-to-retire HRDT and evolve it into something that would perfectly fit current market conditions.

As technologies were changing testing protocols and requirements, such as for electric motors, alternative energy hardware, space vehicles and industrial machine automation, we wanted to add new functionality. Jay Bradley and the Interface engineering team began the process by looking at DIN size optimization, shorter stators, additional coupling options, advanced software configurations and simple “drop-in” replacement parts with a modular design.

After thousands of design hours and testing, Interface released the AxialTQ. The specialized product is a unique combination of accuracy, reliability and ease of use that redefines the standard torque measurement device in terms of function and durability.

Engineers prefer the new AxialTQ because of the time-proven sensing element with longer active area providing greater measurement sensitivity while being less vulnerable to shock loads.  The high-resolution digital electronics are state-of-the art. Uniquely, the large gap design up to 6 mm axial and 12 mm radial minimizes contact damage which is important at high-speed testing. It has 120-degree partial loop antenna on the stator to make installation easier.

Specialized design features of AxialTQ make it a great fit for test and production applications.

  • Crash-proof design for maximum reliability
  • Industry-leading gap to prevent damage to rotor stator at full speed
  • Simultaneous analog and digital outputs, enables real-time control and data collection
  • Interchangeable stators and output modules minimize parts inventory
  • Versatile design and wide range of configurations to match any application
  • Hardware is self-configuring
  • New advanced software with added features and logging capabilities
  • Rotor and stator coils designed using printed circuit boards for durability

The AxialTQ rotor sensing element and electronics are the heart of the system. It has a rugged design for all types of torque measurement applications.  It comes in 8 torque capacities. The status assembly matches to the rotor DIN size and is interchangeable with equipment DIN size rotor assemblies, increasing usability.  The USB digital output module has galvanic isolation on all outputs and has standard IP65 ingress protection.  It enables real-time control and accurate data collection.

Keith Skidmore shared several use cases during the presentation, including engine dynamometers, motor test stands and other automotive production line applications.

The AxialTQ is designed for testing anything that spins. It’s ideal in testing and production of hydraulic motors, EVs, helicopters, aircraft, and drones, along with windmills and industrial fans.  It’s great for testing forklifts, off-road and utility vehicles as wells as tractors and watercraft.  AxialTQ is also generally used for measuring torque on industrial motor assemblies, pumps, appliances, braking systems, and motor vehicle accessories.

Watch the entire webinar below to hear Keith and Jay share tips, specifications, frequently asked questions and how to get the most out of your torque measurement applications.

Learn more about AxialTQ here.

Advancing Auto Testing with Interface Measurement Solutions

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What classifies as the automotive industry involves a complex and dynamic mix of suppliers, makers and designers of all types of vehicles, as well as prototypes of the changing demands and requirements of consumers both big and small.  Whether we look at where we are today with hybrid and electric motors, or autonomous rigs and people movers in test now, one thing that is constant is Interface’s role in providing vital measurement solutions for testing and real-time performance monitoring in the automotive and vehicle markets.

Automotive is one of the industries in which Interface has worked with since the introduction of our first load cells more than five decades ago. Force and torque measurement is critical to testing at every stage of design and manufacturing. Our sensor solutions, instrumentation and accessories are used across all facets of component development, including the testing of engines and exterior bodies, tires, batteries, fuel pumps and more.

Interface products are used for crash walls, brake testing, energy storage tests in the lab, seat belt and headrest testing, just to name a few. The fact is torque and force play a major role in making the vehicle move and ensuring it’s safe for drivers and pedestrians alike.  Interface is showcasing some of these solutions at the upcoming Automotive Test Expo. Registration to attend is free.

As the industry evolves, so do we. In fact, our advanced product AxialTQ was created for the automotive industry for testing of EVs. This revolutionary torque transducer is now used in all types of line production, assembly and part, including:

  • Internal Combustion Engine (ICE) Lab Testing and End of Line (EOL) Testing
  • Drivetrain Lab Testing
  • Automotive Accessory Lab Testing
  • Electric Vehicle (EV) Motor EOL and EV Lab Testing

For more about this dynamic product, you can watch our latest AxialTQ Webinar here.

Interface supplies high quality, precision load cells to automotive manufacturers, including custom one-off sensors and special application-specific designs. Standard off-the-shelf models such as our 2400 series , our 3200 series Stainless Steel LowProfile™ Load Cells, and our WMC Miniature Load Cell family are popular with machine builders and used anywhere a rugged stainless steel load cell is required.

Research and development facilities with precision applications favor our 1200 Series LowProfile™ Load Cells with their special moment compensated design. These are used in auto manufacturer assembly lines in a variety of production monitoring and verification applications. Our exceedingly accurate LowProfile™ Load Cells have been used in NASCAR and IndyCar garages for testing individual springs and entire vehicle suspensions.

A moment compensated Interface load cell has as much as 1,000 times less error from side load or moment as our competitor’s products. And many of our sensors feature 10x mechanical overload protection, which helps protect against unintended loads. Our Model BPL Load Cell is a very LowProfile™ load cell used for measuring force on gas, brakes or clutch pedals.

With a wide range of automotive vehicle load cell sensors, force and torque measurement capabilities, and features such as moment compensation, temperature compensation, and mechanical overload protection, Interface can help you design a solution perfect for your automotive application. In fact, here are a few examples of our products in action.

Airbag Connector Testing

Testing airbag connectors functionality is needed ensure perfect deployment to meet the ultimate test of saving lives. There are eight to twelve connectors installed in each vehicle, and tests are needed to be made in order to clarify the connectors are working effectively. The amount of force needs to be tested in order to see when an electrical current has triggered use.  Utilizing the WMC Sealed Stainless Steel Miniature Load Cell to the actuator of the test rig. The airbag connector is held in place at the bottom of the test rig. Forces are applied and measured using the 9330 High Speed Data Logger as the connector is pushed down to latch together.  Read more about this use case.

Seat Testing

During testing there was consistent overloading and replacing of the single-axis load cells. After a thorough inspection, it was discovered that this was due to bending moments that had never been quantified so a multi-axis sensor was defined as the best solution.  An Interface Model 6A68C 6-Axis load cell was installed in their existing test machine. The 6-Axis Sensor was intentionally oversized allowing the customer to measure the unidentified bending moments while preventing any damage. Data Acquisition and Amplifier BX8 was used to graph, log, & store the data collected at the sensor. Read more here.

Automotive Headrest Testing

When a manufacturer for automotive head rests wanted to test the durability of their products by conducting several fatigue tests and force tests on the head rests to make sure it meets durability and high-quality standards, Interface was able to help. The solution was to install Model 1000 Fatigue-Rated LowProfile™ Dual Bridge Load Cell to the customer’s actuator mechanism. This load cell is perfect for fatigue testing and reports highly accurate results through the fatigue cycling. The results are collected by using the SI-USB4 4-Channel USB Interface Module, which synchronizes the data directly from the load cell and the string pot (for measuring distance) to the customer’s computer. Using this system, the head rest manufacturer was able to get highly accurate data through the fatigue testing cycle. Watch the testing video in action!

 

Engine Dynamometer

Internal combustion engines are by far the most common power source for land vehicles. From a 2-stroke motor in a lawn mower, to a V-8 stock car engine, horsepower and torque are the benchmarks of engine performance. Engine manufacturers and aftermarket suppliers use an engine dynamometer (dyno for short) to accurately measure an engine’s performance. An engine dyno isolates an engine’s power output to help quantify its overall performance, applying a load directly to the engine and utilizing a load cell to measure the torque absorbed by the loading mechanism. Horsepower is then calculated using the torque and RPM of the engine. To conduct this test, a precision S-Type Load Cell is attached to a torque arm which “feels” the torque from the engine loading system. The Interface Model SSMF is a great choice because it is fatigue-rated for a number of fully reversed cycles and is environmentally sealed to withstand harsh environments. Utilizing the Model CSC Signal Conditioner provides a clear signal to a data-acquisition system. Using this test solution, the load cell reacts precisely with the amount of torque being produced by the engine and provides accurate signals to the data-acquisition system. Engineers are then able to analyze the power transfer for the engine and optimize for performance. Read more about this solution here.

For additional automotive solutions and use cases, go here.