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Force Measurement Testing Improves Products and Consumer Safety

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Across every industry, force measurement solutions are utilized to improve product performance, safety and quality. Sensor technologies are used every day to test various consumer products’ weight, torsion, tension, compression, fatigue, impact, and materials.

Force measurement testing is used throughout the product development lifecycle, from concept and R&D, through engineering and testing, to manufacturing and distribution, leading to eventual utilization. Interface load cells are commonly integrated into actual consumer products for activation and to measure performance during use.

Interface force measurement solutions are also used in the testing of equipment, machines, and tools used in the production of all types of products and goods. Our products are used in industrial automation robotic arms as well as within lifting equipment deployed to move materials around a facility.

The key to all force measurement testing is accuracy and reliability of data, as well as selecting the right type of force sensor for the specific product being testing.

Types of Product Testing Applications Using Interface Measurement Solutions

  • Weighing Applications: Interface miniature load cells are often for product testing to measure the exact weight of consumer products, such as food, beverages, and electronics. This information is critical R&D, as well on the production line and to meet the exact product specifications. Our load cells help to ensure that the products are not underweight or overweight, and comply with regulations. Read more about Load Cells for Smarter and More Efficient Weighing
  • Material Applications: Interface LowProfile load cells are often found in product testing labs to assess the strength of materials used in consumer products such as plastics, metals, and mixtures of composites. The measurements gathered during the product testing safeguards consumers and confirms the product’s durability. Read Interface Solutions for Material Testing Engineers
  • Force Applications: Interface load cells, torque transducers, and instrumentation are used in complete test systems that examine the usability of products such as exercise equipment, appliances and electronics. The data acquired in shear, tensile and force testing is important to understand if the product meets design specifications, is easy to use and does not require excessive force to work.
  • Safety Applications: One of the most important product use cases for Interface measurement solutions is to test the safety of products such as furniture, toys and automobile features. It is a requirement for every maker of products that are not hazardous and will not cause injury to consumers. Read Interface Solutions for Safety and Regulation Testing and Monitoring

To give you a better idea of how our load cells and instrumentation are utilized in distinct types of product tests, we have included a few application notes below outlining real-world examples of force testing projects.

Bicycle Helmet Safety and Impact Product Testing

A high production bicycle manufacturing facility set up a product testing lab to measure the impact of the safety of their helmets when dropped from different heights onto a flat surface such as an anvil. This test is necessary to ensure consumer safety and that the products are made with the highest quality materials to protect the rider. Interface suggests installing the 1101 Compression-Only Ultra Precision LowProfile® Load Cellat the bottom of an anvil. The bike helmet is then dropped from multiple heights and at multiple angles onto the anvil. The measurements from impact are then recorded and logged throughout the product testing using Interface’s INF-USB3 Universal Serial Bus Single Channel PC Interface Module with supplied software. Every design or material change runs through the same rigorous testing protocols using these high accuracy measurement solutions.  Read CPG Bike Helmet Impact Test

Product Weighing of Consumer Water Bottles

A manufacturer of glass bottled water needs to dispense the exact amount of fluid into each bottle and then weigh the water bottle to ensure it is at the labeled weight on the product packaging. The product testing of the manufacturing equipment is used to minimize waste and to meet the weight requirements to ensure consumer satisfaction. Interface suggests using the MBP Miniature Beam Load Cell and attaching it under a plate or platform where the water bottle is placed on while it is being filled with fluids. The force weight is measured by the MBP Miniature Beam Load Cell and connected to the 9870 High Speed High Performance TEDS Ready Indicator where results are captured, displayed, and logged for quality control. Read CPG Water Bottle Dispensing and Weighing

Product Test Lab Conducts High Volume Tensile Force Testing

A product test lab is constantly requested to conduct a series of tensile force tests on different samples and materials until failure. These materials include plastic, steel, or woven fabric, and are utilized in the design and manufacturing of several consumer products. The lab professionals want to measure tensile strength, yield strength, and yield stress for every submitted product material sample. For the tensile test stand, we recommend using Interface’s 1200 Standard Precision LowProfile™ Load Cell be installed into the test frame. As the tensile test is conducted, force results captured by the load cell and extensometer are synchronized through the SI-USB4 4 Channel USB Interface Module. The results are displayed on the customer’s computer with supplied software. Learn more by reading Material Tensile Testing.

Interface’s high precision force sensor technologies used in robotics have revolutionized the manufacturing of consumer products. With automated assembly lines and robotic arms taking charge, these machines work efficiently to mass-produce consumer goods. Quality control of all the products we provide you for testing is one of the main focuses of Interface, as we want to keep your customers happy and safe.

Interface’s experienced team are renowned specialists in force, torque and weight measurement manufacturing and technology. Our depth of knowledge and wide range of capabilities create custom solutions of all types, whether special transducers made to your exact specifications or complete customized sensor, instrumentation, and software systems. We collaborate with you to ensure the product specifications you need are designed to match your precise requirements.

ADDITIONAL RESOURCES

Introducing the Interface Consumer Product Testing Case Study

Interface Solutions for Consumer Products

Force Measurement is Reducing Waste and Automating the Consumer Packaging Industry

Applications for Consumer Products and Packaging

Load Cells for Consumer Product Applications

Why Product Design Houses Choose Interface

Testing Labs Choose Interface High Accuracy Products

Interface Solutions for Material Testing Engineers

Interface Solutions in the World of Sports

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With our headquarters in the golf capitol of the U.S., it is easy to see why Interface test and measurement solutions rank top for engineers and golf manufacturers to test the force of golf balls, range equipment, clubs, and even the carts that roam the course. But our sensor technologies have a much broader reach, in both sport and geography.

Why is force measurement so heavily involved in the making and designing of sports equipment? It is obvious even by definition; sports are considered an activity involving physical exertion and skill in which an individual or team competes against another or others for entertainment.

The physical exertion often utilizes some type of apparatus, device, tool, material, equipment, or gear that requires measurement of tension, compression, or rotation. Every sport differs and type of testing also will vary, whether from initial fatigue testing or actual designing sensors into the fitness equipment like a treadmill.

Our force measurement sensors are used across a wide variety of sports equipment to evaluate performance, lifecycle, durability, and quality.

Our specialty is building high accuracy solutions for the testing and monitoring of parts and total systems that move and create force, which is vital to makers and product designers of sports equipment and machines. Our force measurement solutions are ideal for stand-alone testing rigs, production equipment, as well as to embed in sports products in order to increase operability and reliability for end users.

Interface force measurement solutions are commonplace in sports gear and equipment R&D labs, design houses, manufacturer test and production facilities. The range of products we provide is as broad as the variety of sport categories, both individual and team. This applies to products used by consumers, as well as by professional athletes, trainers, and pro sport teams. We also collaborate with several engineers and manufacturers that build exercise and training equipment.

Interface has a history of providing our low profiles, s-types and miniature load cells for testing products used in individual sports such as running, weightlifting, mountain climbing, skiing, skating, bowling, fishing and cycling. We have created solutions that measure force and torque for gear used by competitive team sports including football, soccer, hockey, rugby, tennis, baseball, water sports and more. We have even seen an extended use in tools and equipment used in auto racing and even esports, who are using our sensors to test the actual gaming devices like brake pedals, driving gear and touch screens.

Interface is a global supplier of load cells, torque transducers, multi-axis sensors, and instrumentation for sport and fitness equipment. Here a few examples of where Interface solutions were used to influence the design, test, quality, and user experience.


Fitness Equipment Testing

A premiere maker of machines used in training and gyms around the world needs multiple load measurement systems for their different fitness machines. These machines included elliptical, leg press, rowing machine, and the cable machine to start. They want to ensure the machines functioning properly to prevent injuries. It can also be used for trainers who want to conduct strength and endurance tests.  A combination of products such as the WMCFP Overload Protected Sealed Stainless Steel Miniature Load Cell, SSB Sealed Beam Load Cells, and AT103 Axial Torsion Force and Torque Transducers. Paired with Interface’s proper instrumentation, the forces can be measured, graphed, and displayed during the testing stage. Read more about these solutions here.

Golf Club Swing Accuracy

Golfers undergoing training or practice wanted a system that will monitor and record their striking accuracy and swing movement. Interface created a custom made SSB Sealed Beam Load Cell that can be attached in line with the golf handle. When a golf ball is struck, force measurements are recorded, logged, and graphed using the WTS-AM-1E Wireless Strain Bridge Transmitter. The results transmit directly to the WTS-BS-6 Wireless Telemetry Dongle Base Station when connected to the customer’s PC or laptop. Using this solution, the customer was able to successfully record, graph, and log a golf player’s striking accuracy and swing movement with Interface’s wireless force system. Read more here.

Mountain Bike Load Testing

A mountain bike manufacturing company wanted a system that measures their bike frames load capacities and vibrations on the frame. They want to ensure the bike’s high quality and frame load durability during this final step of the product testing process for their future consumers. Interface suggested installing Model SSMF Fatigue Rated S-Type Load Cell, connected to the WTS-AM-1E Wireless Strain Bridge, between the mountain bike’s seat and the bike frame. This will measure the vibrations and load forces applied onto the bike frame. The results will be captured by the WTS-AM-1E and transmitted to the customer’s PC using the WTS-BS-6 Wireless Telemetry Dongle Base Station. With this system, the mountain bike manufacturing company was able to gather highly accurate data to determine that their bikes met performance standards through this final testing. Learn more here.

 

Golf Ball Tee Testing Machine

A customer wanted to ensure their golf ball automatic tee mechanism is working for their consumers- both buying their tee’s for home use or for golfing ranges. They needed a system that will sense the presence of a golf ball, which will trigger and automatically dispense new golf ball to the tee. Interface’s WMC Sealed Stainless Steel Miniature Load Cell was installed within the golf tee, which would measure the golf balls pressure on the tee when loaded or unloaded. This load cell is electrically connected to the motor which initiates the cycle to release another ball onto the tee. Force measurements can be measured using the 9330 High Speed Data Logger when connected to the customer’s PC or laptop. With Interface’s products, the customer was provided a force solution that was able to measure the presence of a golf ball on their auto-tee machine. Get more information here.

These are just a few examples of Interface’s work in the sporting goods and fitness industry. If it moves, rotates, pushes, or pulls, chances are that Interface has a solution that can help perfect the performance. To learn more about our work in sports and consumer goods.

ADDITIONAL RESOURCES

Interface Measures Fitness Equipment with Extreme Accuracy – Case Study

Why Product Design Engineers Choose Interface

Race Car Suspension Testing

CPG Treadmill Force Measurement

CPG Gaming Simulation Brake Pedal

CPG Bike Power Pedals

CPG Bike Helmet Impact Test

Mountain Bike Shocks Testing

Fine-Tuning Testing Solutions for Championship Racing Vehicles

Fitness Equipment Makers Require Extreme Accuracy

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Interface’s specialty is building solutions for the testing and monitoring of parts and total systems that move and create force. One of the industries where this is critical is the fitness industry. Equipment and fitness machines, whether designed for in-home use or in professional athlete training facilities, needs to perform safely and accurately.

Utilizing Interface sensors and instrumentation, the performance of different fitness apparatus is measured in various testing protocols throughout the product’s lifecycle. Rigorous tests are performed during each phase: R&D, design, manufacturing, and after-market use. These tests look at performance data, as well as measure reliability, durability, fatigue, and safety of the equipment. Manufacturers of fitness devices also utilize feedback from sensors to monitor user experiences in real-time. This means they need accurate data for all types of user profiles, strength variability, weights, and experience levels.

The global fitness market also needs a testing solutions partner as the industry is looking at solid growth over the next few years. In fact, Allied Market Research predicts that the fitness market will reach $14.8 billion by 2028, registering a CAGR of 3.3% year-over-year during this assessment period.

Interface recently captured a series of use cases for how our test and measurement products are used in the fitness industry for testing and in OEM applications. You can read the entire case study here: Interface Measures Fitness Equipment with Extreme Accuracy.

Addressing Challenges in Making Fitness Equipment

In the development of fitness equipment, a lot goes into the manufacturing and engineering process to ensure equipment is safe and reliable for users. Taking a treadmill as an example, the wheels that move the running surfaces must withstand varying speeds and levels of force over extended periods of time. This requires torque and stress testing. Additionally, the sensors on the handrails that send out a pulse to measure the user’s heart rate needs to provide accurate data in health and wellness uses. Manufacturers are looking to install sensors into their equipment that measure various forces and provide fitness data to the user, or data that doctors can use to monitor patients while working out. These makers and product designers for fitness equipment need sensors that can be easily designed into the product or customized to fit into existing products to enable smart functionality and IoT capabilities.

Interface Fitness Equipment Test & Measurement Solutions

Interface provides a variety of measurement solutions used by manufacturers and testing engineers in the fitness equipment sector. This includes our load cells, torque transducers, multi-axis sensors and miniature load cells, along with the popular wireless products and instrumentation. Our products have been used across a wide variety of fitness applications, including elliptical, leg press, rowing machines, bicycles both mobile and stationary, and physical training and therapy equipment. Interface sensor technologies are preferred by product design engineers in this field because of the precision, accuracy, range of options, and quality.

The following application notes examples provide an overview of how Interface serves the fitness industry:

Designing Fitness Equipment and Machines

A fitness machine manufacturer wanted multiple load measurement systems for their different fitness machines such as the elliptical, leg press, rowing machine, and the cable machines used in gyms of all types. The goal of designing sensors into the equipment is to ensure the machines are functioning properly to prevent injuries. The sensors can also be used for trainers who want to conduct strength and endurance tests. Interface provided a combination of products including the WMCFP Overload Protected Sealed Stainless Steel Miniature Load Cell, SSB Sealed Beam Load Cells, and AT103 Axial Torsion Force and Torque Transducers. Paired with Interface’s proper instrumentation, the forces can be measured, graphed, and displayed during the testing stage. Interface’s products all effectively measured forces needed for those working out or undergoing athletic training regiments. Not only did it ensure the designed machines were working properly, but it also helped those using them to track their endurance performance and consider future design enhancements based on consumer use. Read more about this use case.

 

 

Treadmill Rehabilitation

A medical device maker wanted a force measurement system for their experimental rehabilitation treadmill for patients that have pelvic mobility difficulties. For example, patients who have had strokes tend to have difficulty walking. Their goal was to measure the forces applied on the pelvis when the patient is walking on the treadmill and catch any pelvic deviations. The treadmill had a special harness with two actuators on either side of the patient when in use. Interface suggested installing two WMC Sealed Stainless Steel Miniature Load Cells to the actuators, which will measure the forces applied on the pelvis of the patient. Force results would be measured using the SI-USB4 4-Channel USB Interface Module, which could also be graphed and logged on the customer’s computer with supplied VS3 software. Using this solution, the medical company was able to catch different pelvic deviations in their experimental rehabilitation treadmill using Interface’s products. Learn more here.

Bike Power Pedals

A bike manufacturer wanted to evaluate the functionality of their power pedals. They needed a reliable system to measure how much force the cyclist pushes down onto the bike pedals, and they preferred a wireless system that can be paired with their computer to review data results. Interface suggested four Model SML Low Height S-Type Load Cells installed within the bike’s pedals. The four SMLs are paired with two WTS-AM-4 Wireless Strain Bridge Transmitter Modules, which will transmit the force data from the cyclist to the WTS-BS-6 Wireless Telemetry Dongle Base Station Dongle connected to the customer’s computer. The products Interface provided allowed the bike manufacturer to measure the pedal power applied by the cyclist. Read more here.

Interface load cells, torque transducers, and data acquisition systems are ideal for many fitness applications, especially those designed for IoT connectivity. Interface offers products that measure all types of force across the necessary fitness applications. Additionally, if we don’t have a product that works for your exact challenge, our custom solutions team will work alongside your design and test engineers to create the most effective and efficient solution based on the unique specifications.

ADDITIONAL RESOURCES

Bike Frame Fatigue Testing Application Note

E-Bike Torque Measurement

Why Product Design Engineers Choose Interface

Golf Club Swing Accuracy

Golf Ball Tee

Interface’s Steering Role in All Types of Transportation

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Interface serves a wide variety of industries that design and manufacture movers of people and objects. The transportation sector consists of companies that assist in the movement people or goods, as well as supporting infrastructure. Whether it is automobiles or planes, trains or helicopters, spacecraft or water vessels, Interface provides solutions to help test and measure force, weight, torque, lift and more.

The safety, quality and reliability of the overall transportation industry are all important considerations in design, build and performance. Human safety being the most critical requirement of any transport vehicle or structure.

This means that stringent testing is necessary to confirm the design of every part and system on a vehicle. Force measurement sensors can used to test a wide variety of factors on every type of invention that moves or transports a person or thing. From the torque of an electrical vehicle engine to the weight distribution of an aircraft, these types of tests help to refine the designs of components, vessels, and vehicles, confirming safety and dependability.

All Interface product categories have a role in the testing of all these transportation entities.  Many of our sensor technologies are also ideal for performance monitoring and integration into product designs, whether it’s for ongoing measurement of weighing ship cargo with load pins, load shackles and tension links or using our torque transducers for engine testing on e-bikes, automobiles, trucks, buses, and other transport vehicles.  If it moves, it needs to be measured. Our force and torque solutions are ideal for every segment of this market sector.

Let’s take a quick tour of a few application examples that demonstrate the different products we provide that are helping get people and objects safely moving down the road, on the rails, in the air and even into space.

Wind Tunnel Testing

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 offered a Model 6A154 6-Axis Load Cell which was mounted in the floor of the wind tunnel and connected to the scaled model by a stalk. A Model BX8-AS was then connected to the sensor to collect data. The wind tunnel blew air over the scaled model creating lift and drag, which was measured and compared to the theoretical airplane models. Software in the PC converted raw data signals to actual force and torque values at the stalk. Using this solution, the company was able to analyze the collect data and made the necessary adjustments in their design to improve the aerodynamics of their theoretical airplane models. Read more.

Garbage Truck On-Board Weighing

A garbage disposal company wanted to test the load capacity of their garbage truck bins so they know when it reached maximum capacity. Interface’s solution was to customize and install 4 SSB Sealed Beam Load Cells under the garbage box body, on either side. When trash continues to be piled inside the box body, it will push more force down onto the SSB Sealed Beam Load Cells. When maximum load capacity has been reached, the results can be reviewed and displayed when connected to the 482 Battery Powered Bidirectional Weight Indicator in real time. With this system, the customer was able to test the maximum load capacity of the garbage bin attached to the truck, so they know when to empty the truck’s garbage at the transfer station. Read more.

Engine Head Bolt Tightening

 

 

 

 

 

An industrial automation company was building an automated assembly machine for an auto manufactur­ing plant. They needed to tighten all 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. Several Interface Model T33 Spindle Torque Transducers were installed in their new machine to control torque, 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. When the machine comes down and screws on the engine head bolts the torque and angle profile are sent to the customer’s machine controller. Based on the feedback received by the machine controller, the automation will pass the engine to the next step in the assembly line or fail and have the engine evaluated further. This allowed the customer to ensure the head bolts were correctly installed according to manufacturer specifications, producing an engine that meets performance and reliability expectations of the auto manufacturing plant. Read more.

Bicycle Load Testing

A mountain bike manufacturing company wanted a system that measures their bike frames load capacities and vibrations on the frame. They also want to ensure the bike’s high quality and frame load durability during this final step of the product testing process. Interface suggested installing Model SSMF Fatigue Rated S-Type Load Cell, connected to the WTS-AM-1E Wireless Strain Bridge, between the mountain bike’s seat and the bike frame. This will measure the vibrations and load forces applied onto the bike frame. When a heavy load is added to the seat, the SSMF Fatigue Rated S-Type Load Cell measures the vibrations and load forces applied to the bike to indicate any stress points through a number of cycles. The results will be captured by the WTS-AM-1E and transmitted to the customer’s PC using the WTS-BS-6 Wireless Telemetry Dongle Base Station. This solution helped the mountain bike manufacturing company gather highly accurate data to determine that their bikes met performance standards through this final testing cycle. Read more.

These are just a brief example of the work we do in transportation. Interface systems have been involved in projects with boats, races cars, construction vehicles and even rocket ships. Manufacturers turn to Interface because of our track record for accuracy and the transportation industry relies on this data to keep its customers safe.

For additional insights and ideas related to transportation solutions, here are a few more posts to read.

Interface Plays a Role in Testing Bicycles

Evolving Urban Mobility Sector for Test and Measurement

Interface’s Crucial Role in Vehicle and Urban Mobility Markets

Measurement Technologies for Boats, Yachts and Watercraft

Interface and The Race to Space

Driving Force in Automotive Applications

To review more application notes pertaining to transportation or to talk to an application engineer about your next project, contact us or call us at 480-948-5555.