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Interface Solutions for Testing Tools

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

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.

Torque VerificationRatchet 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

Force Measurement Solutions for Bolt and Screw Fastening

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.

 

 

 

Interface Solutions for Robotics and Industrial Automation

As the manufacturing world continues to push towards the 4.0 Industrial Revolution, critical technology is necessary to ensure facilities are running as efficiently as possible. With advancements toward fully or semi-autonomous factories and robotics, manufacturers need to have total trust in their hardware and software to perform with precision in the assigned tasks. This requires collecting accurate and real-time data to constantly monitor every aspect of the facility’s technology and production.

In the development of robotics used in industrial automation, our Interface Multi-Axis Sensors are often used to test the multi-directional movement and force of robotics arms. Whether it’s a fully automated or semi-automated robotic system, manufacturers need to be able to ensure the complex movements and actions of the robotics arm are optimized to take on very precise jobs. These types of robotics are often used for projects that are too precise for the human hand.

Industrial automation and robotics are creating a more efficient manufacturing process, which will help to churn products out more quickly and lower costs. However, to optimize these processes, it’s critical that we trust the hardware to operate autonomously and that we have systems in-place to identify malfunctions quickly.

Interface plays a critical role in robotics and industrial automation by providing our customers with highly accurate load cells and torque transducers to measure and collect data on the force and torque that these machines are exerting. Interface force measurement solutions and products are involved in the testing of the machines before they hit the production line, and in some cases, our products are also installed directly on the machine to allow users to monitor the force in real-time.

One industry that has a high demand for our products is the consumer packaging industry. Many of the processes involved in the production line of a consumer packaging plant have utilized automation for a long time.

For instance, beverage companies that sell bottles of water or soda utilize machines that cap the product all day long. Hundreds of thousands of bottles go through the capping process on the production line daily. If there are any issues with the torque applied in the capping process, the beverage company could see heavy losses because the bottle could be damaged from over torquing the cap, or the beverage could leak during the shipping process if the caps are under torqued. To avoid these loses, the machines are optimized using a torque transducer.

Torque transducers provide data during the testing process to help the machine manufacturer get the force exactly right for the capping process. The torque transducer can also stay installed on the machine so that the beverage company can continuously monitor the torque of the machine and stop production before damages occur if there is an issue.

Interface offers nearly 50 types of reaction (static) torque transducers and rotary (dynamic) torque transducers. All of our torque transducers are precision-machined and use our proprietary torque sensors for the most accurate data possible.

Another common automation use for force and torque measurement products is in the automotive industry. Automation in this industry has been used for some time increase production of cars.

Two examples of how Interface load cells and torque transducers play a role in the automobile production line is with seat durability testing and bolt fastening.

For seat testing, we had a customer use an Interface Multi-Axis Model 6A68C 6-Axis Load Cell to identify previously unknown bending forcing that could negatively influence their testing process. This allowed the customer to redesign their testing fixture to eliminate the bending moment and more accurately perform the durability testing.

For bolt fastening, we installed an Interface Model LWCF Clamping Force Load Washers along with Interface Instrumentation to monitor the force being applied during bolt tightening. This helped the customer avoid over tightening bolts, which could damage the product in the process.

For a more in-depth overview of both applications, please check out our application notes:

Force measurement products are a critical technology in the testing and monitoring of automation equipment. To learn more about the various products and instrumentation Interface supplies to facilitate industrial automation and support advancements in robotics, contact our applications experts here.  We also have a number of application notes focused on industrial automation here.

Contributor: Ken Bishop, Sr Sales Director, Custom Solutions and Services