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Interface Automotive Force Measurement Solutions

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Interface introduced our load cells to the auto and vehicle industry more than five decades ago. Quality and precision sensor technologies are essential to manufacturing and production for vehicles.

Interface force measurement devices are used for critical testing in both commercial and industrial vehicle design and production to ensure safety and reliability in the automotive industry.

As the industry has evolved and transformed, so has the products we supply to our customers in this market. Our range of solutions continues to expand in functionality and capabilities as complexities of testing throughout the entire journey, from component design and prototyping to rigorous safety testing of every piece of equipment progresses.

By creating highly responsive, critically accurate, and safer load cell and torque sensors, we are seeing our products used in all types of test and measurement applications, including:

  • Engine dynamometers
  • Lug nut assembly
  • Airbag connector testing
  • EV battery testing
  • ICE and EV motor torque testing
  • Equipment fatigue testing
  • Motor test stands
  • Brake and clutch pedal force
  • Engine head bolt tightening
  • Vehicle crash test walls
  • Race car suspension testing
  • Transmission gear box and gear mesh
  • Autonomous vehicle tests

Research and development facilities with precision application requirements 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 even been used in NASCAR and IndyCar garages for testing individual springs and entire vehicle suspensions.

Preview Interface products used in the automotive and vehicle markets in this new solutions video.

Here are two highlights of automotive application notes.  You can find more about automotive and vehicle solutions here.

Tire Testing

A top tire manufacturer needed a solution that would provide data analysis for stress testing.  The research would provide advancements to their product by defining the tire’s dynamic control capabilities. In review with our application engineers, they detailed they need to measure both the torque and lateral force in their testing.

Interface recommended the new AT105 Contactless Force Torque Transducer. With the torque and lateral force testing requirements, they determined that the best option to review the results by display as well as with graphing is to connect the transducers to the 4-Channel USB Interface Module SI-USB4.  You can see the entire solution and results in the Tire Testing App Note.

MDPS Testing

A manufacturer wanted to test the power steering for their vehicles. They want to test the linkage tension and compression between the rack and pinion. On a test frame, Interface’s 1200 Standard Precision LowProfile™ Load Cell was installed at the end of the rack and pinion actuator. As the wheel is turned, the load cell tests the push and pull forces. Force measurements can be displayed in real time using the highly accurate 9870 High-Speed High Performance TEDS Ready Indicator. The 1200 Standard Precision LowProfile Load Cell successfully measured the tension and compression between the rack and pinion of the customer’s MDPS system. You can see the entire solution and results in the MDPS testing App Note.

Additional Resources:

Driving Force in Automotive Applications

Advancing Auto Testing with Interface Measurement Solutions

Automotive Window Pinch Force Testing

Test and Measurement for Electric Vehicles

 

Gaming Hardware Benefits from Force Measurement Solutions

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When you think of the video game industry, hardware doesn’t quite get the same attention as the games themselves. Yet, the virtual environments and the software development that goes into creating one of the largest entertainments and now sporting sectors in the world, only operates when you have good hardware solution.

Whether it is the monitor, gaming chair, keyboard, controller, or computer, they all need to endure the enthusiasm of active and competitive gamers. This means each device must go through rigorous testing in the lab before it is ever released to the consumer.

Interface provides a variety of test and measurement solutions for gaming hardware manufacturers, from precision load cells of large and small sizes to wireless instrumentation and digital output modules for integration into simulation components.

One of the most popular gaming genres in the world is racing. It has elevated from single user experiences to the growing and ultra-competitive eSports phenomenon. The physical hardware of gaming pedals, chairs, and steering devices that a gamer uses to move and break the car in a virtual world is critical to creating a true experience.

As an example, the player expects the pedal to provide the feedback and feel of a real race car to not only immerse themselves in the game, but also to improve their performance and accuracy. To create a high-quality gaming pedal, sensors are used in the design engineering and manufacturing of these devices.

Load cells are a key component of a gaming brake pedal. In development and product design, force measurement testing utilizes load cells to help gaming pedal manufacturers perfect the amount of force needed to slow or stop a virtual car in various situations. It also is a benefit for testing durability and reliability.

Testing is also just one application of force measurement. These same sensors are carried over into the actual manufacturing process. Load cells are often integrated into the design of the gaming pedal to measure force in real time during play. This type of OEM solution enhances the overall gamer’s experience because it helps to improve performance of the pedal.

Interface develops a wide variety of highly accurate and reliable force measurement sensors for these types of applications. In addition, we also provide wireless strain bridge transmitters and data acquisition devices, as well as the software needed to create an entire force measurement system for measuring gaming pedals. In fact, we recently had the opportunity to develop a system that would measure brake pedals used for virtual racing.

Included below is an application note we put together to demonstrate the type of system we can develop, as well as the process used to help our customer develop a premium gaming brake pedal.

GAMING SIMULATION BRAKE PEDAL

When a gaming company, our customer, wanted to switch from standard racing pedals to a load cell based pedal system for their racing simulation game, they turned to Interface. Compared to the standard racing simulation pedals, load cell pedals are more advanced and offer more accurate results. Their goal was to find a wireless system that measures the strength of the pressure received by the pedals that will detect the perfect amount of braking power.

Interface provided a BPL Pedal Load Cell, which can be installed onto the gaming brake pedal to measure the force applied when someone puts their foot on it. Forces are measured and recorded using the WTS-AM-1E Wireless Strain Bridge Transmitter Modules, where data is transmitted to the WTS-BS-6 Dongle Base Station when connected to the customer’s PC or laptop.

Using Interface’s BPL Pedal Load Cell, the customer was able to measure and record the pedal forces applied to their racing gaming brake pedals. In comparison to traditional simulation pedals that measure the distance of the pedals when pressed, Interface’s load cell pedal system provided a more realistic experience for gamers.

The applications for Interface load cells grow larger every year. Hardware manufacturers want more data to help improve their products and confirm their designs through test and measurement. Interface is proud to be the world’s leading provider of the most accurate and reliable sensors. From gaming to farming and everything in between, chances are Interface has a solution for that can fit your exact requirements. If we don’t, we have the expertise to work directly with our customers to help develop a custom solution that is guaranteed to fit!

To learn more about Interface and wide range of products and systems built for nearly every industry, call to speak to an application engineer to discuss your next project at 480-948-5555.

Auto Industry Applications

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The automotive and vehicle industry has long relied on Interface products and services for accurate test and measurement programs and OEM products. Whether they are using our standard or custom load cells, calibration systems, load frames, multi-axis sensors or specialized torque transducers like AxialTQ, the applications uses for our quality sensor technologies are diverse in this sector.

Our team of solutions application experts recently put together three application notes that detail how automotive manufacturers, test labs and vehicle product engineers are utilizing our quality force measurement solutions.  Here is a brief summary of each app note.

Lug Nut Assembly Torque Application

T31 T32 T33 and T34 Spindle Style Rotary Torque TransducersThis application addresses the need to increase productivity for automobile wheel installation, while ensuring that the lug nuts are installed to the proper torque values for safety purposes. The solution from Interface was centered on the model T33 Spindle Style Rotary Torque Transducer for use in customer’s wheel installation assembly machine. These reliable and durable transducers come standard with +/-5VDC analog output for torque measurements and a 360 pulse, 2-track encoder for speed and angle measurement with simplified installation. In this application, the customer was able to perform five simultaneous torque measurements during wheel installation in seconds. The T33 Spindle Torque Transducer provided a signal torque and TTL for angle measurement back to customer’s control system so proper values could be applied and recorded.

SEE THE LUG NUT APPLICATION APPLICATION DESIGN HERE.

Fastening Work Bench Application

This application was used to increase productivity by creating a fastening work bench for screw installation with related data collection. The increased productivity would come through the use of automated tooling and torque transducer measurements resulting from an organized and efficient process. Interface supplied a model T15 Hex Drive Style Rotary Torque Transducer with integrated USB output for this project. USB output is used to measure and record torque, rotational speed and angle. The customer was able to utilize the industrial automation robotic functionality efficiently with many different screwdriver bit types with ease of installation due to the quick release feature of model T15.

SEE THE FASTENING WORK BENCH APPLICATION DESIGN HERE.

Bluetooth Brake Pedal Application

Testing engineers are able to utilize advanced connectivity and communication technologies to advance testing. For this specific application, the customer needed to measure brake pedal force when the pedal is pressed during vehicle testing. As the pedal is pressed, force is measured by the BPL-300-C Brake Pedal Load Cell. Results are transmitted by the BTS-AM-1 Bluetooth Low Energy (BLE) Strain Bridge Transmitter Module to the BTS Toolkit Mobile App and displayed on a mobile device. The customer objective has been achieved when a brake test was executed the force measurement was simultaneously displayed and graphed for examination in real time in the tested vehicle.

SEE THE BLUETOOTH BRAKE PEDAL APPLICATION DESIGN HERE

You can see more solutions for the automotive and vehicle industry here.  Need to talk to our application engineers, distributors or representatives, click here to contact us. You can find more Interface application notes here.

Brake Testing with Interface Bluetooth Solutions

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Automotive testing for brakes requires trust and accuracy in ensuring safety is first and foremost for any driver and passenger, no matter the amount of applied force. Automotive safety is most important for all manufacturers in the industry.  Interface products used in the test and measurement applications for brakes are most frequently selected based on quality, reliability, and precision.

In this application note Interface outlines how it was able to help a customer measure brake pedal force using its new Bluetooth Telemetry System (BTS) and a BPL-300-C Brake Pedal Load Cell.

Interface was asked to outline how a customer could help in measuring brake pedal force when the pedal is pressed during automobile testing, preferably with a cordless solution.  There are two critical components that Interface recommended based on all the customer’s requirements.

BPL-300-C Brake Pedal Load Cell:

  • Interface’s Brake Pedal Load Cell has the lowest nonlinearity and hysteresis of any brake load cell available.
  • It features ultra-low height and low sensitivity to off-axis loads.
  • It mounts directly to the pedals with included straps and has interchangeable mounting plates.

BTS-AM-1:

  • The BTS-AM-1 is a Bluetooth Low Energy (BLE) strain bridge transmitter module that provides access to high-quality measurements on a mobile platform such as a phone or tablet.
  • The delivery mechanism is BLE which utilizes the flexibility and availability of Bluetooth receivers while maintaining the low power requirements of embedded systems.
  • Features high measurement resolutions, simple integration into IOS and Android Apps, 30 to 90 m range and advanced security.

Noted in the application use case, as the pedal is pressed, force is measured by the BPL-300-C Brake Pedal Load Cell. Results are transmitted by the BTS-AM-1 Bluetooth Low Energy (BLE) Strain Bridge Transmitter Module to the BTS Toolkit Mobile App and displayed on a mobile device.  As the pedal is compressed, the force measurement data is transmitted through the BTS-AM-1 to the user via the BTS Toolkit Mobile App

How it Works:

  1. The Interface BPL-300-C is securely mounted on the top of the brake pedal.
  2. The load cell is connected to the BTS-AM-1 Module.
  3. The BTS-AM-1 Module transmits via Bluetooth to the BTS Toolkit Mobile App.
  4. The BTS Toolkit Mobile App runs on iPhone or Android devices.
  5. The brake test is performed and results are displayed in real-time on the BTS Toolkit Mobile App.

Using the Interface BPL-300-C Brake Pedal Load Cell and BTS-AM-1, the customer was able to execute the brake pedal test and measure the results in real-time Bluetooth technology. The force measurement data was simultaneously displayed and graphed for accessibility and readability.

Learn more about the Bluetooth and Wireless Telemetry Solutions here.

Bluetooth Brake Pedal App Note

Load Cells for Consumer Product Applications

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Typically, when engineers talk about load cells and their multitude of uses, it is assumed the applications are large-scale industrial projects like airplanes, rockets, and automobiles. However, did you know Interface load cells are regularly used for research and development (R&D), manufacturing, and end-of-line testing for countless consumer products?

Force is one of the most critical pieces of measurement in product development. This is especially true for consumer products that we interact with every day. Load cells are the tools that ensure products feel, handle and react the way they should in a consumer’s hand.

Here are a few examples showcasing how load cells touch almost everything the consumer touches.

A perfect example of a consumer product where force measurement plays a critical role in human interaction is in the abundance of numerous touch screens. Load cells are used in the R&D process to measure the accuracy, pressure, and sensitivity of the touch screen consumer interacts with on a minute-by-minute basis. The little things we don’t think about when using a tablet or smartphone, such as the smooth feeling of scrolling through social media pages, is possible because of testing using a load cell.

Another common consumer application type of load cells being used to improve product feedback and interaction is with simulation programs. High-end flight simulators often use load cells to measure the force of haptic feedback on the joysticks or chair when interacting with a flight simulator. The feeling of drag or rough winds a pilot experiences in a simulation is measured and refined for accuracy using a load cell.

Load cells are also an integral part of the manufacturing process for consumer goods. If you’ve ever seen a piece of candy with a logo stamped on it, chances are high a load cell was involved in determining the level of force to apply an exact brand stamp. Load cells are used on the stamping machine to ensure the right amount of force is used to apply the logo without crushing the candy.

In the food and drug industries, load cells are used in manufacturing facilities and on a wide variety of packaging machines. They are used for ultrasonic welding, which is the sealing process for plastic, paper or fabric shopping bags, garbage bags, and diapers. Potato chip assembly lines use load cells to weigh the bags as they fill them with chips to know when to stop and move on to the next bag. And the same stamping process used for candy in applying labels is used on pills.

Companies also incorporate load cells in end-of-line product testing. Furniture often goes through rigorous testing to ensure reliability. The furniture has various loads applied to it to confirm it can hold heavier weights over time, the furniture can also be bent and flexed to check the quality of the materials.  To reduce waste and ensure product quality, many consumer bottles use a torque transducer for end-of-line testing to test the proper cap implementation.

Batteries are another consumer product that goes through R&D and end of line testing to measure the force needed to damage the casing.  This is used to eliminate poorly designed and assembled batteries, as the acid inside can do immense harm if a child or adult is able to accidentally crush one.

Force measurement is also something that plays a role directly in the products we use. For instance, scales we use to weigh ourselves, food, and more, have load cells in them. Racecar gaming brake pedals are another example. High-end racing simulators need their brake pedal to be very accurate at measuring the amount of force applied to it to react as a real car would. Load cells are implemented in the base to provide accurate force readouts to the simulator in real-time.

Most products we all interact with every day have had some force testing or are currently using a sensor to manage its use and reliability.  Other consumer products that use Interface load cells, in all capacities and models, include treadmills, skis, bicycles, coffee makers, gaming brake pedals, boats, golf balls, desk drawers, guitars and robotic vacuums. And that is just to name a few.

Load cells and other force measurement tools like torque transducers are an integral part of developing, testing, and manufacturing reliable and accurate consumer goods. Think about this the next time you are handling your smartphone or carrying in groceries from the store. None of it would be possible without the use of force measurement equipment.

Contributor:  Kim Williams, Business Development Manager at Interface