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Force Measurement Solutions Support Innovation in Manufacturing

The manufacturing world is enormous, covering multiple industries and applications for force measurement. The manufacturing sector comprises factories and plants that use machines and equipment to build parts and final goods.

With an estimated 21 million manufacturing companies worldwide, the industry is also becoming more advanced and regulated, with technologies such as AI and automation influencing manufacturing processes to drive efficiency and safety.

There are various types of manufacturing, from repetitive, continuous, batch, job shop, and discrete.  All employ tools, machines, and equipment used through multiple processes. Manufacturers use Interface load cells, torque transducers, multi-axis sensors, and instrumentation to improve products and processes, meet performance requirements, automate machines, protect workers, and test designs. Force measurement supports innovation in manufacturing.

With advancements and process improvements, testing and measuring are primary to every manufacturing stage. It begins with product planning through machine building. Moving to assembly and monitoring production lines, sensors are at work through final distribution. Manufacturing engineers use Interface devices to test assembly line equipment, design and operate robotics, improve machinery, and operate tools like presses.

Manufacturing equipment and processes that utilize Interface load cells and torque transducers:

  • Conveyor Belts
  • Robotics and Cobots
  • Torque Wrenches
  • Tension Testing Machines
  • Weighing Systems and Scales
  • Heavy Machinery
  • Transportation and Moving Equipment
  • Mixers
  • Packaging Equipment
  • Sorting and Picking Devices
  • Material and Stress Testing Labs
  • Fatigue and Compression Testing Equip

How Manufacturers Use Interface Products

  • Research and Development: The measurement data from transducers provides a valuable roadmap to improving the design of products and processes.
  • Testing: Every product undergoes rigorous testing before hitting the line. Interface force measurement devices are essential for this manufacturing phase to validate the use, lifecycle, and materials.
  • Machine and Tool Building:  Machine builders use Interface sensor technologies to weigh raw materials, components, and finished products to ensure they meet the required specifications. Force measurement devices are important in measuring applied force by equipment and processes that help control product quality and prevent accidents. Machine builders frequently use load cells to monitor loads over time to detect and prevent potential machine problems. Read more about why Machine Builders Choose Interface.
  • Quality Assurance: Interface products are used to measure the weight of manufactured products to ensure that they meet specifications. This is important for consumer goods, pharmaceuticals, medical devices, and other products where precise weight measurement is critical for safety and effectiveness.
  • Automation: Force measurement products are valuable in automation. As robotics, cobots, tools, and machinery are designed to automate tasks and processes in manufacturing, load cells like our multi-axis sensors provide valuable analysis data through all phases of automation.
  • Retrofitting Existing Equipment with Sensors: Manufacturers require modern tools and equipment to meet growing demands. Interface products are used to retrofit machines and update tools with sensor-based technologies, such as replacing machine pins with load pins that measure loading and lifting in real-time.
  • Safety and Regulation: Sensors prevent accidents by detecting dangerous conditions in the manufacturing industry. Using measurement systems for alarms, alerts, and monitoring of equipment and tools is critical in manufacturing plants.
  • Process Control: Manufacturing operations monitor the force or weight of materials in a facility to control the process and ensure that products are made to the correct specifications.
  • Productivity and Equipment Maintenance: Using Interface products to monitor the condition of equipment and detect potential problems before they cause downtime helps to prevent costly breakdowns and production delays.

Our depth of force measurement expertise and experience enable us to innovate, engineer, and produce the world’s most accurate, reliable, and quality sensor technology for manufacturers worldwide.  This can be seen through some specific application examples in which Interface solutions have been involved. We have included a few of these examples below.

robotic grinder containing 6A40 6-Axis Load Cell and BX8-HD44 BlueDAQ Series Data Acquisition SystemRobotic Grinding and Polishing During Production

Robotic grinding and polishing are commonly used in manufacturing. Robots or cobots are programmed to grind and polish on varied materials and surfaces. A force measurement system must be implemented to monitor and control the force exerted on the grinding workpiece. Interface’s Model 6A40A 6-Axis Load Cell can be installed between the flange and the grinding tool. When connected to the BX8-HD44 Data Acquisition, the customer can receive force and torque measurements when connected to their control system using BlueDAQ software. The 6A40-6 Axis Load Cell measures all forces and torques (Fx, Fʏ, Fz, Mx, Mʏ, Mz), and our BXB-HD44 Data Acquisition logs, displays and graphs these measurements while sending scaled analog output signals for these axes to the robot’s control system. Manufacturing: Robotic Grinding and Polishing application.

Manufacturing Feed Roller System

A customer has a feed roller system that monitors the forces of both ends of the rollers to maintain a constant straight feed. They preferred a wireless system. Interface suggested installing two PBLC Pillow Block Load Cells at both ends of the bottom roller to measure the applied forces. The forces were measured when connected to the WTS-AM-1E Wireless Strain Bridge Transmitter Module. The data was then transmitted wirelessly to the WTS-BS-6 Wireless Telemetry Dongle Base Station and the WTS-BS-1-HA Wireless Handheld Display for multiple transmitters, where data was displayed, graphed, and logged on the customer’s PC or laptop. The PBLC Pillow Block Load Cells installed at the bottom roller were able to measure and monitor the forces to maintain the straight feed by the rollers. Manufacturing: Feed Roller System app note.

Press Load Monitoring for Material Testing

Press forming is a method to deform different materials. For instance, materials such as steel can be bent, stretched, or formed into shapes. A force measurement solution is required to monitor the forces the press-forming machine applies. This ensures quality control and traceability during the production process. Interface recommends installing the 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell for large press forming machines. When the material is placed under the punch plate to form a shape, the force applied is measured by the Interface 1000 Series Load Cell. The captured force results are sent to the INF-USB3 Universal Serial Bus Single Channel PC Interface Module, where results can be graphed and logged on the customer’s PC using the provided software. Interface’s force measurement products and instrumentation accurately monitored and logged the force results of the press force machine, ensuring zero-error production performance.

Interface began designing and manufacturing load cells and other force measurement equipment in 1968. These precision load cells are commonly found in factories worldwide in testing equipment, scales, machines, and production line devices. Load cells help bring life to older machines with accurate measurements while in use, ultimately improving maintenance and worker safety in manufacturing.

Our force measurement products are versatile and valuable tools for manufacturers. Our sensor solutions improve the quality, safety, and efficiency of products and the equipment and tools used to make them.

Manufacturing Solutions Brochure

 

Conveyor Belts Use Load Cells to Keep Things Moving

Conveyor belts are incredibly versatile machines with numerous applications across industries, constantly moving materials from one point to another. During some of the busiest packaging and shipment times of the year, it is a good reminder of why measurement solutions keep things moving fast and efficiently.

Critical for automated manufacturing, conveyor belts rely on precise weight distribution, timing, and speed of the conveyor belt operation to keep production in sync.

Conveyors are used for sorting and merging systems, inspection systems, and automated loading and unloading using robotic arms or other equipment to handle materials efficiently. Their versatility and adaptability make them critical in modernizing industries, including construction, mining, manufacturing, logistics, maritime, and agriculture.

Boxes, cans, bottles, and other packages glide smoothly through packaging lines on conveyor belts, ensuring efficient sorting, labeling, and palletizing. These machines efficiently load and unload ships, trucks, and trains with bulk materials, minimizing manual labor and maximizing throughput. Conveyor belts are crucial in sorting and distributing packages in warehouses and postal facilities, speeding up delivery processes.

It is also important to recognize how specialized conveyor belts transport people in public spaces. Conveyor belts seamlessly whisk luggage from check-in counters to aircraft and vice versa, ensuring a smooth passenger experience.

Force measurement can be applied to testing and monitoring conveyor belts in several ways. One of the most common ways is by using load cells to measure the alignment of the belt. Load cells can detect subtle changes in belt behavior, such as uneven loading or misalignment, which can indicate internal damage like cracks or tears. Early identification of these issues allows for timely interventions, preventing further damage and costly repairs.

Testing the conveyor belt rotation or ability to hold weight is a requirement for equipment makers and engineers. Machine builders use Interface sensors in the design of conveyors. In addition to monitoring the system during peak usage, load cells are instrumental in testing the equipment’s quality and durability.

Load cells on the head and tail pulley shafts continuously monitor belt tension for preventative maintenance. This data helps identify deviations from optimal tension levels, leading to premature belt wear, pulley misalignment, and energy inefficiency.  You can prevent costly repairs and downtime by addressing these issues early on.

Conveyor systems often have multiple belts working in tandem. Load cells can monitor the load distribution across these belts, ensuring balanced operation and preventing the overloading of individual components.

Conveyor Belt Adhesion Test

A customer wanted to test the adhesion strength between a conveyor belt’s many layers and textiles. They wanted to conduct a separation test from the rubber of the conveyor belt from the other layers. They also wanted a wireless solution. Interface suggested a SMA Miniature S-Type Load Cell to be installed in the customer’s tensile test load frame, where it measured the forces applied as the test was conducted and the layers were pulled and separated. When connected to the WTS-AM-1F Wireless Strain Bridge Transmitter Module, the data was wirelessly transmitted to WTS-BS-5 Wireless Analog Output Receiver. The WTS-BS-5 then connected to the 9330 Battery Powered High Speed Data Logging Indicator to display, graph, and log the data with the supplied BlueDAQ software. With Interface’s force measurement system and solution, the customer successfully tested the strength of the adhesion applied to their conveyor belts through the layer separation test.

Force measurement sensors can be built into machines as a real-time monitoring system. This type of force application can let engineers know if there is a problem with the system that needs to be taken down for repairs by reviewing data and seeing discrepancies in the normal forces on the conveyor belt. This is particularly important in maintaining efficiency on production lines to ensure minimal downtown.

Food and Beverage Conveyor Belt equipped with PBLC Pillow Block Load Bearing Load Cells and 920i Programmable Weight Indicator and ControllerFood And Beverage Conveyor Belt

Conveyor belts for the food and beverage industry must be maintained and properly aligned to transport products. A load cell is needed to prevent misalignment and to reduce the risk of damage or malfunction of the belt while in operation. Interface suggested installing PBLC Pillow Block Load Bearing Load Cells onto the conveyor belt. They are designed for easy maintenance. The PBLCs measured and monitored the force of the conveyor belt while preventing misalignment. The PBLC Pillow Block Load Cells successfully maintained the proper alignment of the conveyor belt for the food and beverages being transported while also monitoring the forces being implemented.

In automotive, electronics, and other production settings, conveyor belts move components and products along the assembly line, facilitating efficient workflow and ensuring precise positioning.

Conveyor belts easily handle diverse materials, from transporting heavy metal sheets in steel mills to delicate circuit boards in electronics factories. They are the go-to for transporting vast quantities of mined ores, coal, grains, and other bulk materials over long distances and uneven terrain.

Conveyor belts move waste and recyclables efficiently in processing facilities, ensuring efficient sorting and processing. Industrial automation robotics often supports this as part of advanced conveyor systems.

Automating Conveyor Production Lines

Collaborative robots, known as cobots, are used to working alongside humans next to conveyor belts on the production line. Extensive safety measures must be taken for the conveyor and the robot for optimal efficiency and operations. A multi-axis sensor is a tool for this use case. The 6A40 6-Axis Load Cell is installed at the head of the cobot. The 6A40 6-Axis Load Cell interfaces with the BX8-HD44 BlueDAQ Series Data Acquisition System for data collection of force and torque measurements on the line. The customer connected the BX8’s analog outputs to their control system. As a result, the customer can log, display, and graph these measurements during the robot and belt operations. The results are sent to the customer’s control system via analog or digital output.

Interface products are commonplace in these types of applications. Force measurement is integral to advanced manufacturing systems like conveyor belts. Our sensors are utilized to ensure accuracy and repeatability throughout the production line.

We understand manufacturing test and measurement applications, and our custom OEM solutions are ideal for manufacturers who require direct installation to monitor weight, force, and torque into conveyor belt systems.  Contact our application experts to see how we can help you modernize your conveyor systems with advanced sensor technologies.

ADDITIONAL RESOURCES

Manufacturing Solutions

Interface Solutions for Heavy Equipment

Heavy Machinery Solutions

Production Line Solutions

Interface Solutions for Production Line Engineers

Examining Machine Builder Applications

 

Force Measurement for Efficiency in Food Processing and Packaging

Interface provides the food processing and packaging industry with sensor technologies that increase efficiency and reduce waste. Like many industrial facilities, organizations are pushing hard to integrate new technology and automation that makes processes faster, more adaptable, and smart.

One of the factors critical to creating a smarter factory is by utilizing force measurement sensors that are designed for collecting data in each production phase, as well as monitoring equipment in use for performance optimization.

Interface has a wide variety of precision-based accurate and reliable sensors used for various applications in food processing and packaging. Our customers are using miniature load cells within the production line to apply the exact force needed to delicately press a logo onto a edible product. We have others using multi-axis sensors from Interface to verify accuracy of intricately machined parts while moving through the manufacturing process.

We’ve provided sensors for industrial automation solutions to thousands of customers using in-stock as well as custom application-specific sensors for OEM equipment. Read our Force Measurement is Reducing Waste and Automating the Consumer Packaging Industry OEM case study to learn more.

Below are additional examples that highlight uses case of actual applications in food processing and packaging.  You can see additional industrial application highlights in our solutions overview by clicking here.

Commercial Food Processing

A food processing plant wanted accurate results of their in-motion check weigher when food is weighed and processed while moving down the belt.  A check weigher is an automated machine for checking the weight of packaged commodities. This included ensuring production line efficiency and food quality, real-time results of their food being weighed, and a load cell that can endure the food industry’s soiled environment.

Interface offered a solution using multiple SPI High-Capacity Platform Scale Load Cells that could be installed in the customer’s equipment that is sued through the production line where product is weighed on the conveyor. The SPI High-Capacity Platform Scale Load Cells delivers precise weighing data. When connected to the 920i Programmable Weight Indicator and Controller, the solution provides the customer real-time results of the weight of the food. The 920i Programmable Weight Indicator and Controller can also read up to four scale channels in real-time. The processing gains in efficiency were visualized and managed during the weighing process to optimize control and production. 

Water Bottle Dispensing and Weighing

 

A beverage bottle manufacturer wanted to dispense the right amount of fluid into their bottles, and then weigh their bottles to ensure it is at the labeled weight on their product packaging. This is both to minimize waste, but also to meet the standard requirements noted on the packaging. Interface suggested using the MBP Miniature Beam Load Cell, and attaching it under a plate or platform 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 recorded by the customer utilizing their water bottle assembly machinery. With this solution, the water bottle manufacturer received highly accurate results of each water bottle being weighed in real-time, using the accuracy to reduce waste and speed processing time.

Snack Weighing and Packaging Machine                     

A snack manufacturing brand wanted to weigh the amount of consumable food product automatically dispersed into the bags during the packaging process. In this case, they needed to weigh their potato chips being packaged and ensure the potato chips are at the exact weight needed due to regulatory standards. Interface’s solution was to use multiple SPI Platform Scale Load Cells and install it to the potato multi-head weigher and packaging machine. The SPI Platform Scale Load cells were installed inside of the mount that attaches the head weigher to the packaging machine. Force results from the potato chips bag fill are read by the load cells and sent to the ISG Isolated DIN Rail Mount Signal Conditioner, where the customer was able to control the automated production from their command center.

The customer was able to determine the weight of the potato chips being distributed into their bags with highly accurate results. They also were able to control the automated production process with the provided instrumentation. They will use this same weighing method for other snacks that need to be packaged.

To learn more about Interface solutions designed for the modern factory, or specifically the food and beverage industry, contact our expert application engineers.

Additional Packaging Application Note:

Candy Stamp Force Testing