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Force Measurement Sensors are Essential to Modern Industrial Machinery

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Industrial machinery plays a vital role in the global economy. It helps to improve productivity and efficiency, and it is essential to produce many of the goods we rely on daily.

Industrial machinery use cases range from equipment used in manufacturing and construction to transportation and robotics. Force measurement sensors and instrumentation play a critical role in ensuring industrial machinery’s safe and efficient operation.

Interface sensor technologies, including our load cells and multi-axis sensors, provide critical data for various machinery designs and functions. Interface analog and digital instrumentation products are available to amplify, condition, and display the signals from force measurement sensors.

The accuracy of force, torque, and weight measurements guide industrial machinery’s design and performance mechanisms.

What types of industrial machinery are using Interface measurement products today?

  • Machine tools used for grinding, drills, and lathes
  • Fabrication apparatus used for bending, shearing, and welding
  • Assembly equipment for production environments that include conveyor belts, robotic arms, and picking devices
  • Testing, quality control, and safety inspection equipment
  • Heavy equipment operational controllers for forklifts, cranes, and hoisting gear
  • Construction machinery such as loaders, bulldozers, and lifts

Industrial machinery is prevalent in manufacturing vehicles, aircraft, consumer goods, medical devices, and pharmaceuticals. Heavy-duty machinery is standard in energy production, mining, forestry, agriculture, and transportation.

The machines’ quality heavily depends on the accuracy of measurements used in the initial design, retrofitting, production, and practice. Interface products provide the products that enable machines to operate at peak performance safely and efficiently. Learn more in our new Interface Industrial Machinery Solutions, a part of Industrial Automation market offerings.

How Interface Measurement Solutions Used in Industrial Machinery

Machine Safety Monitoring

Interface products are used for monitoring the performance of machines and for management in sensing potential problems before they cause a failure. Interface measurement technologies are used in construction machinery to enable operators to gauge the force applied to materials, preventing overexertion and potential damage. Read Interface Solutions for Safety and Regulation Testing and Monitoring

Heavy Machinery and Lifting Equipment

In material handling equipment, force sensors help prevent accidents and injuries. Interface load cells, including load pins and shackles, monitor loads, weight, and distribution. Learn more about lifting solutions in our Engineered Solutions for Lifting Webinar.

Manufacturing and Production Machines

Manufacturers rely on Interface sensor solutions in industrial machines such as injection molding machines to monitor the force applied to the mold or how they are used in machines to ensure correct product packaging. The efficiency of machines is enhanced by correctly measuring the forces applied during different operations. Force sensors help ensure products are assembled correctly and within tolerance on production lines.

Industrial Automation Machines and Robotics

Interface sensors in industrial machines such as robots allow for more precise and delicate tasks that measure force at touch and throughout the entire operation. In machine tools, load cells assist in monitoring cutting forces and prevent damage to tools and workpieces. In robotic arms and automated assembly lines, force sensors provide precise force application during welding, riveting, and material handling.

Benefits of Using Interface Products in Industrial Machinery

  • Improved safety: Load cells can help prevent accidents and injuries by monitoring the weight and distribution of loads and ensuring that machines operate correctly.
  • Increased productivity: Force measurement sensors can help improve machines’ efficiency by optimizing the force applied during different operations. Force measurement sensors can help reduce machine downtime and enhance the quality of products with accurate data, helping to make intelligent decisions.
  • Reduced waste and operating costs: Measurement devices can help to reduce costs by preventing machine failures and improving the quality of products.

Force measurement sensors and instrumentation are essential components of modern industrial machinery. They ensure the safe, efficient, and productive operation of these machines. Contact Interface application engineers to evaluate the best sensor technologies for your specific test and measurement pe failures and improving the quality of products.

ADDITIONAL RESOURCES

Hydraulic Press Machines and Load Cells

Sanding Machine Force Monitoring

Interface Solutions for Machine Builders

Metal Press Cutting Machine

Laser Machine Cutting Force App Note

Ice Machine Weighing

Force Measurement Testing Improves Products and Consumer Safety

Cobot Safety Programming

Crane Capacity Verification App Note

Engineered Solutions for Lifting Webinar

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Interface’s technical webinar Engineered Solutions for Lifting details measurement devices used in lifting equipment, machines, and vehicles to improve operations and safety. Interface load cells and instrumentation are used to operate cranes, hoist heavy objects, and measure forces in infrastructure projects. Interface experts answer how load cells are used in safety monitoring for lifting equipment. Learn about Interface sensor products suited for integration into existing equipment and test and measurement projects.

Read more

Interface Load Cells Propel New Torsional Force Measurements for Wind Energy Project

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Amongst the wide variety of industries that Interface serves, clean and renewable energy sectors are some of the hottest in pursuit of sensor-based solutions. Between private and public funding, and the overwhelming desire for humans to become more sustainable, new energy technology and investment is multiplying at a rapid pace. 

Interface force measurement solutions are used in all types of energy-related applications for wind, solar, hydro, nuclear, geothermal, and emerging energy sources worldwide. We are recognized as a provider of choice for our reliability and accuracy in designing, engineering, testing, innovating, and manufacturing precision sensor solutions for the energy industry.  In fact, we have designed unique load cells that are embedded into some of the largest test and production equipment for energy production in the world. Read Interface Most Promising Energy Tech Solution Provider

Advance technologies in renewable and sustainable energy sources continues to drive the critical need to monitor, test, and validate concepts, equipment, and tools used in procurement. In the global energy industry, many of the alternative source technologies are inventive, newer, and require unique measurement solutions to take on the challenges found in R&D, testing, and production.  

In addition, alternative energy sources in their infancy can be very cost prohibitive going from exploration to consumption. Therefore, it is important that quality, cost effective testing solutions are provided to help researchers, engineers and manufacturers minimize total costs. Interface force testing solutions help to solve and lessen the burden of these challenges by offering a wide range of test and measurement solutions.

New Interface case study reveals how our load cells were used by the PTB in Germany to calibrate and test the world’s largest machine that measures torsional forces related to wind turbines.

Interface force measurement sensors were requested to help Physikalisch-Technische Bundesanstalt (PTB), the national metrology institute of the Federal Republic of Germany, in the design of an innovative wind energy project. As the second largest metrology institute in the world, the PTB has an acclaimed international reputation in research relating to units and precise measurement. 

PTB is a service provider for science, business, and society, and advises the German federal government on all metrology issues. Organizationally, the PTB is a departmental research facility and senior authority within the portfolio of the Federal Ministry of Economics and Climate Protection. For more than 135 years, PTB’s role has been making important contributions to advancing the energy transition, heat transition and climate protection with quality and speed. 

Interface, working in tandem with our esteemed partner Interfaceforce e. K. in Germany, was asked to provide load cell solutions to use in the design and testing of the world’s first traceable torque measurements of up to 5 MN ∙ m for a wind energy facility. As a first of its kind project, the PTB needed to include high accuracy, quality test equipment to guarantee precise and reliable data. Interface solutions fit the exact requirements.  Read the complete case study here.

Summarizing the engagement, PTB endeavored to construct a system with highly accurate and repeatable results, and one that enable bending moments, axial forces, and dynamic excitations of up to 3 Hz. Thereby, making it possible to realize a metrological characterization of dynamic influences in the (MN ∙ m) torque range, as well as in the MN force range. Working closely with PTB, Interface’s experts in Germany worked with the metrology lab engineers to identify the correct products for this unique calibration system.  

These products are being used to calibrate and test PTB’s torque measurement system, allowing the system to provide accurate and repeatable results over time. The custom load cell products Interface provided PTB for this innovative wind energy system, as detailed in Interface Supports Incredible Wind Energy Innovation, included:

The load cells that were chosen helped PTB to create the system needed for its wind energy facility, which allows multi-component transducers to be calibrated in a traceable and practice-oriented way for force and torque. The system is also now the world’s largest machine starting up at PTB, with which the large torsional forces that occur in wind turbines can be precisely measured for the first time.  Read the article: World’s largest device for measuring torque in wind turbines opens.

As we detailed in Load Cells for Renewable Energy Production and Testing, Interface and our incredible distributor network continues to work with engineers and industry leaders to find viable measurement solutions. Pushing the boundary forward on new and renewable energy is rewarding for our company, especially as we help those achieve energy innovation using sustainable, quality measurement solutions.

ADDITIONAL RESOURCES

Geothermal Well Drilling

Interface and Green Energy Innovation

Interface Solutions for Growing Green Energy

Demands for Quality Energy Measurement Solutions

Interface Supports Renewable Energy Innovation

Interface Supports Incredible Wind Energy Innovation

Innovative Interface Lifting Solutions

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Interface sensors are utilized in lifting applications to accurately measure the weight or force being exerted on the lifting equipment of all sizes. Our lifting solutions include load cells, load pins, tension links and shackles, wireless technologies, and instrumentation. It is common to see our sensors integrated into hoists, cranes, and lifting devices to provide precise load measurements.

Interface lifting solutions apply to a wide range of industries and settings, including construction sites, warehouses, manufacturing facilities, transportation, healthcare facilities, maritime docks, aircraft testing and assembly, and more. Lifting applications can vary, such as loading and unloading goods, positioning heavy equipment or machinery, transferring patients in healthcare settings, or lifting materials for construction purposes.

Our load cells, load pins and shackles assist in monitoring loads for heavy lifting equipment operators to remain within safe working limits and prevent overloading. Interface tension links and tension load cells are used for measuring lifting or pulling heavy loads with chains, cables, or ropes. The sensors measure the tension in the lifting element, providing feedback on the load being lifted and ensuring it remains within safe limits. Check out our Lifting Solutions Overview for complete details.

Top Interface Lifting Solutions

References of lifting equipment include cranes, hoists, forklifts, aerial work platforms, lifts, jacks, and various types of rigging and slings. These equipment types are designed to provide mechanical advantage, leverage, or power to lift, suspend, move, or position loads safely and efficiently. By leveraging sensor technologies, the benefits include increased safety for the operator, enhanced productivity, and efficiency optimization of load management. Additional benefits include predictive maintenance, plus smart and innovative utilization for modernization of projects and equipment.

Rigging engineers, whether working in testing environments from concert venues to rocket testing sites, use high-accuracy sensor technologies to ensure the safe and efficient movement of heavy equipment, machinery, and materials using cranes, hoists, pulleys, and other lifting devices. They are involved in the entire rigging process, from the initial assessment and design of rigging systems to overseeing the actual lifting operations.

Safety is of utmost importance in all lifting applications due to the potential risks associated with heavy loads, heights, and moving parts. The use of load monitoring devices such as load cells, tension links, load pins, or load shackles are critical to ensure the safe execution of lifting operations.

When Interface defines lifting applications, we are referring to the actions of objects, materials, or loads that are raised, lowered, or moved vertically or horizontally using lifting equipment or mechanisms. For use of our measurement solutions, these lifting applications involve the use of specialized equipment designed to safely and efficiently handle various types of loads.

In the construction industry, Interface load cells and load pins are integrated into smart cranes and construction equipment to provide real-time monitoring of the loads being lifted or carried. Lifting beams and spreader bars need high-accuracy measurement on the site. These sensors accurately measure the weight or force exerted on the equipment and provide data on the load’s status, ensuring safe operation within specified limits. This information can be used to prevent overloading, optimize load distribution, and enhance operational safety and prevent failure of any machinery.

Infrastructure demands durability, quality and accuracy of measurement. Interface load cells, tension links, load pins, and load shackles are employed in load testing applications to verify the strength and capacity of various lifting structures and equipment. They are used for a range of applications, including crane verification and safety monitoring, hoist monitoring, winch measurements, elevator suspension systems, lifting cables, overload alarms, and load testing. These tests measure the applied load and assess the structural integrity. Load cells or load shackles are often temporarily attached to lifting points or incorporated into the testing rig to capture accurate load data.

The maritime industry uses Interface measurement devices in crane systems, winches, and lifting equipment onboard ships, on offshore platforms, or vessels. These ruggedized and often submersible sensors ensure that loads are properly managed and controlled, enabling safe and efficient lifting operations in challenging marine environments. Check out this Boat Hoist application note.

Warehouses and logistics use load cells or load pins for shipping container handling, pallet weighing, conveyor systems and freight and cargo monitoring. The sensors can be easily integrated into forklifts to measure the weight of the lifted load, ensuring safe lifting, and preventing overloading.

Interface load cells and sensor technologies are also being used in applications for patient lifting and transfer. Load cells or load shackles can be integrated into patient lifting and transfer equipment, such as hoists or patient slings, hospital beds and therapy equipment. These sensors help monitor the load and ensure safe and comfortable transfers for patients and caregivers.

By integrating Interface solutions into lifting applications, the result is enhanced safety, improved efficiency, and optimization of load management. Real-time data from sensors allows for precise control, early detection of anomalies, and preventive maintenance, ensuring smooth and secure lifting operations, whether that is for a patient in a hospital or a cargo load moving from dock to ship.

Interface offers standard products for lifting, as well as custom and OEM lifting solutions.  Contact our application engineers to learn more about what type of lifting solution is best for your requirements.

Lifting Solutions Brochure

ADDITIONAL RESOURCES

Aircraft Engine Hoist

Theater Rigging System

Patient Hoyer Lift

IoT Lifting Heavy Objects App Note

Interface Solutions for Lifting Applications

Cranes and Lifting

Aircraft Lifting Equipment App Note

Aerial Lift Overload Control

Announcing the Launch of the Interface Pressure Compensated Downhole Load Cell

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Interface is excited to announce the release of a new downhole solution for the energy industry, the Interface Pressure Compensated Downhole Load Cell (IPCD).

The IPCD is a Wheatstone bridge foil-gaged-based force measurement solution using proprietary compensation methods and designed to provide highly accurate force data in harsh environments, like those found in the oil and gas industry, while requiring limited maintenance compared to similar solutions on the market. This is a product line that is many years in the making, as we’ve offered it as a custom solution. In fact, it has been developed across multiple applications to meet the needs of the oil and gas industry.

Interface’s new IPCD product is best suited for tension head applications of wireline services, particularly useful in deviated or horizontal wells where topside measurements are no longer reliable. Many applications include conveyance, pump down, perforating, tractor, and high pressure high temperature deep offshore use.

The key benefit the IPCD provides over existing solutions, commonly referred to as “wet” load cells, is its method of compensation. Wet load cells have a hydraulic compensation mechanism that uses pistons and seals, requiring frequent maintenance. Hydraulic compensation is complex for smaller tool providers and performance was suboptimal. For the IPCD, Interface developed a proprietary technology that compensates for that pressure influence and allows for bridge isolation. This means that the IPCD is far more rugged, needing little to no repairs, and it can be used downhole without risk of damage, a first of its kind in the industry.

It provides accurate measurement of downhole tension conditions in both vertical and horizontal wells and the proprietary internal compensation actively measures only the portion of the load caused by axial force, ignoring the portion of the load caused by pressure. Since it is an inherently passive system with no active pressure measurement being made or using a separate transducer, it is a completely analog solution for reliability and temperature stability.

We also test the IPCD heavily before it leaves our doors. The oil and gas industry can be extremely volatile, so we understand that our load cells need to be at peak performance for every use. Each load cell is tested individually on force, creep, temperature and pressure.

Advantages of the new proprietary Interface Pressure Compensated Downhole Load Cell include:

  • IPCD is a standard product from Interface and available today
  • IPCD offers maintenance-free service with significant long-term payback by eliminating disassembly, downtime, calibration, and instrumentation configuration
  • Interface’s new product is a precision with unmatched performance
  • IPCD has minimal thermal and pressure error, combined with world class linearity and hysteresis
  • It has field proven reliability and was designed based on a decades of engineering and force measurement experience

To learn more about the IPCD, we recently published a white paper that goes deeper into how the unit works, the specifications of the solution, as well as providing additional information on our testing process. You can read more about the IPCD in our new technical overview, Interface Pressure Compensated Downhole Load Cell White Paper available online for download.

We also issued a press release announcing the launch of IPCD.

This new product launch is a collaborative effort involving many of our team members in engineering, production and sales.

 

Interface Solutions for Testing Tools

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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 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.

Ratchet 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

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.

Why Machine and Equipment Manufacturers Choose Interface

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For innovators in the equipment and components manufacturing industry, data is everything. Quality data can make the difference between average and high-quality products and every bit of information gathered allows OEMs to make improvements that go a long way in performance and accuracy.

This is especially true in the design, test and evaluation of high-volume manufacturing where an increasing number of companies are implementing automation. To ensure consistent and repeatable quality, it’s important that there are capabilities to constantly gather data to monitor automated systems. If a machine is about to break or needs calibration, an automated system should be able to notify them without any human intervention.

How does an organization get more performance measurement data to improve its manufactured products? The answer we know best is with precision sensors. Sensors of all types, sizes, and shapes are being integrated into a wide variety of machines, equipment, and products to gather analytics that improve design and manufacturing. Interface is proud to contribute to this growing wave of big data requirements through our force and torque sensors.

Force sensors can be used in a number of different applications to help enable automation of certain process and systems. Essentially, force sensors are used as part of a controlled feedback loop. When a force is placed on a part within a product, the sensor can tell an electronic system to make something else happen.

As a simple example, force sensors could be placed inside of a large industrial dumpster outside of a manufacturing plant. When the dumpster nears full capacity, a signal could be sent to an automated compactor within the dumpster to make more space. It could also merely notify a waste management company to come and empty the dumpster.

Interface has worked on a number of what we call “OEM Solutions.” This term basically refers to our products that are typically high volume and have Interface sensor technologies integrated into the design and production. We often custom engineer and engineer these solutions to fit the exact requirements of the innovators and product design teams.

As a end-to-end manufacturer, we build to spec, manage the supply chain of sensors, and inventory for our OEM customers. When engineered-to-order requires thousands of products, they can rely on Interface as a trusted partner. Included below are a few examples of products that we provided our products to advance use, performance and quality. Read more about our custom OEM solutions and capabilities here.

Interface OEM Solution Examples

This first example is the design of force sensors in prosthetic limbs. An Interface force transducer provides feedback from a knee or elbow joint and tell an electric motor to move the limb in certain ways. This would allow someone without an arm or leg to have a wider range of movement and enjoy a variety of new capabilities.

Another example is the use of force sensors in the energy industry. Interface sensors can be used to optimize the process of energy production and extraction. In this scenario, a force sensor measures the rate at which the machine removes the source and provides data that tells the operator the most effective rate for getting the most most volume without overloading the mechanics. Not only does this allow for a more efficient process, it also adds another layer of safety to people and the environment. Interface was selected as the top energy solutions provider.

An interesting consumer packaged goods application example we provided a solution for included multiple Interface SPI Platform Scale Load Cells installed on a machine that filled potato chips into a bag. Force results from the potato chips are read by the load cells and sent to an ISG Isolated DIN Rail Mount Signal Conditioner. The supplier is then able to control the automated production from their command center. Using this solution, the manufacturer can determine the weight of the potato chips being distributed into their bags with highly accurate results – meaning every bag of chips is consistent in the amount of chips and total weight.

These are all examples of OEM solutions that turn data into better efficiency or additional capabilities across three industries, while there are countless other applications for OEM solutions from Interface used in consumer goods, robotics and medical devices. From automation to quality control and safety, force measurement helps manufacturers create better products and better production facilities, resulting in a great customer experience.

Interface has invested a great deal of resources into our manufacturing processes and technologies to serve this market. We’ve improved automation in our facilities to lower costs and work directly with our customers to develop the perfect force sensor for every project that can be produced at volume. Not to mention, our propensity for developing the most accurate force sensors on the market mean high quality data and results every time.

To learn more about our OEM solutions, contact our OEM experts and let us know how we can help!
OEM Brochure Web

Load Washers 101

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Load washer load cells are a versatile product used throughout a wide range of industries and applications. These force measurement donut-styled components are frequently used to measure and monitor clamping forces, fastening control, bolt loading and other compressive loads.

A load washer looks remarkably similar to the washers used to distribute the load of a threaded fastener like a screw. A load washer also works in a similar fashion, however they’re made of rugged stainless steel material and use proprietary measurement technologies, like strain gages, which allow it to measure press and compression force rather than just distributing the load.

Interface offers eight different models of load washers of varying sizes and force measuring ranges, all the way from 11.2 to 1124K lbf. The Interface Load Cell Load Washers can be easily designed into products to continuously measure and monitor compression forces. The variety of load washer styles and capacities, all using the thru-hole feature, give product engineers and designers multiple choices for what best fits their application and use case. Specifications for each model are available, along with design files and model ranges online.

For instance, our LWPF1 Load Washer Load Cell is designed to measure press force and is rated at capacities from 450 to 22.5K lbf. It offers a large thru-hole and short height for tight spaces.

Another popular Interface load washer is the LWCF Load Washer Load Cell which can be used to measure clamping forces and also bolt tightening. It has a capacity range of 3.4K to 337.2K lbf and is ideal for determining bolt preloads. We offer precision, high-capacity, and environmentally safe load cell load washers.

Interface also offers two models that have pre-manufactured mounting holes for installation, which are ideal for press force control and measurement. You can see our entire line of load washer load cells here.

Interface load washers are smaller in size, allowing for standard and customized sensors of this type to be used by original equipment manufacturers. We commonly get requests for these load cells for use in industrial automation equipment, medical device testing, test and measurement projects as well as products that need a small but precise sensor.

We’ve also included real-world applications of load washer load cells below. This will give you an idea of the types of projects in which this force device can be used to determine accurate force data used to refine or confirm the design of product or tool.

AIRCRAFT SCREWDRIVER FASTENING CONTROL

An airplane manufacturer was able 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. With a T15 Hex Drive Rotary Torque Transducer attached to the fastening work bench, the system measured and recorded torque, rotational speed, and angle of the screwdriver. The LWCF Clamping Force Load Washer  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 a laptop where data is logged, graphed, and displayed for test results.  This configuration provided data 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.

BOLT FASTENING FORCE AND TORQUE

Using a General Purpose Load Washer Load Cell Model LW in conjunction with a Model T12 Square Drive Rotary Torque Transducer, 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.

To learn more about load washer load cells and our entire product lineup or to talk to an engineer about the specific needs of your next project, please call us at 480-948-5555.