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Enhancing Friction Testing with Multi-Axis Sensors

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Multi-axis sensors premier benefit is the ability to collect multiple data points to provide a more complete picture during product design and testing phases. The ability to measure on multiple axes at one time not only offers more accurate data, but it also speeds up the test process. Essentially it requires fewer variables, like using multiple load cells. One force testing application that benefits greatly from multi-axis sensors is friction force testing.

For purposes of definition, friction is the resistance a surface or object encounters when moving over another.

The coefficient of friction (fr) is a number that is the ratio of the resistive force of friction (Fr) divided by the normal or perpendicular force (N) pushing the objects together.

The force exerted by a surface as an object moves or attempts to move across it is what is called friction force.  Though it is not always the case, the friction force often opposes the motion of an object. A friction test will look to measure the resistance preventing the objects from moving without interference or restriction against each other. For purposes of measurement, sliding and static friction are the two most common.

Traditionally, the friction testing process for trying to measure multiple axes was completed using two or more single axis load cells that would measure force on each axis separately. Unfortunately, this process required the user to have multiple load cells of the same design on hand for such testing. Most importantly, this methods results could include parasitic losses to accuracy.

By introducing a multi-axis load cell like the 3-axis sensor, the user can get a more complete picture with less time and lower costs. The benefits of using a 3-axis sensor include the ability to eliminate parasitic losses and move the measurement closer to the specimen. Also, 3-axis sensors allow for simultaneous measurements of the x, y and z axis without additional load cells.

In our recent webinar Inventive Multi-Axis and Instrumentation Solutions, Keith Skidmore details a friction testing example and the benefits of using multi-axis sensors. He explains, in a friction test where you want to apply a weight to a specimen and then drag that specimen across a surface, that drag force could be measured with the single axis load cell. This works great assuming the weight is constant that you are pulling. The assumption in your testing accuracy is that the specimen doesn’t move during the test, so to prevent it from tipping over you probably have guides or an applied object. The issue is this type of application or guide might create parasitic loads and create a non-repeatability system.

How do you constrain the system without affecting the measurement in this type of friction testing? One way to do it would be using a three-axis sensor right above the specimen. Now you can use guides and it doesn’t matter because the sensor is sensing right at the test specimen. You can pull on it, the data channel shows the change in weight as you slide providing your fixed weight. Then you’ve got your friction force which tends to want to move side to side.

Users can also consider a 6-axis load cell for friction testing. 6-axis load cells provide even more data on all six axes, and also allows the user to adjust out of any off-axis components. Users that are interested in knowing the rotational component of the friction testing machine may also want to consider 6-axis. Using a 6-axis would allow you to measure tendencies in rotation or other effects from fixturing.  More data, better analysis and ability to control your testing specimens.

Recently, Interface introduced an application note detailing the use of a 3-axis load cell to measure and test a friction force machine. Check it out below:

Friction Testing

A testing laboratory was looking to replace two single axis load cells used in their friction testing machine with one sensor that could measure force on the x, y, and z axis simultaneously. Interface suggest installing a 3A60 3-Axis load cell their existing machine with an Interface BSC4D-USB Multi-Channel PC Interface hooked directly to a PC laptop to monitor and log the data in real time. Using this solution, The testing laboratory was able to simplify their sensor set-up and improve their data collection, creating more value for their end customer.  You can read the entire application note on friction testing here.

 

Force Solutions for Testing Machines

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In test and measurement, one of the most common application for force sensors is industrial-scale testing machines of all kinds. Force and torque data is used in several ways with these types of applications. They can be used in the design phase to help perfect a product or component as it relates to force input or output. They can also be used as a monitoring device to tell users when a machine or its accessories need to be repaired or replaced.

For machine makers, product engineers and test lab equipment users, Interface supplies precision load cells, torque transducers, data acquisition devices and accessories.

Machine testing is one of our most prominent use cases for measurement sensors. Interface has seen quite a few different applications across industries. We’ve noted a few of our application notes that highlight these use cases by outlining how force measurement solutions are used in various machines.

Proving Theoretical Cutting Forces of Rotary Ultrasonic Machining

Rotary ultrasonic machining is a hybrid process that combines diamond grinding with ultrasonic machining to provide fast, high-quality drilling of many ceramic and glass applications. This new method has been theoretically proven using computer models. Rotary ultrasonic machining generates forces of a very small magnitude. To prove this theory, any load cell used for measurement must be sensitive, while at the same time retaining high structural stiffness within a compact, low-profile envelope. Interface suggest using its 3A120 3-Axis load cell installed in the rotary ultrasonic machine to measure the forces being applied to a sample part. With clear signals and minimal crosstalk, the applied forces are recorded and stored using an the BSC4D Multi-Channel PC Interface Module. The 3-Axis load cell provides excellent data helping uncover the relationship between machine cutting parameters and the forces applied on the component. Using this knowledge, the machining process can be reliably optimized for new materials and operations. Review the complete cutting forces of rotary ultrasonic machine application note.

Friction Testing Machine

A testing laboratory was looking to replace two single axis load cells used in their friction testing machine with one sensor that could measure force on the x, y, and z axis simultaneously. Interface’s 3A60 3-Axis load cell was installed on their existing machine with an Interface BSC4D-USB Multi-Channel PC Interface hooked directly to a PC laptop to monitor and log the data in real time. The testing laboratory was able to simplify their sensor set-up and improve their data collection, creating more value for their end customer. Friction testing is a common use case.  To learn more about this application for a friction testing machine, go here.

Spring Compression Testing Machine

In an upgrade in machinery and testing equipment, a customer sought a solution to test the performance of their springs in their specially designed spring test stand using a new wireless solution. Interface suggests using the WTS-5200XYZ 3-Axis Force Moment Load Cell which has 3 integral WTSAM-1E Wireless Transmitters and installing it into the customer’s spring compression frame. The WTS-5200XYZ 3-Axis Force Moment Load Cell will measure the force compression of the spring. The integral WTS-AM-1E Wireless Strain Bridge Transmitter Modules will transmit and display the information wirelessly to the LCCA Wireless Instrument enclosure. It can also be programmed to trigger an alarm.  You can read about the spring testing machine here.

Weighing and Packaging Machine

A food brand wanted to weigh the amount of their snacks that is automatically dispersed into the bags during the packaging process. In this case, they also want to weigh their potato chips being packaged and ensure the potato chips are at the exact weight needed due to regulatory standards. Interface’s suggested using multiple SPI Platform Scale Load Cells and install them 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 were read by the load cells and sent to the ISG Isolated DIN Rail Mount Signal Conditioner, where the customer could control the automated production from their command center. With these products, 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. Learn more about the packaging machine here.

Interface sensors are used across industries to test advanced machinery because our products provide the most accurate data on the market to help improve the efficiency and quality of equipment and testing machines. To learn more about Interface solutions for testing machines, check out our application notes page at www.interfaceforce.com/application-notes/.

Interface Multi-Axis Sensor Market Research

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Recently, Interface commissioned an independent research report on multi-axis sensors demand and use cases. This is a product line that Interface has made significant investments in as more customers require increased load cell functionality and additional source data from their force sensors. The research results confirm that the current demand is in fact expanding worldwide, and the overall users and market size is expected to grow by double digits over the next six years.

Included below is a brief overview of the state of the multi-axis, as well as an explanation of their overall purpose and why the growth of this type of test and measurement device continues to increase in popularity. We will also continue to break out the results of this research paper, so tune into the InterfaceIQ blog for more multi-axis research content. To learn more about these advanced sensors, view our ForceLeaders webinar Dimensions of Multi-Axis Sensors.

Multi-Axis Sensors Market Overview: The rise of IoT and Industry 4.0 had enabled automation. Machines continue to get smarter and can make split-second decisions using real-time data. Force measurement plays a key role in this transformation. Load cells that are tracking performance and reliability have more insights than ever before. They will continue to grow in their accuracy and capabilities. Load cell and sensor technologies are being used to identify precisely when and where something went wrong on a production line. Load cells will be growing in playing a key role in making production lines more efficient, less reliant on human resources and less costly.

There has been increased need for multi-axis sensors that measure and collect data points on up to six axes. Multi-axis sensors were invented because of the increased requirements for data, both in testing and during actual product use. And this is not slowing down anytime soon. Over the next decade, load cells will continue to keep up with the demand to handle more measurement data points. More sensors will need to be packed into a single device to collect more data with less equipment.

Five Key Take-Aways from Interface’s Multi-Axis Market Research:

  1. There is a growing requirement for high-performance sensor fusion of multi-axis sensor systems to enable the newly emerging technologies and highly demanding applications.
  2. Advancements in technology enabling effective components at a lighter and smaller size, such as the swift rise of unmanned vehicles in both the defense and civil applications and the increasing applications based on motion sensing, are the factors driving the multi-axis sensor use cases for testing and to embed into products.
  3. Digitizing force sensors is another trend changing our product innovators and manufacturer’s designs of machines and equipment through advanced measurement data. Many have strongly invested in more advanced digital electronics to efficiently harvest and store more data. Revolutions in industries and technologies is the dominant trend in force measurement, not to mention the entire manufacturing and engineering industry. Harnessing big data enables product users to remotely monitor assets and increase use of analytics.
  4. With network-connected force measurement through sensors and instrumentation, OEMs have greater control over testing and product development. Equipment using multi-axis sensors to track performance and reliability provide valuable data on how equipment is performing and predict when machines need maintenance.
  5. Global machine makers and equipment builders want smaller force sensors they can permanently install in the products. Smaller, wireless sensors are easier and less expensive to install. As more industrial networks are created to share higher-quality data, more and more sensors will be added to these machines.

What: Multi-axis sensors allow the user to measure forces and torques, which occur in more than one spatial direction, as with measurements in x- and y-direction. This allows manufacturers to obtain more data on a wider variety of axes, allowing them to make better design decisions and ultimately improve the product quality. A crucial focus is force measurement in manufacturing, where force transducers are frequently used to determine the force for weight measurement or in the process of production.

Why? Data-driven test and measurement is at the forefront of product development, especially in highly regulated markets like aerospace, automotive, medical, and industrial. One of the most significant applications for multi-axis sensors is seen in manufacturing facilities who want to integrate more autonomy and robotic processes. The goal is to streamline logistics procedures and reduce human errors and workplace accidents. The report also found that there is a great deal interest for last-mile delivery robots, either on the ground, on the sea or drones in the air.

Interface’s Role: Interface multi-axis load cells are ideal for industrial and scientific applications. They are used by engineers and testing labs in various industries and market segments including aerospace, robotics, automotive, advanced manufacturing, for medical devices and research. Our products designed to provide the most comprehensive force and torque data points on advanced machinery. With our industry-leading reliability and accuracy, these multi-axis sensors can provide the data our customers need to ensure performance and safety in their product design.

In fact, their unique capabilities are helping the medical industry optimize prosthetic designs and usability standards with multi-axis sensor testing. The automotive industry is using Interface’s multi-axis products in wind tunnels, and the military is using them to test the center of gravity in aerospace applications.

Here are a few applications use cases that show how multi-axis is advancing products in multiple industries:

Wind Tunnel

Seat Testing Machine

Friction Testing

Industrial Robotic Arm

Ball and Socket Prosthetic

Prosthetic Foot Performance

Syringe Plunger Force Measurement

Research was conducted independently by Search4Research.

Dimensions of Multi-Axis Sensors Virtual Event Recap

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The Interface ForceLeaders hosted forums are designed to answer frequently asked questions from testing engineers and product designers about new technologies and uses cases. In our recent virtual event, Dimensions of Multi-Axis Sensors, we discussed the considerations for these types of sensors, the test and measurement benefits, products Interface offers and various applications.

Interface recognizes that there are growing demands for multi-axis sensors.  In our hosted event, Interface’s Brian Peters kicked-off the conversation by highlighting benefits and reasoning for the use of these types of sensors, including answering some common questions. We’ve provided a recap of the event below or you can watch the event here https://youtu.be/zua1lvTh488.

What is Unique about Multi-Axis Sensors?

Multi-axis sensors have additional bridges to provide output signals for varying axes or types of mechanical loading. They are designed to measure a multitude of forces and moments simultaneously with a single load cell sensor. Fundamentally similar to other force and torque sensors with strain gage bridges bonded to machined “flexures,” each bridge typically defines a measurement axis. 

There are multiple configurations of 2, 3, or 6-axis options.

  • Axial + Torque
  • Axial + Shear
  • Axial + Moment
  • All 6 degrees of freedom

Should You Use Multi-Axis Sensors?

The largest factor to consider is the accuracy of your test model. In many test applications using standard load cells we often notice side or eccentric load, which can skew your data. While many Interface load cells, particularly mini load cells, have been designed to reject indirect loads, nothing can handle side and eccentric loads quite like a multi-axis sensor. Dedicated multi-axis designs are typically more balanced axis capacity limits with discrete signal outputs. Composite signal outputs are common in 6-axis models.

What are the Benefits of Multi-Axis Sensor Technology?

There are a number of benefits to using multi-axis sensors in addition to accounting for and accurately measuring or rejecting side and eccentric load. These benefits include:

  • Consolidate measurement signals, conserve test space
  • Measure unwanted system crosstalk
  • Quantify reaction loads through test article on “non-measure” side 
  • More successful fatigue testing through setup and load verification
  • More data, more understanding, more complete picture

What Considerations Should Engineer Make When Using Multi-Axis Sensors?

If you’ve made the decision to utilize a multi-axis sensor in your test model, please note the following considerations:

  • System-level loads and geometry
  • Maximum loading conditions
  • Chosen capacity is adequate for measurement loads as well as potential peak or extraneous loads
  • Choosing the right sensor based on primary axis measurements

Interface Multi-Axis Sensor Products

Ken Bishop details various types of multi-axis sensor technology from Interface during the highlighted ForceLeaders event you can watch here.  Interface offers a wide range of multi-axis sensors, including 3-axis, 6-axis, axial torsion and 2-axis versions. The product options give you the ability to measure forces simultaneously in three mutually perpendicular axes, with the 6-axis load cells also measuring torque around those axes.

AXIAL TORSION LOAD CELLS

Interface’s axial torsion load cell is used for measuring both torque and force in a single sensor. Typical applications of its axial torsion transducer include bearing test and material test machines. The features of our axial torsion load cell include minimal cross talk, extraneous load resistance, and the load cell is fatigue rated. Customers can also add the following options: an integral cable, compression overload protection, and connector protectors.

2-AXIS LOAD CELLS

The Interface 2-Axis load cells can measure in two directions, X and Y simultaneously. It is commonly used in applications where dual-axis measurement is important in design and testing. They are effective for applications that measure lateral forces and the narrow design fits into compact areas.

2-Axis Interface Products:

3-AXIS LOAD CELLS

Interface’s 3-axis load cell measures force simultaneously in three mutually perpendicular axes: X, Y, and Z – tension and compression. Each axis provides a unique mV/V output and requires no mathematical manipulation. The 3-axis load cell is built to minimize eccentric loading effects and crosstalk between axes. We offer five different models in its 3A Series 3-axis load cell designed for a wide variety of capacities. They are compact in size, provide 3 full bridge mV/V outputs with an IP68 option.

3-Axis Products:

6-AXIS LOAD CELLS

Interface’s 6-Axis Load Cell measures force simultaneously in three mutually perpendicular axes and three simultaneous torques about those same axes. Six full bridges provide mV/V output on six independent channels. A 36-term coefficient matrix is included for calculating the load and torque values in each axis. An 8-channel amplifier with a USB PC interface is also available which simplifies data analysis. The company offers five different models of 6-axis load cells for a wide variety of capacities. In the end, they provide more data, accuracy, are very stiff and cost-effective for a wide range of testing options.

6-Axis Products:

Keith Skidmore, an application expert at Interface, outlined a number of use cases spanning across multiple industries. They included testing programs using multi-axis sensors in automotive, medical, aerospace and defense, consumer packaging and more. Some of the application notes discussed during this recorded event include:

  • Wind tunnel testing
  • Aerospace structural and fatigue testing
  • Computer model validation
  • Friction testing
  • Medical device: ball socket testing
  • Prosthetics
  • Robotic arm
  • Hydrofoil
  • Seat testing
  • Center of gravity

Be sure to watch the YouTube video below to gain insight into some of the most frequently asked questions about multi-axis sensors.

We had a great time introducing our audience to the possibilities of Interface Multi-Axis Sensors. If you are interested in watching the video on demand of the webinar, you can click on the link below to watch the presentation in its entirety.