Posts

Demands for Quality Energy Measurement Solutions

Powering the world is no simple task, especially as research and innovation into alternative energy sources are at an all time high. Across the energy supply chain there are soaring demands from engineers, scientists, equipment makers and suppliers to provide quality and accurate market solutions.

The energy market is constantly evolving to power our infrastructure as well as finding new ways to reduce our carbon footprint. Interface is a key differentiator when it comes to test and measurement. We play an important role in the development and deployment of effective energy market solutions as our sensor technologies are used to test and monitor energy equipment, sources and methods for extraction and containment. As well, Interface is center in supplying devices used in the development of fueling alternatives and introducing new energy solutions.

To explain our role in the energy market and how are products can be used by engineers in these industries, Interface Energy Solutions Overview details the types of products and examples of applications used by industry market leaders and innovators.

Interface force measurement solutions are used in all types of energy related applications to produce oil, gas, wind, coal, solar, hydrogen, nuclear, geothermal and emerging energy sources around the world. We are recognized as a provider of choice for our reliability and accuracy in designing, engineering, testing, innovating, and manufacturing precision sensor-based solutions for the energy industry.

One of the industries where Interface’s experience and knowledge of force measurement is vertically integrated into production and manufacturing processes is in the energy industry. The conditions energy professionals work in can be harsh. They are often in hazardous environments extracting oil and natural gas, wind, or coal to fuel our world’s dependencies for power. The equipment our energy sector customers use must be rugged and provide the most accurate results possible. If the equipment fails, our customers risk steep losses and exposure to safety hazards.

Based on market requirements, we recently introduced the new Interface Pressure Compensated Downhole Load Cell solution specifically designed for the energy sector. The downhole environment poses many challenges for well-drillers, operators, tool-string designers, and other engineers in the oil and gas industry. This innovation eliminates the need for “wet” load cells to monitor forces on their downhole load strings, which don’t hold up for extended use where there are extreme pressures and temperatures in a caustic environment. Interface created a dry load cell with an innovative protective design that reduces the number of sensors required in any downhole load string, extending the life of the load cell by a decade or more.

The types of products the energy market demands from Interface for these applications include standard LowProfile load cells, various torque transducers, multi-axis sensors and all types of instrumentation. We supply engineered to order and custom products for various energy testing environments and OEM solutions. The range of options include uniquely designed torque transducers, load washers, tension and compression load cells, load pins, wireless gear and more.

ENERGY APPLICATIONS USING INTERFACE PRODUCTS

  • Solar panel design and testing
  • Wireless monitoring devices
  • Submersible and hazardous environment products
  • Hydrogen electrolyzer devices
  • Storing and transporting crude oil and natural gas
  • Windmill testing and management
  • Wireline spool tension control
  • Oil and gas equipment
  • Hydro power generation
  • Hook load tension
  • Torque tong monitoring
  • Tool recovery and fishing
  • Wave energy
  • Downhole OEM parts
  • Calibration and equipment maintenance

Interface force measurement solutions are used in components, machines and field equipment for energy R&D and production. From prototyping to monitoring equipment, our durable load cells and torque transducers assist suppliers of parts along with energy industry leaders and innovators to fuel the world. You can find more energy applications here.

Energy-Brochure

To learn more about our work in the energy industry or to inquire about how our force sensors can benefit your next project, contact our application engineers today.

Additional Resources

Interface Helps Power the World

Interface Most Promising Energy Tech Solution Provider

Announcing the Launch of the Interface Pressure Compensated Downhole Load Cell

Fueling Global Demand for Interface Solutions

 

Force Sensing Keeps Factories Running Feature in Fierce Electronics

In the recent article, ‘May the force be with you: Force sensing keeps factories running, product quality high’ Dan O’Shea at Fierce Electronics writes about the growing demand for sensors in industrial automation applications.

Following his interview with Interface’s Keith Skidmore, Dan writes:

‘While some sensors are more focused on monitoring equipment or measuring environmental conditions around a manufacturing process, force sensors measure mechanical forces occurring in the equipment and processes, and the products being manufactured. They measure things like load, tension, resistance, weight or total pressure applied. By employing this kind of sensing technology, manufacturers can monitor the health of their equipment and improve quality assurance for their products.’

“Testing things by applying a force to them is super common. Many products in lots of industries get tested this way, from aerospace to automotive, through to consumer goods. Chairs, furniture, mattresses, ladders–basically, anything that’s being manufactured, there can be a desire to figure out how strong the various parts of those products are.” Keith Skidmore, engineer and regional sales director at Interface

Read the entire Fierce Electronics article here.

Interface provides industrial automation and IoT solutions to manufacturers, equipment makers and factories around the world. Sensors play a pivotal role in production and optimization through tools and process improvements.

Industrial Robotic Arm

Robotic arms are frequently used in production facilities throughout the manufacturing process. Suppliers of these devices heavily rely on accurate and quality sensors to provide feedback. In this application, the designer needed to test the force of the arm apparatus to ensure it could safely secure packages on a moving conveyor belt without damaging any materials or products. This automated function helps to improve quality of packaging and increase productivity on the line.

Interface provided the model 6A40A 6-Axis Load Cell with model BX8-HD44 Data Acquisition Amplifier instrumentation. The 6-Axis load cell provides measurement of all forces and torques (Fx, Fʏ, Fz, Mx, Mʏ, Mz) and the BXB-HD44 Data Acquisition Amplifier logs, displays, and graphs these measurements while sending scaled analog output signals for these axes to the robot’s control system. Customer installed 6A40 6-Axis Load Cell between robot flange and robot grabber. The extensive data outputs from the multi-axis sensor provided the exact detailed measurements needed for the industrial robotic application.

Flange Style Load Cells and Torque Transducers

Interface offers several flange type load cells and torque transducers for easy mounting and installation. Interface provides the complete solutions for a flange mount including the adapters, bases, bolts, connector options and cables.

Standard flange designs mount directly to cylinders for stability and accuracy in measurement. We also offer mounting plates for more complex testing systems that use one or more sensors.

The primary advantage of the Interface Flange Load Cell is that the hub of the transducer is mounted using several smaller screws instead of one large central thread. It is easier to preload multiple smaller screws (bolts) than a single central thread. In certain applications it may not be possible to properly preload a central thread due to the torque limits of the load cell. There’s also the important benefit of clocking a load cell fixtures alignment.

The most popular low profile flange mount load cell is the 12X8 Flange Load Cell. This load cell is similar in design to our Interface 1200 series.  Instead of a center hole, the 12X8 has multiple smaller holes making installation easier for certain types of cylinders. The 12X8 is for tension and compression measurement. It is fatigue rated with the ability to survive 100 million fully reversed cycles. The load cell has proprietary Interface temperature compensated strain gages and performance to 0.05%. It is eccentric load compensated with low deflection. The 12X8 is ideal for long-term cycle testing.

Watch How to Mount a Flange Style Load Cell

Interface offers a variety of flange style products including load cells, miniature load cells, torque transducers and multi-axis sensors. Here are a few of the flange offerings available from Interface:

12X8 Flange Standard Precision LowProfile® Load Cell

2300 High Capacity Flange Mount Column Load Cell

1700 Flange LowProfile® Load Cell

MRT Miniature Flange Style Reaction Torque Transducer

MRT2 Miniature Flange Style Reaction Torque Transducer

MRT2P Miniature Overload Protected Flange Style Reaction Torque Transducer

5400 Series Flange Style Reaction Torque Transducer

TS18 Shaft to Flange Style Reaction Torque Transducer

TS16 Male Square Drive to Flange Style Reaction Torque Transducer

TSCF C-Face Flange Torque Transducer

6ADF Series 6-Axis DIN Flange-Type Load Cells

Flange style load cells are commonly used in a wide range of applications, from automotive testing to agriculture equipment tests. The variety of flange style solutions are ideal for specialized product designs, including robotics, medical devices, OEM products and equipment requiring secure mounting with sensor capabilities.

TRACTOR POWER TAKE OFF SYSTEM TESTING

In this example you can see how a tractor manufacturer needed to measure the torque and speed of the tractor’s PTO (power takeoff test) system. The purpose of the applied sensor solution was to ensure the PTO was working properly when an implement is attached to the tractor. It also provides ongoing maintenance monitoring for optimum performance. Interface provided a T27 Bearingless Hollow Flange Style Rotary Torque Transducer to measure the tractor’s torque and speed of their tractor’s PTO system.

ROBOTIC SURVEY FORCE FEEDBACK SYSTEM

Robotic Surgery Force Feedback App Note

Additional flange style models can be found in our extensive product catalog, which defines the specifications, capacities and design features.

Recap of Accurate Report on Calibration

Interface recently hosted an in-depth discussion on the topic of calibration.  As one of the largest calibration labs in the world for force and torque sensors, our team shared insider tips, frequently asked questions, set up techniques and best practices in the lab during this extensive calibration webinar.

The ForceLeaders seminar also covered details about various calibration grade equipment like our 1800 Platinum Standard® Calibration LowProfile® Load Cell, 1600 Gold Standard® Calibration LowProfile® Load Cell, fixtures, load frames, and calibration systems.  We also delved into topics that include instrumentation, verification frames and software.

During the event, we covered a diverse set of subjects due to the range of experiences of our attendees including the top five reasons why calibration matters, the measurement of uncertainty, identifying errors and the parameters of calibration.

You will find the recorded event Accurate Report on Calibration is available to review the technical details related to each of these important calibration subjects.

Elliot Speidell, Brian Peters and Chris Brandenburg covered a wide range of topics, including:

  • The Metrology Perspective
  • Interface Calibration Methodology: What, Why & How
  • Top 5 Reasons Why Calibration Matters
  • Calibration and Measurement Uncertainty
  • What Errors are Characterized in the Calibration Process?
  • System Calibration Considerations
  • Calibration Lab Set Up Best Practices + Tips
  • Optimization + Calibration Applications
  • Fixtures + Standard Equipment
  • Interface Calibration Services
  • Do & Don’t Tips + FAQ

To get things started, we began the event with a quick conversation about metrology, the science of measurement, which embraces both experimental and theoretical determinations at any level of uncertainty in any field of science and technology.

Metrology is the global network standardizing measurement units. Calibration is the action taken at each step in the metrology network.

Metrology is important to Interface because it provides the standards for controlled processes, systems, reliability, accuracy, quality and science. Calibration is the set of operations that compares the accuracy of a measuring instrument of any type, such as a load cell or torque transducer, against a recognized standard. The process of calibration includes adjusting the measuring instrument to bring it in alignment with the standard.

Why is calibration of load cells and torque transducers important?

  • All load cells are subject to performance degradation due mistreatment, drift, or aging
  • You need traceability and quality system requirements
  • Pre and post-test verification is critical for data validity
  • Even load cells manufactured to the highest standards require regular calibration

Interface calibrates every load cell and torque transducer to spec before it leaves our facility. We also provide recalibration services for all types of devices, even those we don’t manufacturer. This results in more than 100,000 calibrations every year by our trained technicians. During this event we shared valuable tips for setting up and operating a world-class calibration lab.

Best practices for calibration labs:

  • Define workspace requirements
  • Qualify measurement types and models
  • Identify suppliers
  • Select calibration grade equipment
  • Assemble lab
  • Train lab techs
  • Create certification and testing protocols
  • Define workflows
  • Utilize software for tracking assets and certificates
  • Know maintenance and recalibration schedules

The Accurate Report on Calibration recorded event is available online to watch at your convenience.

If you need help in defining the best calibration grade systems or equipment for your specific test environment, contact our application engineers.  If you need a calibration service, you can submit your request online.

Why Civil Engineers Prefer Interface Products

Infrastructure is one of the most vital industries that utilize Interface force measurement solutions. Our products are chosen for the design, engineering and construction of public works projects including roads, energy structures, bridges, dams, airports, sewage systems, and pipelines.

Civil engineering is a professional discipline that deals with the design, construction, and maintenance of the physical and naturally built environments. It’s the oldest engineering discipline after military engineering, and it was specifically defined to distinguish non-military engineering from military engineering.

Civil engineering is traditionally broken into several sub-disciplines including environmental engineering, geotechnical engineering, structural engineering, transportation engineering, municipal or urban engineering, water resources engineering, materials engineering, coastal engineering, surveying, and construction engineering.

Civil engineers choose Interface sensors for testing structural components as well as for embedding sensors within buildings, waterways, and railways to ensure sustainable and safe construction, modifications, improvements, repairs and use.

Civil engineers’ relationship with and use of force measurement devices is based on two things: testing designs and monitoring completed projects.

Load cells are used from a test perspective throughout the development of infrastructure projects. For example, load cells test specific materials used in the construction of a building to ensure they can handle the required weights and environmental conditions. In the design of a drawbridge bridge, engineers use load cells to test the hydraulic system to ensure it will provide enough force to lift the bridge from a single time to thousands of times by using stress test rigs.

The use of various sensors and measurement devices in civil engineering and construction sectors has grown significantly in recent years. The sensor data from Interface load cells is utilized in every aspect, from rugged construction equipment for regulatory and safety monitoring to real-time quality monitoring of physical structures. One of the reasons is due to the advances in monitoring and reporting capabilities of sensor data. Accessibility to data has improved the ability to use it for complex calculations as well as analyze enormous amounts of output information in real-time. The benefits are improvements in structural designs and overall engineering as a result.

By accessing data remotely through Interface digital instrumentation products, those within the industry can deploy more practical solutions than were historically impossible during some of the original designs. This has transformed approaches to force measurement and load monitoring, providing robust calculations in structural and material engineering. This functionality is why civil engineering sectors rely on Interface for advanced products that deliver accurate, quality and reliable performance.

The following video highlights many products utilized in the infrastructure industry by civil engineers and for the equipment used in construction of their designs.

Force measurement is even used by civil engineers in testing the construction equipment used in a variety of infrastructure projects. One example of this is when Interface supplied a force measurement system to construction engineers to test an aerial lifts capabilities and capacities for safe use.

Aerial Lift Overload Control

A manufacturing company for aerial lifts wanted to test its self-propelled boom lift to ensure it can operate at heavy capacities when in use, and at different angles. They also wanted to prevent any accidents in case of a lifting overload, for the safety of any working individual who uses it. Interface’s solution was to attach the 3A160 3-Axis Force Load Cell to the bottom of the bucket of the boom lift. The 3A160 3-Axis Force Load Cell gave high accuracy results, which can be displayed using the 920i Programmable Weight Indicator and Controller in real time. The manufacturing company tested their aerial boom lifts and determined it was safely operable when maximum capacities had been reached.

Adversely, engineers are also designing force sensors into projects allowing them to monitor the effects of force on certain infrastructure over time. Take for example a project that Interface was involved in that required the monitoring of a bridge.

Bridge Seismic

Bridge Seismic Force Monitoring Solution

A customer wanted to monitor seismic activity that occurred to a bridge by using force sensors, and then continuously monitor bridge forces before, during and after earthquakes. Engineers on the project also preferred a wireless solution so they would not need to run long cables on the bridge. Using Interface’s LP Load Pin custom made to fit their needs, along with Interface Inc. WTS Wireless Telemetry System, continuous force monitoring was able to take place without long cables. The engineers were then able to monitor continuous loads, log information to the cloud and review information, ensuring the bridge would uphold over time and constant seismic activity. Or, allowing engineers to determine when and where repairs are necessary.

Civil engineers represent the minds and hands building critical infrastructure. This is why Interface works closely with those in this profession to ensure our sensors provide the highest quality, accuracy and reliability to keep people safe and moving across our country. To learn more about our work in infrastructure, please visit our Interface Infrastructure Solutions.

Additional Resources

Interface and Infrastructure Markets Form a Perfect Partnership

Infrastructure Industry Relies on Interface Force Measurement

Interface Solutions Designed for Infrastructure Challenges

Infrastructure Projects Rely on Interface

Monitoring the Seismic Force of a Suspension Bridge

Infrastructure-Brochure

Get an Inside Look at Interface’s Famously Blue Load Cells

Interface “blue” load cells have been utilized for millions of test and measurement projects and programs around the world.  Since the invention of Interface’s LowProfile® Load Cell, the world’s most popular pancake style load cell series has become a standard for testing engineers and lab technicians for more than five and half decades.  Today, Interface has more than 60 different types of Load Cells, including our line of Mini Load Cells.

Interface load cells come in capacities ranging from 1 lbf (500 gf) to 2 million lbf (9,000 kN). As a U.S.-based manufacturer, our extensive production and engineering facilities produce several shapes and sizes of our Interface load cells, as well as calibrate every model before it leaves our facilities.

Our expansive line of sensor models includes pancake and donut styled load cells in our LowProfile® Load Cell series and thru-hole load cells. Additionally, we offer canister, rod end, downhole, column, coil tubing, load buttons, and load washers. All of these models use Interface’s proprietary alloy strain gages to provide higher output, higher signal to noise ratio, higher resolution and superior fatigue life. This helps us build the most accurate and reliable sensors for test and measurement applications.

What makes Interface’s LowProfile Load Cells a top pick?

Here is a look inside our famous blue load cell, highlighting the top reasons Interface is selected for accuracy, quality and performance.

Interface’s load cell model that has the highest demand and usage is the 1200 Precision LowProfile series. They are used in all types of industry applications, from Material Tensile Testing to Aircraft Lifting Equipment Tests. It’s followed closely by the 1000 Fatigue-Rated LowProfile series and 1100 Ultra Precision Load Cell series.  Every series has multiple configuration and capacity options. For example, the 1200 series provides off-the-shelf model options including:

1200 Standard Precision LowProfile® Load Cell

1200 and 1201 Series 3-Wire Amplified Load Cell Universal or Compression-Only

WTS 1200 Standard Precision LowProfile® Wireless Load Cell

1200 High-Capacity Standard Precision LowProfile® Load Cell

1201 Compression-Only Standard Precision LowProfile® Load Cell

Every designed load cell can also be engineered-to-order or customized to unique specifications.

The accuracy of data, engineered designs, proprietary strain gages, comprehensive specifications, quality inspections, detailed certifications and multiple calibrations of every load cell to ensure performance make the top of the list as to why Interface is considered best in class.

Here is an opportunity to get another inside look at the Interface LowProfile Load Cell:

If you are interested in reviewing this insider’s view with SI measurements, go here.

Take a closer look at the advantages of Interface’s LowProfile Load Cell in this cutaway view.

LowProfile Cutaway

TEDS 101

In the electronics industry, sensor compatibility challenges can lead to significant issues with efficiency, accuracy, safety and more. When it comes to force measurement sensors, incompatibility issues can railroad an entire project.  This is where the role of Transducer Electronic Data Sheets (TEDS) comes into play.

TEDS is a set of electronic data in a standardized format stored in a chip that is attached to a transducer, therefore allowing the transducer to identify and describe itself to the network and ease automatic system configuration. This self-identification capability for the transducer is needed for maintenance, diagnostics, and to determine mean time between failure characteristics. The chip stores information such as manufacturer name, identification number, type of device, serial number, as well as calibration data. The TEDS can be uploaded to the system upon power up or request. It also serves as documentation for the transducer.

Transducer Electronic Data Sheets (TEDS) provide:

  • Sensor with electronic identification
  • IEEE 1451.4 standard for smart transducer interface
  • Plug and play readiness
  • Storage of sensor information and calibration data
  • Use with new or existing sensors

IEEE1451.4 specifies a table of identifying parameters that are stored in the load cell in the form of a TEDS. TEDS is a table of parameters that identify the transducer and is held in the transducer on a EEPROM for interrogation by external electronics.

A TEDS chip becomes the ultimate tool to allow users to take off-the-shelf sensor solutions and integrate them into a total force measurement solution. The key benefits TEDS provide includes:

  • Eliminating potential for data entry error
  • Simplifying new system setup and speeds up the process
  • Making swapping load cells in and out of a test system seamless
  • Improving safety by ensuring the system has the correct sensors
  • Easily identifying and tagging sensor locations
  • Improving inventory control of sensors
  • Changing sensors out without jeopardizing integrity of the system

TEDS chips can be sold separately or integrated into existing systems such as instrumentation products. Interface offers both options, selling TEDS as a standalone accessory, as well as integrating them into instrumentation solutions, such as:

9840 Calibration Grade Multi-Channel Load Cell Indicator

Model 9840 is suitable for use in calibration labs, field service, or anywhere high accuracy is important. This product’s features include a bipolar 6-digit 2-line display, remote sense, low noise, 24-bit internal resolution, USB port with RS232 communication, mV/V calibration, store calibrations for up to 25 sensors. 6-point linearization, unit conversion and front-panel tare. This unit also has Self-calibration via TEDS Plug and Play ready IEEE 1451.4 compliance.

9320 Battery Powered Portable Load Cell Indicator

Model 9320 is a bipolar 7-digit handheld meter featuring two independently scalable ranges, peak and valley monitoring, display hold, mV/V calibration, and a power save feature. Typical battery life exceeds 45 hours of continuous use and 450 in low power mode. IEEE1451.4 TEDS Plug and Play compliant.

Additional TEDS Ready Interface Solutions

9840-400-1-T 4-Channel Intelligent Indicator

9840TQ mV/V Input Torque Transducer Indicator

9870 High-Speed High Performance Teds Ready Indicator

BX6-BT Portable 6-Channel High Speed Bluetooth Data Logger

BX8-AS BlueDAQ Series Data Acquisition System With Industrial Enclosure

BX8-HD15 BlueDAQ Series Data Acquisition System For Discreet Sensors With Lab Enclosure

BX8-HD44 BlueDAQ Series Data Acquisition System For Multi-Axis Sensors With Lab Enclosure

These solutions make a great addition to any testing environment as they enable quick compatibility and are very easy to setup. To learn more about TEDS or to explore how TEDS can help solve your force measurement challenges, contact us to explore the possibilities.

Faces of Interface Featuring Tin Nguyen

Today’s Faces of Interface features a person who might possibly hold the most titles in the company, and for good reason. Tin Nguyen is our calibration engineer, manufacturing engineer and business unit manager for calibration. Tin has earned all these titles along with the important responsibility through his relentless ability to take on and excel in new tasks, as well as his desire to learn. Check out his story.

Since he was about the age of eight years old, Tin had a proficiency for learning how to design and build things. It all started growing up on his grandparent’s farm where he would theorize ways to make tools and machines around the farm easier to use or more efficient. He vowed then that when he grew up, he would find a way to build things to make life easier for people.

Tin went on to attend Arizona State University (ASU), where he received a bachelor’s degree in manufacturing engineering and in technology in 2000. He really enjoyed the ASU engineering school experience because it was hands on and he got to work with the latest technology, preparing him for the real world. While attending school, Tin also served as an auto mechanic for racing cars to earn some extra money on the side and because he really enjoyed the work.

Tin joined Interface in September 2001. He began his career as a calibration associate in the calibration lab. After a few years in the lab, Tin was then promoted to manufacturing engineer. A year later, he was promoted to calibration supervisor followed by the calibration departments business unit manager. His success in each of these roles allowed him to retain some of his titles and work throughout the company to lend his skills and expertise.

Today, his role covers quite a bit of what we do here at Interface. His day-to-day responsibilities include developing and maintaining tooling for calibration, fixturing, improving production processes, auditing equipment, figuring out ways to reduce costs, training calibration techs, maintaining calibration standards, looking after 20 different rigs, to highlight a few. His depth of experience and expertise lends to supporting and helping the company meet the growing demands for Interface’s quality products.

What Tin enjoys so much about working at Interface and continuing to take on new roles is that he loves to learn everything there is to know about the company and serving customers. Tin noted, there are a lot of talented people around him to provide that knowledge and support. After more than 20 years with the company, Tin still feels that he has more to learn. He’s also very honored by the trust that Interface and its leadership have placed in Tin to take on all of his important roles.

In his free time, Tin loves to travel and explore the great outdoors. He enjoys hiking, camping, fishing, boating and more. And, as if he doesn’t already have enough projects in his work life, Tin is also very fond of upgrading and remodeling his home. He takes a lot of ownership over the process and will do everything that he can before hiring somebody to help.

With all the hats Tin wears, he knows Interface inside out and we’re thrilled to have him and his cross-departmental expertise as part of the Interface family! We hope you enjoyed the newest entry into our Faces of Interface and if you’re looking to learn more about our talented staff, visit our ForceLeaders feature here.

EV Battery Testing Solutions Utilize Interface Mini Load Cells

Automotive components undergo rigorous testing to meet regulatory standards, guarantee performance, and ensure consumer safety. These components continually require investment in innovation to meet the expressed governmental, consumer and commercial use requirements.

One of the vehicle components that is undergoing intense change is the battery. The market is heavily focused on increasing mileage use and life, which includes the shift from single-use lithium batteries to lithium-ion batteries which are rechargeable.

These customer sentiments are noticeable in the growing global electric vehicle (EV) and hybrid electric vehicle (HEV) demands for sustainable and longer-lasting battery solutions. Customer satisfaction and commercial applications are closely intertwined with a vehicle’s ability to travel longer distances without refueling or charging. The demands and changes drive robust test and measurement programs to bring new battery models and designs to market.

In 2021, it is estimated the EV battery market exceeded 38% of total battery sales. As technology continues to improve the lifecycle and reducing battery costs, Precedence Research estimates 32% CAGR through 2030. This translated to $46B in the US alone of market share, while Asia Pacific is leading the production of EVs and overall demand for the EV batteries. Based on global adoption of electric vehicles, supported by government initiatives and an intense focus on reduced carbon emissions, the EV battery market is expected to continue expanding around the world.

The testing of batteries is growing in complexity with the increase in number of cells, modern designs, materials, cycles, installation, vehicle models, certifications and charging equipment to name a few. Battery simulation and real battery integration testing are two examples of commonly used T&M programs used to validate battery adaptability and use requirements. In battery testing, accuracy and quality of the measurement devices are vital. The following are the most common battery types today:

  • Lithium-ion Battery
  • Lead-Acid Battery
  • Sodium-ion Battery
  • Nickel-Metal Hydride Battery
  • Others

Due to the market shift to EVs, the lithium-ion battery is the number one battery type today. The domination of the lithium-ion battery exceeded all other battery types in 2021. Manufacturers of EVs prefer partnering with OEMs of newer model Li-ion batteries because they are lighter in weight and have higher energy density. The following details one of many Interface solutions offered to automotive component and battery manufacturers.

Electric Vehicle Battery Monitoring

The EV battery manufacturer required a system to monitor their lithium-ion batteries. Normally, lithium-ion batteries are measured through voltage and current measurements or (ICV) to analyze and monitor the battery life. In consultation with the design and testing engineers, Interface recommended a solution that required installing the LBM Compression Load Button Load Cell in between two garolite end plates, and measuring the force due to cell swelling or expansion. Instead of monitoring through voltage (ICV), this method is based on measured force (ICF). To monitor the testing, the load cell was paired with the 9330 Battery Powered High Speed Data Logging Indicator. This instrumentation solution provides the ability to display, record and log the force measurement results with supplied software.  To review the results and complete application note, go here.

Interface has long partnered with auto manufacturers and suppliers of various parts and components to provide a large range of automotive industry test and measurement solutions.  This includes sensors and instrumentation solutions for the development, testing and performance monitoring of all types of batteries, with growing interest for lithium-ion battery testing.

Interface will be discussing this and other force measurement solutions at the upcoming Auto Test Expo in Europe. Join us in Stuttgart or contact our application engineers to collaborate on a testing solution that works for your next project.

Additional Automotive Industry Resources

Interface Automotive Force Measurement Solutions

Driving Force in Automotive Applications

Test and Measurement for Electric Vehicles

The Future of Automotive is Electric

AxialTQ Technical White Paper Details Comparative Testing

WTS Brake Pedal Force Testing

Automotive + Vehicle Brochure

Automotive Window Pinch Force Testing App Note

Automotive Head Rest Testing App Note

Advancing Auto Testing with Interface Measurement Solutions