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Collaborative Robots Using Interface Sensors

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Industrial evolutions continue to find new and innovative ways to use technologies, from AI to advanced robotics. What is not changing over time is the unique ability for humans to solve challenges and create new solutions. Pairing human ingenuity with machines to increase efficiencies and productivity is what we see today with the fast growing use of collaborative robots.

A cobot, short for collaborative robot, is a type of robot designed to work alongside humans in a shared workspace. Unlike traditional industrial robots, which are typically separated from human workers, cobots are designed to be safe and easy to use working side-by-side people. This interactivity is often referenced as part of moving from Industry 4.0 to Industry 5.0.

Cobots are typically equipped with sensors technologies that allow them to detect the presence of humans and react accordingly. This can include slowing down, stopping, or changing direction to avoid collisions or other safety hazards. Cobots are often used in tasks that are repetitive, dangerous, or require a high level of precision, such as assembly, packaging, or inspection.

One of the main advantages of cobots is their flexibility and ease of use. They can be quickly reprogrammed or taught new tasks, making them a cost-effective solution for many distinct types of manufacturing and assembly operations. Additionally, because they can collaborate with human workers, they can help to improve efficiency and productivity while also reducing the risk of injury or accidents.

In our new case study, Advancements in Robotics and Cobots Using Interface Sensors, we explore how are force measurement sensors used for cobots.

Force measurement sensors are often used in collaborative robotics to provide feedback on the force being applied during a task. This information can be used to ensure that the cobot is performing the task correctly and to detect any issues or errors that may occur. There are several types of force measurement sensors that can be used in cobots.

  • Strain gage sensors: Interface uses proprietary strain gages in our load cells. Use of this type of sensor helps to measure the deformation of a material in response to applied forces. They are commonly used in cobots to measure forces applied to a gripper or end effector.
  • Miniature load cells and load cell load buttons: Interface load cells of all sizes are used for both testing during design as well as embedded into the actual cobot for continuous monitoring. These types of sensors measure the force applied to a structure, such as a robotic arm or a part being manipulated by a gripper. Load cells can be used to ensure that the cobot is applying the correct amount of force to the part being worked on. Our smallest load cells are often used in the production and design of cobots.
  • Torque transducers: Interface transducers are utilized to measure the movement of robots, in rotation and for pivotal activity. These are critical in tasks on production lines, as well in unique industry cobots, such as entertainment.
  • Tactile sensors: These sensors measure the pressure or force applied to a surface. They are commonly used in cobots for tasks that require a high level of sensitivity, such as grasping and manipulating fragile objects.

Advancements in Technology Leads to Multi-Axis Sensors and Cobots

As use of cobots grows, so do the demands for using more data to define precision measured responses and actions. Multi-axis sensors can provide several benefits for cobots, as they allow for more accurate and precise sensing of the robot’s position, orientation, and movement. Here are some ways that cobots can benefit from multi-axis sensors:

  • Improved accuracy: Multi-axis sensors can provide more accurate readings of a cobot’s position and orientation, allowing it to perform tasks with greater precision and accuracy. This can be particularly important for tasks that require precision accuracy, such as assembly or inspection.
  • Enhanced safety: Multi-axis sensors can help to improve the safety of cobots by detecting when the robot is approaching an object or a person and slowing down or stopping to prevent collisions. This can be particularly important when cobots are working near human workers.
  • Greater flexibility: Multi-axis sensors can allow cobots to perform a wider range of tasks, as they can adapt to changes in the environment or the task at hand. For example, a cobot with multi-axis sensors can adjust its position and orientation to grip an object from a variety of angles, or to perform a task in a confined space.
  • Faster response time: Multi-axis sensors can provide real-time feedback on the cobot’s movement, allowing it to adjust more quickly and with greater accuracy. This can help to improve the speed and efficiency of the cobot’s performance.

Cobots are being used in a wide range of industries, as they offer benefits such as improved efficiency, precision, and safety. Some of the industries that are currently using cobots include:

  • Automotive: Cobots are being used in the automotive industry for tasks such as assembly, material handling, and inspection.
  • Electronics: Cobots are being used in the electronics industry for tasks such as assembly, testing, and inspection.
  • Food and beverage: Cobots are being used in the food and beverage industry for tasks such as packaging, sorting, and palletizing.
  • Medical: Cobots are being used in the medical industry for tasks such as assembly, inspection, and material handling.
  • Pharmaceuticals: Cobots are being used in the pharmaceutical industry for tasks such as packaging, inspection, and dispensing.
  • Aerospace: Cobots are being used in the aerospace industry for tasks such as drilling, riveting, and assembly.
  • Plastics and rubber: Cobots are being used in the plastics and rubber industry for tasks such as injection molding, material handling, and inspection.

By using force measurement sensors, cobots can perform tasks with greater accuracy and precision, reducing the risk of errors and improving overall efficiency. They can also help to prevent damage to parts or products being worked on and ensure that safety standards are being met.  Read the full case study below.

Advancement in Robotics and Cobots Using Interface Sensors Case Study

 

Detailing Pillow Block Load Bearing Load Cells

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Most commonly, a pillow block bearing is used to create a rolling system. This type of bearing is often utilized for industrial rolls for textiles, paper, and materials. It is also used on conveyor belts in manufacturing facilities. There are other common use cases in a variety of industries, including in transportation, medical device design, and aerospace.

Interface offers specialized loads cells designed to measure and monitor weight and other forces on pillow block bearings, aptly known as Interface Pillow Block Load Bearing Load Cells. The force measurement is performed for this load cell between two supports.

Pillow Block Bearing Load Cell Spans Multiple Industries

Pillow block bearing load cells are important in all types of industries where accurate load measurement is required during production and use of rollers, small and large. Some examples include:

  • Steel industry: Pillow block load cells can be used in roller mills to measure the force required to crush or shape steel.
  • Textile industry: Pillow block load cells can be used in textile machines such as looms and knitting machines to measure the tension on the yarn.
  • Packaging industry: Pillow block load cells can be used in packaging machines to measure the force required to cut or seal packaging materials.

Pillow block load cells are valuable in building and enhancing infrastructure. Using our PBLC1 is a great solution for monitoring trains on a track, in-motion. When our PBLC1 is installed on a track, and the train runs across it, the sensor can provide a signal to a station elsewhere in the world. If any force indicators suggest that there could be a problem with the weight the train is holding or the train itself, the sensor can also trigger an automatic shutdown of the train. These sensors could prevent major damage from train derailments and other train related incidents by detecting errors before the inflict damage.

These weights are important to measure or monitor as they can tell you if you are running out of material on a roll, or if a production line conveyor belt is holding too much weight. An example of the feed roller system using our wireless options is below.

Manufacturing Feed Roller System

Feed roller systems are common in production and manufacturing. In this example, a feed roller system needs to monitor the forces of both ends of the rollers, to maintain a constant straight feed. This reduces waste and ensure quality in the product use. They would also prefer a wireless system. Interface suggests installing two PBLC Pillow Block Load Cells at both ends of the bottom roller to measure the applied forces. The output of measurement is sent to the instrumentation device, our WTS-AM-1E Wireless Strain Bridge Transmitter Module. The data is then transmitted wirelessly to the WTS-BS-6 Wireless Telemetry Dongle Base Station and the WTS-BS-1-HA Wireless Handheld Display for multiple transmitters, where data can be displayed, graphed, and logged a computer. Learn more about this type of use case in our Feed Roller System Application Note.

In addition to this use case, here are a few other ways Pillow Block Load Cells are used to measure weight and force:

  • Material handling: Pillow block load cells are commonly used in conveyor systems to measure the weight of materials being transported.
  • Automotive industry: Pillow block load cells are used in assembly line applications to measure the weight of parts and components being assembled.
  • Heavy machinery: Pillow block load cells are used in cranes, bulldozers, and other heavy machinery to measure loads and monitor the equipment’s performance.
  • Manufacturing: Pillow block load cells are used in material testing machines to measure the force required to break or deform materials.
  • Aerospace: Pillow block load cells are used in aerospace applications to measure the weight and balance of aircraft and spacecraft.
  • Medical industry: Pillow block load cells are used in medical equipment such as patient lifts and hospital beds to measure the weight of patients.
  • Food industry: Pillow block load cells are used in food processing and packaging equipment to measure the weight of ingredients and finished products.

Pillow Block Bearing Load Cells Product Overview

This type of force sensor is suitable for the measurement of forces under pillow block bearings for diameter Ø 20mm (Ø 0.79 in) and for the measurement of axle weight in test stands for trains and vehicles. Our system is compatible with INA Pillow Block Bearings and is installed underneath the bearing to measure force. There are three model versions, with the options for additional multi-axis measurements for engineer to order products.

PBLC1 Pillow Block Load Bearing Load Cell

PBLC2 Pillow Block Load Bearing Load Cell

PBLC3 Pillow Block Load Bearing Load Cell

Features and benefits of our Pillow Block Load Cell include:

  • Capacities from 5 to 30 kN (1.1K to 6.7K lbf)
  • Compatible with INA pillow block bearings
  • IP65 moisture protection
  • Rugged electro-galvanized surface

In addition, our Pillow Block Load Cell are also available in multi-axis versions, which allows for more force data from your test application. This helps with measuring forces such as center of gravity, tension across a load bearing beam and more. These multi-axis versions come in two and three axis models. If you are looking to get accurate measurement for your pillow block bearing use cases, contact our specialized application engineers.

ADDITIONAL RESOURCES

Interface Manufacturing and Production Solutions

Quality Engineers Require Accurate Force Measurement Solutions

Interface New Product Releases Winter 2023

Infrastructure Industry Relies on Interface Force Measurement

Interface Solutions for Production Line Engineers

Industrial Automation

 

How Load Cells Can Go Bad

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Load cells are electronic devices that measure the force applied to them. Interface products are made to last, in fact we have many load cells that are in-market and being used for high-accuracy testing that were manufactured decades ago. Why do they last? Quality of design, material construction, build process, calibration, and regular maintenance prolong the life of a load cell.

Like any electronic device, load cells can go bad for a few reasons. It is also important to know that load cells can be repaired. Outside of complete destructive testing, the following issues are most common for how load cell can go bad.

Overloading: Load cells have a maximum capacity, and if they are subjected to a force beyond that limit, they can get damaged. Overloading can cause the load cell to deform or break, resulting in inaccurate readings or complete failure. Preventative options are to use overload protected load cells.

Mechanical and physical damage: Load cells are sensitive devices and can be damaged by impact, vibration, or shock. Mechanical damage can cause the load cell to deform or lose its calibration, resulting in inaccurate readings. Physical damage to devices is often because the load cells are dropped or mishandled during use.

Moisture: Load cells are often used in damp or wet environments, and prolonged exposure to moisture can cause corrosion or damage to the internal circuitry. Environmental exposure to moisture can also cause electrical shorts or create a conductive path between the components, resulting in inaccurate readings or complete failure. Review submersible options if testing in these environments is common.

Temperature: Load cells can be sensitive to temperature changes, and extreme temperatures can cause damage to the internal components. Thermal expansion or contraction can cause mechanical stress, resulting in deformation or damage to the load cell. Interface offers high-temperature and low-temperature load cells options.

Electrical noise: Load cells are susceptible to electrical noise, which can cause interference in the signals and result in inaccurate readings. Electrical noise can be caused by electromagnetic interference (EMI), radio-frequency interference (RFI), or other sources of electrical interference.

Aging: Not all load cells are made the same way. Interface load cells are designed to outlast any testing use for long-periods, we are talking millions of cycles. However, some load cells can wear out over time due to repeated use, exposure to the environment, or other factors. Aging can cause a decrease in sensitivity, accuracy, or stability, resulting in inaccurate readings or complete failure. All load cells need good health checks to stay working at optimal performance.

To avoid load cell failures, it is important to use them within their rated capacity, protect them from mechanical damage, and provide adequate protection from moisture, temperature, and electrical noise. Regular maintenance and calibration services, preferably every year, can also help ensure accurate and reliable performance over time.

What is the best way to determine if a load cell is bad or not working?

There are several ways to determine if a load cell is bad or not working. Here is a reminder of five quick checks:

#1 Visual Inspection: Start by visually inspecting the load cell for any signs of physical damage, such as cracks, deformations, or loose connections. Check for any corrosion or signs of moisture, as well as any visible wear and tear.

#2 Zero Balance Testing: A zero balance test is a quick and straightforward way to check if a load cell is functioning properly. With no weight applied, the load cell should read zero. If it does not, there may be an issue with the load cell or its connections.

#3 Load Testing: Load testing involves applying a known weight to the load cell and checking the reading. If the load cell is accurate, the reading should match the known weight. If there is a significant discrepancy, the load cell may be faulty.

#4 Bridge Resistance Tests: Load cells are typically constructed with a Wheatstone bridge circuit, which can be assessed for proper resistance values. If there is a significant deviation from the expected resistance values, there may be an issue with the load cell or its connections.

#5 Temperature Tests: Load cells can be sensitive to temperature changes, and extreme temperatures can cause damage to the internal components. Evaluating the load cell at different temperatures can help to identify any issues with temperature sensitivity.

Interface provides complete evaluations of any product we manufacture, to determine if the load cell is working properly. To request services, go here.

How does calibration help load cells from going bad?

Calibration is the process of adjusting a load cell to ensure its accuracy and reliability in measuring weight or force. Regular calibration is essential for maintaining the accuracy and reliability of load cells. Interface recommends annual calibration services as a preventative measure and for good maintenance of your force measurement devices.

Calibration helps to ensure that a load cell provides accurate and consistent readings. Over time, load cells can drift from their initial calibration due to environmental factors, wear and tear, and other factors. Regular calibration ensures that any deviations from the standard are detected and corrected, preventing inaccurate readings that can lead to errors in weighing and other measurements.

Load cells that are not calibrated regularly may experience premature wear and tear due to repeated use, leading to damage or failure. Calibration helps to identify any issues early on and prevent further damage, extending the lifespan of the load cell and saving on replacement costs.

Many industries and applications have strict standards and regulations for measuring weight and force. Regular calibration helps to ensure that load cells meet these standards and regulations.

Regular calibration can help load cells from going bad in multiple ways. It can help to prevent inaccurate readings, extend the lifespan of load cells, improve efficiency, and ensure compliance with standards and regulations. Accurate measurements are critical, and calibration helps to ensure that load cells is working properly. Request a repair or calibration service online.

ADDITIONAL SERVICES

Load Cell 101 and What You Need to Know

Load Cell Sensitivity 101

Can Load Cells Be Repaired?

Services & Repair

Mechanical Installation Load Cell Troubleshooting 101

How Do Load Cells Work?

Regular Calibration Service Maintains Load Cell Accuracy

Interface Manufacturing and Production Solutions

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Force measurement is integral to advanced manufacturing systems, especially when it comes to how this technology is used in production lines. Force sensors are utilized in both testing and monitoring of a wide variety of machines to ensure accuracy and repeatability throughout the production line. These sensors are also used by production line engineers in the design and development of systems used to ensure accuracy in measurements of force, weight, compression, and torque as products and components move throughout the line, including distribution.

Watch how Interface provided an industrial automation solution for small pallets used in the distribution of manufactured products. In the video, we highlight a request for a pallet weighing solution to use in their warehouse to monitor their products and goods 24/7. They need to use sensor technologies to verify if any products are missing based on the weight, and able to determine pricing for their goods based on the weight.

Interface works with a large range of manufacturers and equipment makers to improve quality and productivity by supplying high-performance measurement solutions. From using miniature load cells to apply the exact force needed to press a brand identity onto fragile consumable, to using multi-axis sensors for verifying performance data when making intricately machined parts, Interface products are commonplace in manufacturing and production.

In fact, Interface offers manufacturing and production standard off-the-shelf, engineered to order and complete OEM solutions including load cells, instrumentation and weighing devices. Our products provide the quality and durability necessary within industrial environments. In addition, we can customize the majority of our products to fit unique and evolving needs as sensor technologies like robotics and advanced manufacturing devices are integrated into production lines.

Load cells are frequently used in monitoring equipment. Interface can custom design force sensors to be installed directly into product for monitoring certain forces in real-time, including for use in industrial automation robotics. This is particularly popular in manufacturing because you can monitor equipment to understand when it may be out of alignment and needs to come down for repair, rather than risking a disruption in production. This is particularly important in automated production lines because it gives engineers and extra set of eyes on machines and improves efficiency overall by reducing downtime.

One of the unique use cases for load cells used for monitoring is in weighing materials held on pillow blocks bearings. Pillow block bearings, or similarly constructed bearing, are used to carry rolled materials or conveyor belt. Interface’s new PBLC1 Pillow Block Load Bearing Load Cell can be placed underneath the bearing to measure the weight of whatever material is being held up. These types of bearing are often found in machines with similar type of bearing are used on conveyor belts moving products down a production line.

Manufacturing Feed Roller System

A customer has a feed roller system and needs to monitor the forces of both ends of the rollers, in order to maintain a constant straight feed. They would also prefer a wireless system. Interface came to the rescue with our Pillow Block Load Cells and WTS Wireless Telemetry Systems. Interface suggests installing two PBLC Pillow Block Load Cells at both ends of the bottom roller to measure the forces being applied. The forces are measured when connected to WTS-AM-1E Wireless Strain Bridge Transmitter Module. The data is then transmitted wirelessly to the WTS-BS-6 Wireless Telemetry Dongle Base Station and the WTS-BS-1-HA Wireless Handheld Display for multiple transmitters, where data can be displayed, graphed, and logged on the customer’s computer.

Production Line Conveyor Belt Adhesion Test

A customer wants to test the adhesion strength in between the many layers and textiles of a conveyor belt. They want to conduct a separation test from the rubber of the conveyor belt from the other layers. They would also like a wireless solution. Interface’s SMA Miniature S-Type Load Cell is installed in the customer’s tensile test load frame, where it measures the forces applied as the test is conducted and the layers are pulled and separated. When connected to the WTS-AM-1F Wireless Strain Bridge Transmitter Module, the data is wirelessly transmitted to WTS-BS-5 Wireless Analog Output Receiver Module with nV output. The WTS-BS-5 can then connect to the 9330 Battery Powered High Speed Data Logging Indicator to display, graph, and log the data with supplied BlueDAQ software.

Industrial Automation Robotic Arm for Production

A manufacturer of a robot arm needs to measure force and torque when the arm picks up and places objects. The manufacturer needs a wireless system to accomplish this in order to log the measurement results. Interface supplied Model 6A40A 6-Axis Load Cell with Model BX8-HD44 Data Acquisition/Amplifier.

Interface force sensors can be used in a number of ways within the manufacturing industry across a variety of applications for the test and monitoring of machines and production lines.

ADDITIONAL RESOURCES

Force Measurement Solutions for Advanced Manufacturing Robotics

Robotics and Automation are Changing Modern Manufacturing at Interface

Vision Sensor Technology Increases Production Reliability

Industrial Automation Brochure

Weighing Solutions Brochure

Smart Pallet Solution

Interface Solutions for Safety and Regulation Testing and Monitoring

Basics on Load Cell Base Kits

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As resilient and accurate as load cells are engineered, there is risk of damaging a load cell if they are not properly supported through mounting or mating to the test subject or test bench.

Load cell bases are designed to support and stabilize load cells. Load cell bases come in assorted sizes and configurations, depending on the intended application and the weight capacity.

Load cell bases are used with load cells that are frequently utilized in industrial equipment, test machines, and commercial testing labs. They may also be integrated into several types of equipment, such as weighbridges, conveyor systems, structural test stands, and packaging machines.

Interface publishes numerous guides on properly supporting a load cell during a test. However, for our LowProfile™ load cells, we provide complete Load Cell Base Kits to provide the engineered accuracy and necessary support for precision performance as intended in regular use. Bases minimize risks in damaging load cells from improper use.

Load cells with positive overload protection must be ordered with an Interface installed base. The positive overload option is useful when high overloads occur in applications such as: impact loads on weighing platforms; engine malfunctions during rocket or jet engine testing; transient overloads on engine dynamometers.

Interface’s Load Cell Base Kits are a type of mounting plate guaranteed to provide optimum support for the flexure. Using the base, or a support surface with its equivalent flatness and stability, is required to ensure the exceptional performance. They are heat treated and high strength bases, available in all standard sizes of our low profile models.

Standard thread size is the same as the mating load cell. Bases or flat mounting surfaces are required for all low profile load cell installations. A mounting surface that is flat to 0.0002″ T.I.R. (total indicator reading) is required, unless a base is installed.

Use of the base, or a support surface with its equivalent flatness and stability, is required to ensure the exceptional performance of the LowProfile® Series.

The threaded hole in the base is on center, and a plug is permanently installed to seal dirt and moisture out of the space between the bottom hub of the flexure and the flat surface of the base. Center hub deflects under the load until it contacts the base which provides positive overload protection. The center tapped hole is sealed to keep overload surfaces clean.

When the base and load cell are ordered together, the base and plug are factory installed using the proper hardware tightened to the required torque specs. A plug is supplied in between the cell and the base to prevent damage or errors caused by over engagement of mating parts.

There are 14 model options in standard Load Cell Base Kits in both U.S. and Metric Threads. They are available for our standard 1000, 1100 and 1200 Load Cell Series of various capacities. We offer 15 stainless steel model options to be paired with our 2400 and 3200 Load Cell Series.

Load Cell Base Kits are an excellent accessory to ensuring the most out of your LowProfile Load Cells provide the performance as designed. For complete instructions on installations, please reference our Support section on the website.

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Accessories

Load Cell Basics Sensor Specifications

Interface Presents Load Cell Basics

Technical Library

Force Measurement Installation Guides

Mechanical Installation Load Cell Troubleshooting 101

Electrical Engineers Choose Interface Sensor Technologies

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Interface is a premier provider of force, torque and weighing solutions to electrical engineers around the world who are responsible for creating new products, solving problems, and improving systems.

Electrical engineers vary in specialization and industry experience with responsibilities for designing and testing electrical systems and components such as power generators, electric motors, lighting systems, and production robots. They use their expertise and knowledge of electrical systems and components to design, develop, assess, and maintain safe and reliable electrical systems. There are many electrical engineers who work on complex systems and who are responsible for troubleshooting and diagnosing problems that may arise.

The electrical engineers whose primary focus is research and development look to create new electrical technologies and advance existing systems. Projects related to renewable energy, smart grids, wireless communication systems, and electric vehicles utilize all types of measurement solutions throughout all phases of their R&D. Accuracy of testing is essential for electrical engineers, to ensure components comply with safety regulations and industry standards.

How does an electrical engineer use sensor technology for testing?

Sensors are a critical tool for electrical engineers in testing and optimizing the performance of electronic devices, systems, and processes. The type of sensor used, and the specific testing application will depend on the needs of the project or product, including the following examples.

  • Structural testing: Sensors are used to measure the structural integrity of materials and components. Load cells convert force or weight into an electrical signal that can be measured and analyzed. For example, Interface’s standard load cells are frequently used to measure the amount of strain or deformation in a material under load, which can help electrical engineers design stronger and more reliable structures. See how Interface’s products were used in an EV battery structural testing project.
  • Process control: Sensor technologies, including load cells and torque transducers are frequently utilized in manufacturing processes to monitor and control various parameters. Electrical use this data gathered through various instrumentation devices to ensure that the manufacturing process is operating within the desired parameters and to optimize the process for efficiency and quality.
  • Environmental testing: Environmental sensors are commonplace for measuring temperature, humidity, pressure, and other environmental factors. Electrical engineers can use this data to test and optimize the performance of electronic devices and systems under various environmental conditions. Read Hazardous Environment Solutions from Interface to learn more.

Electrical engineers use load cells in a variety of applications, such as measuring the weight of objects, monitoring the force applied to a structure, or controlling the tension in a cable or wire. The choice of load cell will depend on the specific application and the requirements for accuracy, sensitivity, and capacity. Electrical engineers must also consider factors such as environmental conditions, installation requirements, and cost when selecting a load cell.

Electrical engineers work in a wide range of industries and sectors, as their expertise is required in many different areas of technology and engineering. Interface has supplied quality testing devices and components to EEs in every sector, from electronics to construction.

Electrical engineers in the electronics industry use Interface products in designing and developing components such as microchips, sensors, and circuits. Demands for intrinsically safe load cells and instrumentation come from electrical engineers that are responsible for designing, maintaining, and improving power generation and distribution systems, including renewable energy systems such as solar, wind, and hydropower.

More than any time in Interface’s 55-year history, electrical engineers who work on a variety of aerospace and defense projects, are using Interface sensor products for designing and testing avionics systems, communication systems, and navigation systems.

We also continue provide electrical engineers who engage in designing and developing the electrical and electronic systems in vehicles, including everything from powertrains and engine management systems to infotainment systems and driver assistance technologies with new and innovative force measurement solutions.

Manufacturing electrical engineers who engage in designing and optimizing manufacturing processes, as well as designing and evaluating the electronic components and systems used in manufacturing equipment are frequently using Interface sensors. This includes the rising demands for sensors in robotics.

Electrical engineers across many different industries depend on Interface, just as all the companies and organizations around the world depend on their expertise. Interface is a proud partner of engineers across all disciplines.

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Quality Engineers Require Accurate Force Measurement Solutions

Interface Solutions for Material Testing Engineers

Why Civil Engineers Prefer Interface Products

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Using Multi-Axis Sensors to Bring Robotics to Life

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The advent of robotics brought with it the expansion of machine capabilities across many industries. The range of robotics today spans industrial, entertainment, autonomous, medical, educational, defense and consumer robots.

As with all invention and innovation, the demands for more data and precision testing have grown dramatically in recent years. Due to the nature of robotic movement, and the engineering that must be done to make this movement work, testing sensor technologies are advancing to improve robotics capabilities and to make them more accurate.

In the force measurement world, one of the best sensor devices that lends itself perfectly to robotics are multi-axis sensors. Interface’s multi-axis sensors are designed to provide the most comprehensive data points for advanced testing. With our industry-leading reliability and accuracy, Interface’s multi-axis sensors can provide the data our customers need to ensure performance and safety requirements are met in their robotic designs.

Multi-axis sensors can provide several benefits for use in robotics, as they allow for accurately measuring the robot’s position, orientation, and movement. Here are some ways that robots can benefit from multi-axis sensors:

  • Improved accuracy: Multi-axis sensors provide more accurate readings of a robot’s position and orientation, allowing it to perform tasks with greater precision and accuracy. This can be particularly important for tasks that require precision accuracy, such as assembly or inspection.
  • Enhanced safety: Multi-axis sensors help to improve the safety of robots by detecting when the robot is approaching an object or a person and slowing down or stopping to prevent collisions. This can be particularly important when robots are working near human workers.
  • Greater flexibility: Multi-axis sensors allow robots to perform a wider range of tasks, as they can adapt to changes in the environment or the task at hand. For example, a robot with multi-axis sensors can adjust its position and orientation to grip an object from a variety of angles, or to perform a task in a confined space.
  • Faster response time: Multi-axis sensors can provide real-time feedback on the robot’s movement, allowing it to adjust more quickly and with greater accuracy. This can help to improve the speed and efficiency of the robot’s performance.

Multi-Axis Robotic Arm Using Force Plate

In this application note, we highlight a customer that needs to measure the reaction forces of their robotic arm for safety purposes. The reaction loads occur at the robotic arm’s base; therefore, they need a force measurement system at the base of the robotic arm. Interface suggests using our force plate option to install at the base of the robotic arm. The solutions includes 3-Axis Force Load Cells are installed between two force plates, then installed at the bottom of the arm. This creates one large 6-Axis Force Plate. The sensors force data is recorded and displayed through the two BX8 Multi-Channel Bridge Amplifier and Data Acquisition Systems onto the customer’s computer. Read more about this application here.

Sensors must be able to provide the robust data requirements needed in designing and using robotics. Testing for industrial robots, which are used in manufacturing and assembly processes to automate tasks that are repetitive, dangerous or require precision, need exact measurements to clear the path to use. This data from sensors is used in design and production to evaluate reliability and quality of craftmanship. These types of robots are used in a variety of industries such as automotive, electronics, and aerospace.

Safety is primary for service and medical robots, as they are designed to interact with humans and perform tasks in healthcare, cleaning and surgical procedures, diagnosis, and rehabilitation.

Precision and accuracy are what defines the testing requirements for military robots. Whether these robots are used in military applications, such as bomb disposal, reconnaissance, and search and rescue missions or to operate in dangerous environments where it is not safe for humans to work, they must be thoroughly tested for high accuracy in operation.

While educational and entertainment robotics involve human interaction, so sensor technologies must match the use cases for teaching students about robotics, programming, and technology. They are often designed to be easy to use and intuitive, allowing students to experiment and learn through direct experience. Robots designed for entertainment purposes, such as robotic toys or theme park attractions are interactive. Robust sensor data makes the robots more engaging and may incorporate features like voice recognition or facial recognition to provide an authentic experience.

Lastly, autonomous robots undergo vast amounts of design tests using force and torque sensors due to the requirements of operating independently, without human intervention. They are often used in applications such as space exploration, agriculture, or transportation.

Interface offers a wide variety of multi-axis sensor options including 2-axis, 3-axis, 6-axis, and axial torsion load cell sensors. The benefits of using multi-axis sensors aligns to the advancements in robotics, as the expectations to do more means more data is needed to thoroughly test and measure every capability and interaction with accuracy.

ADDITIONAL RESOURCES

BX8 & 6-Axis

Multi-Axis Sensor Applications

Mounting Tips for Multi-Axis Sensors

Recap of Inventive Multi-Axis and Instrumentation Webinar

Dimensions of Multi-Axis Sensors An Interface Hosted Forum

Multi-Axis Sensors

Multi-Axis Sensors 101

 

Off-Axis Loading 101

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Off-axis loading refers to a situation where a load cell, which is a device designed to measure force or weight, is subject to forces that are not aligned with its primary sensing axis. Load cells are typically designed to measure forces that are applied along a specific direction or axis, which is known as the primary sensing axis. When forces are applied to the load cell in other directions, this is referred to as off-axis loading.

Off-axis loading can affect the accuracy of load cell measurements, as the load cell may not be able to accurately distinguish between forces that are applied along the primary sensing axis and forces that are applied in other directions. This can result in errors in the measured weight or force.

To minimize the effects of off-axis loading, load cells are often designed with measures to reduce sensitivity to forces applied in other directions. These may include mechanical features such as strain relief structures or specialized materials that are more resistant to off-axis loading. Additionally, load cells are often installed and used in ways that minimize the likelihood of off-axis loading, such as aligning the primary sensing axis with the direction of the applied force. Be sure to carefully follow all Force Measurement Installation Guides provided with sensor.

What can be done to protect from off-axis loading?

Off-axis loading can affect the accuracy of load cell measurements, so it is important to take steps to protect against it. Here are a few ways to do so:

  • Use proper mounting and alignment: Load cells should be mounted and aligned in a way that ensures that the primary sensing axis is aligned with the direction of the applied force. This helps to minimize off-axis loading and ensure accurate measurements.
  • Use appropriate accessories: Using accessories such as adapters or mounting bases can help to ensure that load cells are properly aligned and oriented, minimizing the potential for off-axis loading.
  • Use anti-rotation features: Many load cells are equipped with anti-rotation features, such as bolt-hole patterns or keyway slots, which help to prevent the load cell from rotating around its mounting point. This can help to maintain proper alignment and reduce the effects of off-axis loading.
  • Use overload protection: Overload protection features, such as limit switches or stoppers, can be used to prevent load cells from being subjected to excessive forces or moments. This can help to prevent damage to the load cell and ensure accurate measurements.
  • Use a protective enclosure: Load cells can be placed in protective enclosures that shield them from external forces and environmental factors. These enclosures can help to protect against off-axis loading, as well as other types of interference.

By taking these steps, load cell users can help to protect against the effects of off-axis loading and ensure accurate and reliable measurements.

Product designs that mitigate off-axis loading

Engineers are constantly working to design new load cells that are more resistant to off-axis loading.  In fact, Interface product engineers have several products that are designed to protect from off-axis loading, including:

  1. ConvexBT Load Button Load Cell
  2. SuperSC S-Type Miniature Load Cell
  3. MBP Overload Protected Miniature Beam Load Cell
  4. MRTP Miniature Overload Protected Flange Style Reaction Torque Transducer
  5. MBI Overload Protected Miniature Beam Load Cell
  6. LBMP Overload Protected Compression Load Button Load Cell
  7. SMT Overload Protected S-Type Load Cell
  8. WMCP Overload Protected Stainless Steel Miniature Load Cell with Male Threads

By optimizing the mechanical design of load cells to minimize their sensitivity to off-axis loading this can include use of materials, such as composites or alloys, which are more resistant to deformation and strain. It also includes the use of specialized geometries that can help to distribute forces more evenly and reduce the effects of off-axis loading.

As well, engineers utilize built-in electronic compensation to correct for the effects of off-axis loading. This may involve using additional sensors or feedback loops to monitor the load cell’s response to external forces and adjust the output accordingly.

Interface engineers use a multi-disciplinary approach to designing load cells that are more resistant to off-axis loading. By combining advances in mechanical design, electronics, manufacturing, and simulation, they are creating load cells that are the most accurate in by classification in the world.

ADDITIONAL RESOURCES

ConvexBT – The Most Innovative Load Button Load Cell

Eccentric Loading Analysis for SuperSC S-Type Miniature Load Cell White Paper

Addressing Off-Axis Loads and Temperature Sensitive Applications

Benefits of Proof Loading Verification

How Do Load Cells Work?

Innovative Interface Load Pin Applications

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A load pin, which often replaces a standard clevis or pivot pin, is a strain gage sensor that measures the force applied across the device. The strain gages are installed within a small bore through the center of the pin. Interface load pins have been used in a wide variety of projects across industries.

Load pins are a simple, but highly powerful sensor that provides data collection for accurate and frequent measurement. The load pin can replace a bolt, clevis, sheave, and an equalizer pin, as well as other load-bearing components to measure tensile and compression forces.

Machined from high tensile stainless steel, Interface load pins are suitable for exposed situations including seawater. We offer standard sizes of load pins between 1.1K lbf to 3.3M lbf (500kgs to 1500 MT). We also have wireless load pins. Interface load pins are custom manufactured to meet specific dimensional requirements for each application, as detailed in our Use Cases for Load Pins webinar.

The most commonly referenced applications for load pins are for overhead equipment like cranes and lifts. Through ingenuity of engineers and our customers, load pins are rapidly expanding in popularity for infrastructure, aerospace, maritime, agriculture, and industrial use cases. The load pins of today are used to test and measure force, load and weight in a much larger variety of applications. They are also growing in demands due to their wireless capabilities for both short and long distances. This includes uses not only for cranes and lifting devices, as well as construction equipment, industrial machines, nautical craft and equipment, aerospace structural environments, and civil engineering applications.

Infrastructure investment and projects around the world are on the rise. Investments in transportation ways like highways, waterways, bridges, mass transit, water supplies and power generation are frequently in demand of load pin solutions for use in all phases of the projects, from construction to maintenance and real-time monitoring.  Some of these examples are highlighted in Infrastructure Projects Rely on Interface.

Interface has a great deal of experience supplying ruggedized and standard use load pins for testing. Our load pins are highly demanded in the infrastructure industry not only due to the accuracy and reliability of our sensors, but also due to the fact that we offer a myriad of communication channels to offer both wired and wireless solutions. As requirements are made to repair and rebuild public infrastructure resilience, equity, and safety for all users are key criteria in design and build stages.  This is where Interface load pins are key to the solution, for durability, accuracy, quality, and ease-of-use.

Interface captured a few application examples of how our load pins are used for different types of projects, from maritime submersibles to monitoring new bridges during earth’s constant shifting.

AEROPSPACE:  Landing Gear Joint Testing

A global manufacturer in aerospace needs to test their new assembly and design by testing its landing gear joints. They want to ensure there are no flaws in the gear shock absorber design and can handle the applied forces when the craft lands from a flight. Interface’s WTSLP Wireless Stainless Steel Load Pins can be installed and replace the normal pin joints. The aircraft undergoes multiple drop tests at different heights, where the forces applied on the load pins transmitting the measurement data. The force results are transmitted wirelessly to the WTS-BS-4 USB Industrial Base Station and the WTS-BS-1-HA Handheld Digital Display for multiple transmitters. Read more about this load pin use case here.

MARITIME: Quick Release Hooks (QRH)

A customer wanted to test their quick release hook (QRH) system when their vessels are docked. They wanted to ensure the mooring lines are secured, but also, the quick release hooks were able to be easily and safely released. Interface’s WTSLP Stainless Steel Load Pin was installed into the quick release hook, where forces from the mooring lines can be measured and displayed when paired with the WTS-BS-4 USB Industrial Base Station. The load tension forces were displayed in real-time on the customers PC or laptop. The WTS-RM1 Wireless Relay Output Receiver Module alarm could also be triggered for the customer when maximum safety work load capacities have been reached or are overloaded. Using this solution, the customer was able to determine if their quick release hooks worked effectively within the safe working limit specifications, and was aware of any potential overload situations. Read more here.

INFRASTRUCTURE: Bridge Seismic Force Monitoring

A customer wanted to monitor seismic activity that occurs to a bridge by using force sensors and then continuously monitoring bridge forces before, during and after earthquakes occur. The customer preferred a wireless solution so they would not need to run long cables on the bridge. Interface helped to develop its LP Load Pin, which were custom made to fit their needs along Interface Inc. WTS Wireless Telemetry System continuous force monitoring was able to take place without long cables. Using this solution, the customer was able to monitor continuous loads, log information to the cloud and review information. Read about this solution here.

AGRICULTURE: Tractor Linkage Draft Control

A farming operation needs to measure the forces applied on their tractor’s draft control, between the tractor and any linked on attachments. Measuring the force helps the farmer sense any strains on the hitch of the tractor, and will be needed in order to apply any specific settings to the draft control when the tractor encounters rough terrain.  Interface’s WTSLP Wireless Stainless Steel Load Pin is a wireless load pin that can be installed directly in the hitch, replacing the normal shear pin of the tractor. Force results are transmitted wirelessly to the WTS-BS-4 USB Industrial Base Station, where they can view the results on a computer using Interface’s WTS toolkit. The customer can also view results on the WTS-BS-1-HS Handheld Display for Single Transmitters in real-time. Read more about this IoT Agriculture solution here.

 

INDUSTRIAL AUTOMATION: Crane Block Safety Check

A customer wanted a system to detect if their crane block can lift heavy loads securely, in order to keep working conditions and personnel safe. If lifting capacities are exceeded, the customer wanted a system to alarm them in real-time. Interface’s WTSLP Wireless Stainless Steel Load Pin replaced the existing load bearing pin in the crane block in order to measure the force being applied by the heavy load. The data was transmitted and displayed through both the WTS-BS-4 USB Base Station (when paired with the customer’s supplied PC computer/Laptop) and the WTS-BS-1-HA Wireless Handheld for real-time results. The WTS-RM1 Wireless Relay Output Receiver Module could also trigger an alarm when maximum capacity has been reached. The WTSLP Wireless Stainless Steel Load Pin, combined with the WTS products, was able to measure and determine force applied the moment a heavy load is lifted. The results were transmitted wirelessly, and ensured the customer whether or not the crane block was safely operational during production.

Are load pins the right solution for your project? Contact our load pin application engineers to learn more.

ADDITIONAL RESOURCES

Load Pins, Tension Links, and Shackles

Uses Cases for Load Pins

Recap of Use Cases for Load Pins Webinar

Applications Catalog

Load Pins 101

LP-TL-Shackles-Brochure