Posts

AxialTQ Technical White Paper Details Comparative Testing

/0 Comments/in /by

Recently, Interface put together a full comparison of our AxialTQ™ Torque Transducer measurement systems versus a competitor’s system that offers a DIN120, 1kNm capacity transducer. To view the complete details, read the new Interface technical white paper A Comparison of Torque Measurement Systems, authored by Jay Bradley, Interface Electrical Engineering Manager.

Here is a brief overview covering the crucial results of the comparison testing.

About AxialTQ Torque Transducer

Since 2018, the AxialTQ has redefined the category of torque measurement systems in terms of function, accuracy, and customizable compatibility. It’s a must have torque transducer for anyone working to minimize uncertainty when measuring anything that turns. It is specifically designed for the expanding torque measurement needs in fields that include the automotive industry, as well as the aerospace and industrial automation sectors.

At the heart of AxialTQ’s innovation is the rotor and high-precision sensing element technology, which when combined with the electronics component, produces industry-leading accuracy. This product is also fully customizable due to its ability to use simultaneous analog and digital outputs. This is key, as it enables real-time control and data collection. The flexible capability of the stator and output module mounting offers an infinite number of configurations to meet any application needs.

AxialTQ was designed and engineered by Interface in direct collaboration with end-users who shared their wish-lists for operational priorities, user profiles, design specifications, feature preferences, and real-world field challenges they wanted a solution to resolve.

The unique decision to implement an axial gap, as opposed to the industry standard radial gap, means there is minimized concern that the shaft, rotor and stator will make contact, significantly reducing the possibility of damaging the system.

Installation Overview

AxialTQ features a 120° stator coil giving it the ability to be mounted in several different orientations. While the full stator loop of the competing system must be carefully aligned with the rotor. AxialTQ’s large axial gap of up to 6mm and radial gap of up to 12mm also allows for small misalignments or rotor movement. The competing system has a small radial gap of 1mm and ±2mm when installed, providing less flexibility and durability. The stators of both the AxialTQ and the competing system have multicolor status LEDs that indicate proper alignment and data transmission.

Performance Testing and Validation

The tests found that both systems performed well and met their respective operating specifications. Some of the dynamic testing was performed only once due to time constraints. This testing also has a greater uncertainty of measurement because of the test setup.

In this comparison we tested the installation process, as well as performance for the following specifications:

  • Zero balance stability
  • Shunt calibration stability and repeatability
  • Measurement repeatability
  • Measurement non-linearity
  • Measurement hysteresis
  • Axial force crosstalk
  • Zero balance over operating temperature
  • Axial gradient temperature performance

Overall, both systems performed in line with specifications. Areas in which the AxialTQ stood out included change in zero-balance readings, performance in operating temperature ranges, and in the in-house spin testing cycles.

Configuration Advantages

Unlike the competing system, the AxialTQ has one analog voltage or current output, two analog frequency outputs, and a digital serial output which are all active and independently scalable and filtered. This means that by applying different scaling to two different outputs, the AxialTQ can operate like a dual range sensor.

Durability

AxialTQ also has a significant advantage in durability. The large axial (up to 6mm) and radial (typically 12 mm) gaps between the rotor and stator make it highly unlikely that the rotor will contact the stator because of harmonic vibration, torque pulse or some other event. Both the rotor and stator coils of the AxialTQ are fabricated from 0.125in (3.18mm) thick FR4, with any conductors located at least 0.05in (1.27mm) from the edge. If damaged, these coils are easily replaced in the factory.

AxialTQ is innovative alternative to current systems and includes creative solutions to overcome some of the challenges that diminish performance in these systems as well. To learn more about go to our AxialTQ product page.

Additional Resources

Recap of Latest Spin on AxialTQ Webinar

AxialTQ Engine Dynamometer Application Note

The AxialTQ Dynamometer

AxialTQ for Anything That Turns and Needs Testing

Recap of Latest Spin on AxialTQ Webinar

/0 Comments/in /by

Interface recently hosted a new webinar in our ForceLeaders series that highlighted the revolutionary AxialTQ product.  The event reviewed the bearingless wireless rotary torque transducer design and detailed component specifications, why test engineers prefer the AxialTQ, and use cases for this precision measurement system.

If you were not able to attend the Latest Spin on AxialTQ event, you can watch the entire recording online here.

The revolutionary AxialTQ was first introduced in 2018. The design originated from the popular HRDT product that utilized a rotor stator gap design as a single component. After hundreds of users, we started the product engineering exercise to see how we could advance the soon-to-retire HRDT and evolve it into something that would perfectly fit current market conditions.

As technologies were changing testing protocols and requirements, such as for electric motors, alternative energy hardware, space vehicles and industrial machine automation, we wanted to add new functionality. Jay Bradley and the Interface engineering team began the process by looking at DIN size optimization, shorter stators, additional coupling options, advanced software configurations and simple “drop-in” replacement parts with a modular design.

After thousands of design hours and testing, Interface released the AxialTQ. The specialized product is a unique combination of accuracy, reliability and ease of use that redefines the standard torque measurement device in terms of function and durability.

Engineers prefer the new AxialTQ because of the time-proven sensing element with longer active area providing greater measurement sensitivity while being less vulnerable to shock loads.  The high-resolution digital electronics are state-of-the art. Uniquely, the large gap design up to 6 mm axial and 12 mm radial minimizes contact damage which is important at high-speed testing. It has 120-degree partial loop antenna on the stator to make installation easier.

Specialized design features of AxialTQ make it a great fit for test and production applications.

  • Crash-proof design for maximum reliability
  • Industry-leading gap to prevent damage to rotor stator at full speed
  • Simultaneous analog and digital outputs, enables real-time control and data collection
  • Interchangeable stators and output modules minimize parts inventory
  • Versatile design and wide range of configurations to match any application
  • Hardware is self-configuring
  • New advanced software with added features and logging capabilities
  • Rotor and stator coils designed using printed circuit boards for durability

The AxialTQ rotor sensing element and electronics are the heart of the system. It has a rugged design for all types of torque measurement applications.  It comes in 8 torque capacities. The status assembly matches to the rotor DIN size and is interchangeable with equipment DIN size rotor assemblies, increasing usability.  The USB digital output module has galvanic isolation on all outputs and has standard IP65 ingress protection.  It enables real-time control and accurate data collection.

Keith Skidmore shared several use cases during the presentation, including engine dynamometers, motor test stands and other automotive production line applications.

The AxialTQ is designed for testing anything that spins. It’s ideal in testing and production of hydraulic motors, EVs, helicopters, aircraft, and drones, along with windmills and industrial fans.  It’s great for testing forklifts, off-road and utility vehicles as wells as tractors and watercraft.  AxialTQ is also generally used for measuring torque on industrial motor assemblies, pumps, appliances, braking systems, and motor vehicle accessories.

Watch the entire webinar below to hear Keith and Jay share tips, specifications, frequently asked questions and how to get the most out of your torque measurement applications.

Learn more about AxialTQ here.

Latest Spin on AxialTQ

/0 Comments/in /by

Our latest webinar, Latest Spin on AxialTQ features Keith Skidmore and Jay Bradley detailing all aspects of AxialTQ including design, features, performance specifications, customizable options, and applications of this revolutionary torque transducer.

Read more

Faces of Interface Featuring Ginny Bradley

/0 Comments/in /by

In today’s Faces of Interface, we’re introducing you to Ginny Bradley. As International Application Engineer, Ginny is responsible for supporting our Global Sales Network of distributors outside of the U.S. This includes distributors on every continent, from Asia to South America, and expanding in operations due to continued growth and demands for Interface products worldwide.

Ginny’s journey into the engineering and manufacturing world is quite different than her husband’s, Jay Bradley, who was featured in a previous ForceLeaders post. Now we are sharing the story of his equally brilliant wife of 33 years, and we’re excited to tell her story.

Ginny grew up as a military brat moving up and down the east coast of the United States, after living in Japan as a young child. Her father was a flight deck officer on an aircraft carrier, and due to her exposure to the world of aerospace, Ginny was always extremely interested in science, math, and technology. This led Ginny to pursue a degree in computer science, which eventually became her minor, and she graduated with a degree in accounting and business administration from the University of Central Florida.

After college, Ginny went to work for the nonprofit organization, Foundation for Senior Living. She began as a staff accountant and eventually was promoted to head of HR and accounting. Ginny spent 24 years with the Foundation for Senior Living and really enjoyed her time there. However, she was on call 24/7 due to the fast-paced nature and small staff typical of nonprofits, and eventually she felt it was time for a change.

Ginny took on contract accounting jobs for a few years and then began talking to her husband about Interface. She was always intrigued about his work at Interface because of her interest in math and science, so she decided to give it a shot when a position on our front desk opened 10 years ago.

Ginny’s propensity for learning had her right in the thick of the Interface world not too long after she started. She quickly moved into an accounting and sales role, followed by a data entry and sales role. Ginny picked up on the ins and outs of Interface and its customers, and soon she was asked to become an international application engineer.

In this role, Ginny is responsible for ensuring products and solutions are aligned with customer needs. Her math and science background, along with her interest in and exposure to the aerospace and defense industries, helped her quickly grasp the various Interface product lines and provide valuable advice to customers. She also has the special benefit of being able to lean on her husband, who is an experienced engineer, when she needs a little more technical detail. In addition, she can apply her accounting background to process large POs, help customers align pricing with their needs, and more.

As international application engineer, Ginny’s day is always engaging as she works with people from all over the world from Europe to APAC, including distributors in Germany, China, Canada, India, United Kingdom, Australia, and many others around the globe.

“My favorite thing about working at Interface is the ability to work with these customers directly and help them solve real-world challenges,” Ginny Bradley, International Application Engineer

In her free time, Ginny likes to spend time with Jay and their three children. She enjoys being hands on with various projects around the house including arts and crafts. She and Jay are currently renovating their home. Her absolute favorite pastime is adventuring around Northern and Southern Arizona with her best friend and going on wine tours. Their most recent big trip was a wine tour back East in the Finger Lakes area near where Jay grew up, and Jay accompanied them.

Now you know a little bit more about the Bradleys, our Interface dynamic duo! If you want to learn more about our outstanding team, check back in every month for a new entry about our ForceLeaders in our Faces of Interface Series.

To locate and contact any of our International Distributors, go here.

Calibration Systems 101

/0 Comments/in , /by

Even with the most accurate load cells available, the toll of constant use over long periods, and in some cases accidental misuse, can impact the reliability of the output. Calibration of force measurement products is vital in performance management, and necessary for safety and compliance with ISO and industry-specific standards.

In a recent Interface customer survey, 21% of respondents are calibrating load cells in-house. This is one of the reasons why Interface provides world-class load cell calibration solutions in several design configurations, as well as custom products, for a wide range of rigid and portable systems. Interface calibration offerings include complete systems for desktop and portable configurations, load frames, signal conditioning boards, intelligent digital indicators, calibration grade load cells, and calibration adapters.

The Interface Gold Standard® Calibration Systems, using the Interface Gold or Platinum Standard® Load Cells, ensures a metrology system of the highest accuracy and lowest uncertainty available.

The GS-SYS Gold Standard® Calibration System Load Frame consists of a four-post rigid load frame, proprietary load feedback loop, signal conditioning hardware, and fully-automated calibration software for the highest accuracy and lowest uncertainty available. Portable versions of the GS-SYS system are also available for calibrating load cells and test equipment.

Features of the system include:

  • 2 channels with an option available for 3 and 4 channels
  • 9840 Intelligent Indicator
  • Less than 0.04% RDG uncertainty
  • Testing and reporting per ASTM E74 and/or ISO 376 standards
  • Automated reports, graphs, and performance parameter calculations with custom reporting options
  • Innovative fixturing allows for tension and compression calibration without changing the setup
  • Proprietary load feedback design for accurate and reliable load control
  • Data archiving

A fully automated Interface Calibration System can reduce calibration time by 50% to 90% and can be set for automated calibration runs to be completed in less than five minutes.

The top calibration grade load cells from Interface are the 1800 Platinum Standard® Calibration Load Cell in ranges of 1.1K lbf to 55K lbf, 4.89 kN to 245 kN, followed by the 1600 Gold Standard® Calibration Load Cell with options from 500 lbf to 200K lbf and 2.22 kN to 900 kN.

Interface also has a compression-only calibration load cell, the 1601 Gold Standard®, in capacities of 1K lbf to 100K lbf and 4.45 kN to 445 kN.  The 1606 Gold Standard® Low Capacity Calibration load cell is also used in metrology labs, with products available in 50 lbf to 300 lbf ad 222 N to 1.33 kN sizes.

Interface also offers calibration software included with our calibration products. The ICS-202 Gold Standard® Load Cell Calibration Software will provide exact load output at specific load points. Calibration results from other runs can be compared, measured, and displayed with current run results.

Interface provides the most accurate and reliable load cells in the force measurement industry. We are able to do this because we control the entire load cell development process from design to production, including manufacturing our own strain gauges. Controlling the complete process ensures outstanding product quality which is confirmed through our stringent calibration requirements before any Interface product is shipped to our customer.

Interface load cells are capable of lasting a very long time. In fact, we recently received a calibration service request on some of the very first load cells that we have ever manufactured, decades old. To ensure load cells last as long as possible, Interface recommends customers calibrating their load cells on an annual basis. The frequency of calibrations should also be determined by the following factors:

  • Measurement quality and allowable tolerance range
  • Subjected level of stress on the equipment
  • Stability of past calibrations
  • Required measuring accuracy
  • Quality assurance requirements

Whether you rely on Interface for calibration maintenance services or perform the services in-house, we have calibration solutions to meet your exact needs including load frames, signal conditioning boards, and intelligent digital indicators.  Contact our specialized Application Engineers to discuss the best options for your requirements.

Download or view the Calibration Systems Brochure

Contributor:  Jay Bradley, Sr. Electrical Engineer, Interface

Faces of Interface Featuring Jay Bradley

/0 Comments/in /by

It is not often that we have a team member we are highlighting that has both engineering and musical talent. That sums up our next feature of the multi-talented Jay Bradley. He is Interface Engineer by day and rockstar by night.

Jay discovered his passion for music and engineering at a young age. He could often be found taking apart and tinkering with amplifiers for his guitar. “Anything that was given to me as a kid that included moving parts or electronics was disassembled pretty quickly,” said Jay.

After high school, Jay joined the United States Air Force. During his time in the service, he began to realize that he was destined for a career in engineering. Jay worked on a number of projects that were, in his words, “very cool,” involving the operation and development of classified electronic warfare equipment. This job went on for several years after his service because he continued to work with the U.S. Air Force as a contractor.

Upon leaving contracting, Jay started working for Microwave Systems Engineering, manufacturers of RF devices such as downconverters and microwave amplifiers. The knowledge and experience he gained in this field helped him to land a job at Honeywell, where he became immersed in navigation-related RF engineering. Before joining Interface, he worked for 10 years at Osmonics and Instrulink specializing in PH and conductivity sensors.

Today, Jay enjoys his career as an electrical engineer at Interface. He started at the force measurement solutions company designing amplifiers, a familiar field, where he applied his knowledge specifically for load cells. He worked his way up the ladder and is currently a lead designer on many of the products Interface makes today.

As a part of his responsibility for designing products, Jay works closely with customers to understand their technological challenges.

“The work I enjoy the most involves solving specific and complex pain points customers are experiencing.” Jay Bradley

A recent example of this type of work came with the development of one of Interface’s latest innovations, AxialTQ. This product was a direct result of customer feedback, mixed with Interface’s continuous drive to innovate.

Another aspect of Jay’s position with Interface that he enjoys is leading a group of engineers.

“My approach to leading these individuals is getting out of their way. I know that the engineers at Interface are incredibly talented, and it’s my job is to facilitate a work environment that is based on communication, supporting one another and allowing smart people to do what they do best without micro-management.” Jay Bradley

To satisfy his inner “rockstar,” Jay can be found jamming with his buddies in a garage band or tinkering with amplifiers to get the sound right. He has carried this passion with him throughout his life. Another creative outlet that Bradley has enjoyed since he was a teenager is photography. To this day, he shares these activities with his wife Ginny and three children. Rock on Jay!

Considerations for Fatigue-Rated Load Cells

/0 Comments/in /by

There are many products that are made to serve a single or limited use. Needs for these types of products, often consumable, are immediate and buying decisions usually require limited research or comparisons. On the other end of the spectrum, there are products that need to be extremely reliable, durable, and built to last a long time. The buying decisions for these types of products often require more research to make certain they are highly rated, safe, and made from sturdy and reliable materials.

How do original equipment manufacturers (OEMs) determine how long a product should last with consistent use? What design decisions need to be made to improve product reliability? The answer is often found in the defined fatigue requirements of a product. In the test and measurement and design phase of a product, answers to these questions frequently require product and component testing with fatigue-rated load cells.

Fatigue is the weakening of a material caused by repeatedly applied loads. Similar to if you repeatedly bend a paper clip, it will eventually weaken and then break. The only way to test fatigue is to put prototypes of the product through stress tests for long periods of time or use an apparatus that tests the lifetime “wear and tear” in a few hours. The tool that reports the data gathered from stress tests is the load cell.

With Interface fatigue-rated load cells, designers and engineers can predict the time and force it will take for wear and tear to take its toll on their products. They can then create safety instructions for customers or redesign the product for better results.

Interface Model 1000 series is a portfolio of fatigue-rated low profile load cells with 300% safe overload, extremely low moment sensitivity of 0.1%/in and higher fatigue life. If you need to measure 1 pound (4.45N) or 1 million pounds (4500kN) of force, Interface fatigue-rated load cells are built for this type of testing.

Interface fatigue-rated load cells are designed for an operational life of in excess of 100 million fully reversed cycles.

It’s also important to note that Interface fatigue-rated load cells are based on fully reversed load cycles, which means they are rated for two directions. This type of loading cycle is considerably more stringent than unidirectional loading. It is the more common application of load cells. If a fatigue load cell is repeatedly loaded in only one direction, it can be loaded to about 133% of the bidirectional fatigue-rated capacity with no degradation of its fatigue rating.

Interface works with customers to provide our fatigue-rated load cells for products that can’t fail. It is our mission to ensure precision products are safe, reliable and durable. If they do fail, it could result in significant harm.

Two examples of products dependent on fatigue-rated load cells for testing are aircraft wings and furniture stability. In aircraft wing testing, load cells test the materials used to build the wings to ensure they are strong and lightweight. The load cells are also used in wind tunnels to test the stress of high winds on the wings over time. Safety protocols manufacturing for furniture products require fatigue testing, seat testing, shock testing, and proof testing. These tests must be rigorously performed before entering the marketplace.

Force testing simulations using fatigue-rated load cells help the manufacturer define max loads in order to protect manufacturers from liability due to damages resulting in the misuse or overloading of their products. These types of applications require the most accurate data available provided by our load cells to ensure that testing results produce a quality product that lasts.

Fatigue-rated load cells are one of the many Interface force measurement tools available to help customers develop quality products. For information on all of the load cells we provide, please visit www.interfaceforce.com/product-category/load-cells/.

Contributor:  Jay Bradley, Sr. Electrical Engineer, Interface