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Conveyor Belts Use Load Cells to Keep Things Moving

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Conveyor belts are incredibly versatile machines with numerous applications across industries, constantly moving materials from one point to another. During some of the busiest packaging and shipment times of the year, it is a good reminder of why measurement solutions keep things moving fast and efficiently.

Critical for automated manufacturing, conveyor belts rely on precise weight distribution, timing, and speed of the conveyor belt operation to keep production in sync.

Conveyors are used for sorting and merging systems, inspection systems, and automated loading and unloading using robotic arms or other equipment to handle materials efficiently. Their versatility and adaptability make them critical in modernizing industries, including construction, mining, manufacturing, logistics, maritime, and agriculture.

Boxes, cans, bottles, and other packages glide smoothly through packaging lines on conveyor belts, ensuring efficient sorting, labeling, and palletizing. These machines efficiently load and unload ships, trucks, and trains with bulk materials, minimizing manual labor and maximizing throughput. Conveyor belts are crucial in sorting and distributing packages in warehouses and postal facilities, speeding up delivery processes.

It is also important to recognize how specialized conveyor belts transport people in public spaces. Conveyor belts seamlessly whisk luggage from check-in counters to aircraft and vice versa, ensuring a smooth passenger experience.

Force measurement can be applied to testing and monitoring conveyor belts in several ways. One of the most common ways is by using load cells to measure the alignment of the belt. Load cells can detect subtle changes in belt behavior, such as uneven loading or misalignment, which can indicate internal damage like cracks or tears. Early identification of these issues allows for timely interventions, preventing further damage and costly repairs.

Testing the conveyor belt rotation or ability to hold weight is a requirement for equipment makers and engineers. Machine builders use Interface sensors in the design of conveyors. In addition to monitoring the system during peak usage, load cells are instrumental in testing the equipment’s quality and durability.

Load cells on the head and tail pulley shafts continuously monitor belt tension for preventative maintenance. This data helps identify deviations from optimal tension levels, leading to premature belt wear, pulley misalignment, and energy inefficiency.  You can prevent costly repairs and downtime by addressing these issues early on.

Conveyor systems often have multiple belts working in tandem. Load cells can monitor the load distribution across these belts, ensuring balanced operation and preventing the overloading of individual components.

Conveyor Belt Adhesion Test

A customer wanted to test the adhesion strength between a conveyor belt’s many layers and textiles. They wanted to conduct a separation test from the rubber of the conveyor belt from the other layers. They also wanted a wireless solution. Interface suggested a SMA Miniature S-Type Load Cell to be installed in the customer’s tensile test load frame, where it measured the forces applied as the test was conducted and the layers were pulled and separated. When connected to the WTS-AM-1F Wireless Strain Bridge Transmitter Module, the data was wirelessly transmitted to WTS-BS-5 Wireless Analog Output Receiver. The WTS-BS-5 then connected to the 9330 Battery Powered High Speed Data Logging Indicator to display, graph, and log the data with the supplied BlueDAQ software. With Interface’s force measurement system and solution, the customer successfully tested the strength of the adhesion applied to their conveyor belts through the layer separation test.

Force measurement sensors can be built into machines as a real-time monitoring system. This type of force application can let engineers know if there is a problem with the system that needs to be taken down for repairs by reviewing data and seeing discrepancies in the normal forces on the conveyor belt. This is particularly important in maintaining efficiency on production lines to ensure minimal downtown.

Food and Beverage Conveyor Belt equipped with PBLC Pillow Block Load Bearing Load Cells and 920i Programmable Weight Indicator and ControllerFood And Beverage Conveyor Belt

Conveyor belts for the food and beverage industry must be maintained and properly aligned to transport products. A load cell is needed to prevent misalignment and to reduce the risk of damage or malfunction of the belt while in operation. Interface suggested installing PBLC Pillow Block Load Bearing Load Cells onto the conveyor belt. They are designed for easy maintenance. The PBLCs measured and monitored the force of the conveyor belt while preventing misalignment. The PBLC Pillow Block Load Cells successfully maintained the proper alignment of the conveyor belt for the food and beverages being transported while also monitoring the forces being implemented.

In automotive, electronics, and other production settings, conveyor belts move components and products along the assembly line, facilitating efficient workflow and ensuring precise positioning.

Conveyor belts easily handle diverse materials, from transporting heavy metal sheets in steel mills to delicate circuit boards in electronics factories. They are the go-to for transporting vast quantities of mined ores, coal, grains, and other bulk materials over long distances and uneven terrain.

Conveyor belts move waste and recyclables efficiently in processing facilities, ensuring efficient sorting and processing. Industrial automation robotics often supports this as part of advanced conveyor systems.

Automating Conveyor Production Lines

Collaborative robots, known as cobots, are used to working alongside humans next to conveyor belts on the production line. Extensive safety measures must be taken for the conveyor and the robot for optimal efficiency and operations. A multi-axis sensor is a tool for this use case. The 6A40 6-Axis Load Cell is installed at the head of the cobot. The 6A40 6-Axis Load Cell interfaces with the BX8-HD44 BlueDAQ Series Data Acquisition System for data collection of force and torque measurements on the line. The customer connected the BX8’s analog outputs to their control system. As a result, the customer can log, display, and graph these measurements during the robot and belt operations. The results are sent to the customer’s control system via analog or digital output.

Interface products are commonplace in these types of applications. Force measurement is integral to advanced manufacturing systems like conveyor belts. Our sensors are utilized to ensure accuracy and repeatability throughout the production line.

We understand manufacturing test and measurement applications, and our custom OEM solutions are ideal for manufacturers who require direct installation to monitor weight, force, and torque into conveyor belt systems.  Contact our application experts to see how we can help you modernize your conveyor systems with advanced sensor technologies.

ADDITIONAL RESOURCES

Manufacturing Solutions

Interface Solutions for Heavy Equipment

Heavy Machinery Solutions

Production Line Solutions

Interface Solutions for Production Line Engineers

Examining Machine Builder Applications

 

Understanding Torque Transducers for Motion Control Systems

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A motion control system is an integrated set of components that work together to control the movement of a machine or device. It typically includes four main elements: controllers, sensors, actuators, and drives.

Torque transducers are essential components in motion control systems. They are important in controlling rotating machinery by providing real-time feedback on the applied torque accurately and efficiently.

Selecting the right torque transducer for a motion control system depends on several major factors, including use case, measurement range, accuracy requirements, speed, and environment.

Industry use cases of motion control systems require different torque measurement capabilities. For example, a robotic arm may need a torque transducer with a high resolution and fast response time. In contrast, a wind turbine may need a torque transducer with a high torque capacity and a long lifespan.

Motion control systems have the same basic goal: to control the movement of a machine or device in a precise and controlled method. Evaluation of the type of torque transducer for your motion control system is important based on type, measurement capacities, accuracy, and speed. Do you need a rotary torque transducer or a static device, known as a reaction torque transducer?

Torque Transducers for Motion Control Systems

Rotary torque transducers are designed to be mounted directly on a rotating shaft. These dynamic transducers are ideal for measuring torque in motors, pumps, and turbines.

Reaction transducers measure the torque applied to a stationary object. These static transducers are ideal for measuring torque in automotive applications such as brakes and clutches.

The torque transducer should withstand the environmental conditions it will be used, including factors such as temperature, vibration, and chemical exposure. These details should be easily identifiable in a review of the transducer’s specifications.

TIP: Use Interface’s Torque Transducer Selection Guide for easy device comparisons.

Why are torque transducers used in motion control systems?

Closed-loop control: Torque transducers enable closed-loop control of motors and drives. By measuring the actual torque output, the control system can compare it to the desired torque and adjust the motor speed or power output to maintain it. This ensures precise and consistent operation of the system, regardless of load variations.

Overload protection: Torque transducers can protect motors and other components from damage caused by excessive torque. By monitoring the torque in real-time, the system can shut down the motor or activate other protective measures if the torque exceeds a predetermined safe limit. This prevents costly equipment failures and downtime.

Optimization and efficiency: Torque transducers help optimize the performance of motion control systems by providing valuable data for analysis and improvement. Engineers can identify areas where the system can be more efficient by measuring the torque at different operating points. This can lead to reduced energy consumption, improved productivity, and increased product quality.

Safety: In safety-critical applications, torque transducers play a vital role in ensuring the safe operation of machinery. The system can take appropriate action to prevent accidents or injuries if the torque exceeds a safe limit by providing data on the torque applied to safety-related components.

Motion Control Applications

Here are four examples of how torque transducers are used in different types of motion control systems:

ROBOTICS: Torque transducers are used to control the movement of robotic arms with high precision. They ensure the robot arm applies the correct force to move objects without damaging them.

MACHINERY: Torque transducers control the spindle speed and feed rate of CNC machines, ensuring accurate and consistent machining operations.

ENERGY: Torque transducers are used to monitor the torque output of wind turbines and optimize their performance. This helps maximize energy production and ensure the safe operation of the turbines.

EV: Torque transducers are used in the drivetrains of electric vehicles to control the torque delivered to the wheels. This enables efficient and smooth acceleration and deceleration.

Should you use torque couplings instead of key shafts in motion control systems?

If your motion control system demands high precision, efficiency, and reliability, removing key shafts and employing torque couplings might be beneficial.

Keyless solutions can reduce downtime and associated costs in applications requiring frequent maintenance. Compact torque couplings can be a better fit than bulky key shafts in tight spaces.

If perfect shaft alignment is challenging, flexible torque couplings can compensate for misalignment and prevent potential problems.

TIP: Visit Torque Coupling Selection Guide for options.

Reviewing your use case to determine if key shafts are necessary for your motion control system is important. There are advantages to keeping key shafts. Replacing key shafts with torque couplings can offer several advantages, including:

  • Elimination of keyways: Keyways are slots cut into the shaft and hub to accommodate a key. This weakens the shaft and can lead to stress concentrations and fatigue failures. Torque couplings eliminate the need for keyways, improving the strength and integrity of the shaft.
  • Reduced maintenance: Keys can wear and loosen over time, requiring periodic maintenance and replacement. Torque couplings, on the other hand, are generally maintenance-free.
  • Improved performance: Torque couplings can transmit torque more efficiently than keys. This can lead to improved performance and efficiency in the overall system.
  • Reduced noise and vibration: Keys can cause noise and vibration, especially at high speeds. Torque couplings can help to reduce noise and vibration levels.
  • Simplified assembly and disassembly: Keys can be difficult to install and remove, especially in tight spaces. Torque couplings are generally easier to assemble and disassemble.
  • Increased flexibility: Some torque couplings can accommodate misalignment between shafts, which can be helpful in applications where perfect alignment is difficult to achieve.

Whether to use torque couplings to replace key shafts depends on the specific application. However, torque couplings can offer significant advantages in strength, performance, and ease of use in many cases.

Torque transducers are versatile tools that play a vital role in various motion control systems. They provide accurate and reliable data on the applied torque, enabling closed-loop control, overload protection, system optimization, and enhanced safety.

ADDITIONAL RESOURCES

Trends in Torque Transducer Applications in the Auto Industry

Interface Introduces New Torque Coupling Guide

Torque Transducers and Couplings are the Perfect Pairing

Miniature Torque Transducers 101

Choosing the Right Torque Transducer

A Comparison of Torque Measurement Systems: Download the white paper.

AxialTQ for Anything That Turns and Needs Testing

Force Measurement Solutions for Advanced Manufacturing Robotics

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One of the most significant trends in advancing manufacturing is the use of robotics for smart factory automation. These types of machines are designed and coded to perform a variety of mundane and repetitive tasks on a manufacturing line or within an industrial facility. This allows humans to utilize their skills to work on more complex and productive tasks.

These activities are often characterized as picking, assembly, labeling, packaging, finishing work and inspection. Integrating robotics into manufacturing has many benefits including improved workplace safety, increasing productivity, and reducing material waste and costs. Interface uses robotics in our advanced manufacturing efforts in the assembly and building of world-class sensor technologies that are used around the world.

As with all points within a factory, there are many tasks that are very simple, while others can be very intricate requiring precision. As tasks become more difficult, the accuracy of the robot’s functionality is incredibly important. This is when sensors and precision measurement become instrumental to automation.

To ensure supreme accuracy, force measurement sensors are being used to improve processes as well as designed into robotic systems for monitoring performance data in real time. Force measurement sensors help manufacturers optimize the activities and tasks assigned to automated functions.

Popular types or robots used in advanced manufacturing environments using Interface load cells and our force measurement solutions include:

  1. Articulated – Often used in assembly, these robots have rotary joints to allow for a range of motion. Sensors such as mini or load button load cells are used in the testing and actual embedded in the joints to measure force and pressure.
  2. Gantry – These robots have three linear joints that move in different axes The X, Y, Z measurements are often tested with multi-axis load cells as this cartesian robot requires accuracy and precision.
  3. Cylindrical – This type of single robotic arm moves up and down, often stabilized by a cylindrical rod. They often are used in assemblies, welding, and handling of materials. These are tested with load cells for their ability to articulate the movement with exactness.

Interface products are playing a big role in manufacturing automation, especially in the design and development of robotics that use measurement in performance. They are used in all types of industries including automotive, medical, agriculture, and of course general manufacturing.

We supply a wide variety of sensors that measure force, torque, pressure, pulling force and more. We also are well-known worldwide for the accuracy and reliability of our products, making us the perfect fit for high-precision robotics applications.

Here are a few application examples where force measurement provides enormous value in testing and using robotics to advance manufacturing.

Industrial Robotic Arm in Production Line

Robotic arm solutions are becoming commonly used on production lines. When a manufacturer of a robot arm needed to measure force and torque when the arm picks up and places objects, Interface supplied a Model 6A40A 6-Axis Load Cell with Model BX8-HD44 Data Acquisition and Amplifier. The 6A40-6 Axis Load Cell was able to measure all forces and torques (Fx, Fʏ, Fz, Mx, Mʏ, Mz) and the BXB-HD44 Data Acquisition Amplifier was able to log, display, and graph these measurements while sending scaled analog output signals for these axes to the robot’s control system. This helped the customer optimize the multiple forces on the robot needed for moving objects on the production line. Read more about this solution here.

Robotic Arm

This customer needed to lift and move delicate objects, like a glass bottle, in an automated environment with a robotic arm without causing damage to the objects that are being lifted and moved. Delicacy was the key here. Two ConvexBT Load Button Load Cells were used in the grips of the robotic arm to measure the amount of pressure being applied to the object it is lifting and moving. The DMA2 DIN Rail Mount Signal Conditioner converts the signal received from the 2 ConvexBT Load Button Load Cells from mV/V to volts to the PLC Controller which tells the robotic arm to stop clamping pressure when a specified amount of pressure is applied to the object. The two ConvexBT Load Button Load Cells accurately measured the amount of pressure applied to the object the robotic arm was lifting and moving without causing any harm or damage to the object. Watch Robotic Arm Application Note and read more here.

More robotic applications are being tested every day. Interface is proud to be able to supply the necessary technology to enhance production lines, improve shipping and logistics operations and speed up repetitive processes with robotics so workforces can thrive and develop skills that advance manufacturing overall.

Additional Resources

OEM Industrial Robotic Arm App Note

Automation and Robotics Demands Absolute Precision

Robotics in Play with New Animated Application Using ConvexBT

Interface Solutions for Robotics and Industrial Automation