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Advancing Battery Possibilities with Measurement Solutions

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Advancements in batteries have opened new possibilities for the types of cars we drive, products we use in our homes, and even the way we store energy. Force measurement solutions play a crucial role in supporting advancements and innovation in battery technologies, as noted in Advancing Lithium-Ion Battery Test and Measurement.

The primary areas for battery developement utilizing Interface load cells and instrumentation are design, testing, and manufacturing. From structural integrity and safety tests to material testing and optimization, Interface measurement solutions are used for evolving batteries and their applications across many industries.

Interface is a preferred provider of force measurment solutions to the automotive industry, where they have long utilized our load cells and instrumentation for different battery testing. Learn more about our battery solutions for the auto and vehicle industry here.

As batteries become more powerful, ensuring their structural integrity for safety purposes becomes paramount. Our load cells are used to accurately measure the forces during various mechanical stresses, such as compression and impact testing. These measurement solutions can help to assess their robustness and identify potential weak points of the battery structure. Read: Electric Vehicle Structural Battery Testing

Understanding how battery materials respond to forces is critical in optimizing their performance and durability. Testing new materials is critical in developing new battery capabilities and capacities. With the introduction of new battery types, there is a requirement to thoroughly assess the chemicals and materials used in the battery, it’s encasing and the surrounding environment.

Load cells can be integrated into battery testing setups to monitor the mechanical stress on batteries during charge and discharge cycles. Load cells are utilized in thermal testing chambers to measure the mechanical stress experienced by batteries during thermal cycling. Load cells that are designed for high cycle counts for fatigue and stress testing are ideal for this type of measurement.

Interface products are important in the quality control processes of battery manufacturing. By validating the mechanical properties of batteries at different production stages, manufacturers can maintain consistent quality and comply with industry standards and safety regulations. All types of batteries are regulated in many countries to ensure safety, environmental protection, and consumer rights. The specific regulations may vary; however, most batteries are designed to meet the maximum industry standards.

Advancements in battery testing are essential for a wide range of industries that rely on batteries as a crucial component of their products or operations. Some of the industries that heavily rely on battery testing include automotive, particularly electric vehicles (EVs), renewable energy, consumer electronics, manufacturers, aerospace and aviation, medical devices, military, industrial equipment,, transportation and shipping, and maritime.

How are load cells used in battery testing?

The most common types of battery testing include capacity testing, safety testing, environmental testing, and manufacturing quality control. Load cells are commonly used for battery compression tests, impact testing, and thermal expansion and contraction.

Battery Compression Testing

This is crucial to ensure the battery’s structural integrity and safety under different conditions. During compression testing, the battery is subjected to controlled forces using hydraulic or mechanical presses, and load cells placed between the battery and the press measure the applied force accurately. Engineers can analyze the data to determine how the battery deforms and behaves under pressure, helping them design safer and more robust battery packs.

Interface low profile load cells, like our popular 1200 series or through-hole load cells like our precision load washers are often used for compression tests on batteries. Low profile load cells have a flat, disk-like shape and are suitable for applications where the force needs to be applied in a perpendicular direction to the cell’s surface. Through-hole load cells, on the other hand, have a central hole through which the force is applied, making them suitable for applications where the load needs to pass through the load cell.  Interface offers a wide range of models including high-capacity, compression-only, precision, and mounting options for our load cells.

Battery Impact Testing

Load cells can be integrated into a machine, drop tower or other testing setups, where the battery is dropped from a specific height to create impact. The load cells measure the impact force experienced by the battery during the fall. This data is vital for evaluating the battery’s ability to withstand sudden shocks and impacts, ensuring it meets safety standards for real-world situations.

For impact testing, high-capacity load cells with a rugged and robust design are preferred. Impact events can generate high forces in a short period, so the load cells must be capable of handling such sudden loads without damage. Interface’s S-type load cells or rod-end load cells are commonly used for impact testing applications due to their ability to measure tension and compression forces accurately.

Battery Thermal Expansion and Contraction Testing

Load cells are used in thermal testing chambers to measure the changes in mechanical stress that occur within the battery as the temperature fluctuates. By analyzing how the load on the cells changes with temperature, engineers can assess the battery’s performance and structural stability under different thermal conditions, which is critical for battery design and optimization.

In thermal testing applications, miniature load cells often used. Miniature WMC load cells are compact and can be easily integrated into small spaces within thermal chambers. Strain gages offer excellent sensitivity and are suitable for measuring small changes in mechanical stress that occur during thermal expansion and contraction testing.

Read EV Battery Testing Solutions Utilize Interface Mini Load Cells

Interface Force Load Cell Considerations Used for Battery Testing

  • Capacity: Choose a load cell with a capacity that covers the expected force range during testing. Ensure that the load cell can handle the maximum force that might be applied during compression, impact, or thermal testing.
  • Accuracy: Look for load cells with high accuracy and low hysteresis to ensure precise and repeatable measurements, especially when evaluating the mechanical properties and behavior of EV batteries under various test conditions. Interface is known for accuracy in measurement. All specifications related to the accuracy are available on each product’s datasheet.
  • Model Design: The load cell’s form factor should be robust and durable to withstand the demands of testing. A rugged design, preferrably stainless steel, is essential for impact testing and to ensure the load cell remains stable and reliable throughout the testing process.
  • Compatibility: Ensure that the measurement device is compatible with the testing equipment and data acquisition system being used in the battery testing setup. Interface will work with you in selecting the right sensor, instrumentation, cable and any accessories based on your test plan.
  • Calibration and Temperature Compensation: All Interface load cells have calibration certificates. The temperature compensation features are outlined in the model specifications. Accurate calibration and temperature compensation are vital for obtaining reliable and accurate force measurements, especially during thermal testing.
  • Application-specific features: Depending on the type of battery testing, certain load cell features, such as high-frequency response for impact testing or low profile designs for compression testing in confined spaces, might be beneficial. Discuss with our application engineers if you have questions on selecting the right products.

Overall, advancements in battery testing have far-reaching implications across various industries, enabling the development and deployment of safer, more efficient, and higher-performing battery technologies, which are essential for the ongoing transition to a sustainable and electrified future. To learn more about solutions that Interface has supplied for battery testing, and affiliated components used in the advancements of batteries, contact us. Our solutions team is ready to help.

Additional Resources

Electric Vehicle Battery Load Testing Feature and Application

Feature Article Highlights Interface Solutions for EV Battery Testing

EV Battery Testing Solutions Utilize Interface Mini Load Cells

Advancing Lithium-Ion Battery Test and Measurement

Electric Vehicle Structural Battery Testing App Note

Electric Vehicle Battery Monitoring

Interface Powers Smart Transportation Solutions

 

Webinar Recap of Taking Measure of Miniature Load Cells

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Interface’s first event of 2023 focuses on a growing line of miniaturized load cells and torque transducers.  The presentation by Brian Peters and Justin Walker emphasizes that though the form factor is small for Interface Minis, accuracy and measurement capacities are high.

Through out the event Taking Measure of Miniature Load Cells, Interface product experts detailed specific applications and use cases for miniature force measurement devices. Interface’s Minis are commonly used across all types of industries from medical device testing to embedded sensors in machines to provide real-time system health and performance data.

Watch the recorded event here.

After inventing the LowProfile load cell more than five and half decades ago, Interface engineers and founder first introduced the miniature s-type load cells in 1974.  How does Interface classify a miniature load cell?

  • Miniature load cells are engineered for use in applications for light touch, light weight, or for less space. 
  • Miniature load cells provide exceedingly accurate measurements similar to our full-size load cells with proprietary alloy strain gages. 
  • Miniature load cells can measure both tension and compression.
  • Miniature load cells and torque transducers are available in a wide range of capacities and models.
  • Miniature load cells are not just small in physical size, they also have a range to test minimal forces with extremely high accuracy
  • Interface defines our trademarked Mini™ Load Cells as anything that isn’t a low profile load cell

The team also covered new products that provide extremely high accuracy measurement in very small envelopes, including our new SuperSC, ConvexBT, the popular WMC and MRT, along with our new Pillow Block Load Cells. They also highlight some of the special options, including wireless and submersible products. Throughout the recorded event, products were introduced to showcase the range and options available for miniature load cells and torque transducers, including:

  • Miniature beam load cells
  • Miniature load button load cells
  • Miniature load washers
  • Miniature tension and compression, compression only load cells
  • S-type load cells
  • Miniature sealed stainless steel load cells
  • Column rod end miniature load cells
  • Torque transducer miniatures

You can watch the entire event online on the Interface YouTube Channel. You don’t want to miss out on the answers to our most frequently asked questions, like do you can you calibrate a load button or can you make a mini load cell without cables (wireless)?  They also give you the details on the smallest measurement capacity for a miniature load cell and the largest measurement capacity for an Interface miniature. Can you imagine a million lbf mini? Tune in to learn more and a special section on do and don’t tips.

Additional Resources

Miniature Torque Transducers 101

New Technical White Paper Analyzes SuperSC S-Type Miniature Load Cells

Interface Introduces SuperSC S-Type Miniature Load Cell

Superior S-Types Webinar Recap and New SuperSC

MTFS Miniature Tension Force Load Cell

WMCF Miniature Sealed Stainless Steel Load Cell

WMCP Overload Protected Stainless Steel Miniature Load Cell with Male Threads

New Technical White Paper Analyzes SuperSC S-Type Miniature Load Cells

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Interface recently introduced a revolutionary new miniature load cell, the SuperSC. The extremely compact design makes it an ideal all-purpose load cell with high accuracy measurement in an exceedingly small form factor.

The SuperSC (SSC) models are part of the Interface product line of shear s-cells. They are specifically designed as environmentally sealed and insensitive to off axis loading. This product is available in capacities ranging from 25 to 1000 lbf (100 N to 5 kN). The new SuperSC force transducer easily fits requirements for a high accuracy sensor that can be designed into components, equipment, and end products.

In our new technical white paper, Eccentric Loading Analysis for SuperSC S-Type Miniature Load Cell, Interface’s Raymunn Machado-Prisbrey, Design Engineer for OEM Solutions, provides an extensive review of the performance and capabilities of the new SuperSC.

The paper details FEA analysis performed on spring elements of equivalent capacity, in this case 250 lbs. Two eccentric load scenarios were considered: a full scale axially applied load with three degrees of misalignment and a full scale load applied to the edge of the element loading surface. Results of this analysis are available in the new white paper, available for download here.

Additionally, the new technical review highlights SuperSC data, misalignment analysis and edge loading, providing results and images of each test.

The Eccentric Loading Analysis for SuperSC S-Type Miniature Load Cell conclusion sums it up clearly. The Interface SuperSC S-Type Load Cell outperforms traditional s-type bending cells in output consistency and safety factor stability when loaded at three degrees of axial misalignment.

The SuperSC has a higher output change under edge loading conditions than the s-type design; however, linearity is much better and safety factor remains acceptable. S-bending cells are not capable of withstanding this level of edge loading from a mechanical standpoint.

You can also watch the recorded online seminar below to get the inside scoop on this revolutionary new product.

ADDITIONAL RESOURCES

Interface Introduces SuperSC S-Type Miniature Load Cell

Superior S-Types Webinar Recap and New SuperSC

 S-Type Load Cells 101

Interface OEM Solutions Process

 

Interface Introduces SuperSC S-Type Miniature Load Cell

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Interface has released its latest load cell invention, the SuperSC S-Type Miniature Load Cell. Interface’s new product is an s-type miniature load cell that offers capacities in a form factor 80% smaller and 50% lighter than other models of s-type load cells. It’s ideal for industry 4.0 applications.

The Interface SuperSC is an economical general purpose load cell with a compact design. It is perfect for all types of test and measurement applications in confined spaces and for OEM use cases with smaller product dimensions. The miniature sensor is also environmentally sealed and insensitive to off axis loading.

Designed by Interface’s engineer Raymunn Machado-Prisbrey, SuperSC comes in 12 capacities ranging from 25 to 1K lbf and 100 N to 5 kN. Six designs for international standards of measurement (metric) and six are imperial standards. They are environmentally sealed with an IP66 rating and offer high stiffness with low detection.

“S-type load cells have grown in popularity every year since their introduction in 1974 by Interface’s founder, primarily due to their design features and performance for use in diverse force measurement applications.” Mark Weathers, VP of Advanced Manufacturing and OEM Products

Due to its high capacity and compact housing, it is an ideal sensor for weighing and test machines, as well as in OEM product designs for ongoing performance measurement and monitoring. S-type load cells are some of Interface’s most popular products. The new product release of the SuperSC represents the next generation of the versatile Interface Mini product offerings.

“The SuperSC is the next generation of s-type load cells with the Interface’s distinguishable high quality, accuracy, reliability, and range of capacities, while also offering a more compact design and options for customization and embedding into products and machines,” said Mark Weathers, VP of Advanced Manufacturing and OEM Products

The Interface SuperSC is manufactured at Interface’s headquarters in Arizona. It has accessories and different build options, including a high-temperature rated version, fatigue rated, special calibrations, and it also can be pre-installed with rod end bearings. Interface also plans to introduce a submersible, IP68 rated version and a model specialized for load compensation.

The new Interface SuperSC S-Type Miniature Load Cell and review specification sheets and pricing are here.

Interface highlighted the product in the recent Superior S-Type Load Cells webinar recording.

PRESS RELEASE

ADDITIONAL RESOURCES

Superior S-Types Webinar Recap and New SuperSC

SuperSC S-Type Miniature Load Cell

Superior S-Type Load Cells Webinar

S-Type Load Cells 101

Superior S-Types Webinar Recap and New SuperSC

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Interface hosted a new online seminar, Superior S-Type Load Cells, to highlight the different models, capabilities, and features of this popular type of force measurement transducer. It also provided a terrific opportunity to showcase one of Interface’s latest inventions, the new SuperSC S-Type Load Cell.

Interface’s Raymunn Machado-Prisbrey, Randy White and Mark Weathers detail important topics during this essential force sensors event. The presentation focuses on various S-type products, an engineering perspective, use cases and applications, along with the news of the SuperSC product release.

S-type load cells, sometimes called s-beams, get its nomenclature from the “S” looking model of the load cell. The classification of this type of load cell is considered a miniature sensor. They are part of Interface’s extensive line of Mini Load Cells.

One of the clear advantages of this load cell, that Interface brought to market in 1974 through an invention by our founder Richard F. Caris, is that it can be used to measure tension and compression.

Common Standard S-Types Use Cases

  • Controlled tension and compression measurement applications
  • Proof loading
  • Fatigue and high cycle count tests
  • Material testing
  • Suspended weighing and platform scales
  • Rigs, cranes, and hoists
  • OEM systems
  • Test machine integrations

The “S” shaped load cell has mechanical attachments on the top and bottom. The strain gage bridge is located at center. Interface uses a Wheatstone bridge with proprietary strain gages in a bending configuration. This offers a more efficient inline package versus standard bending bridge sensors for improved off axis insensitivity.

Watch our latest webinar to learn more about the versatile miniature S-Type Load Cells and the news about our SuperSC.


As detailed in the webinar, one of the biggest benefits is the scalable design that can accommodate a wide range of capacities through material and dimensional changes. S-types gained their popularity with requirements for small form factors and precision. They are now some of Interface’s top 10 products.

Engineers and testing labs prefer Interface’s s-type sensors for:

  • Proven load cell form with Interface’s strain gages
  • High accuracy
  • Size and much smaller than typical load cells
  • Value and cost-effective solution
  • Flexibility to fit in limited spaces
  • Easy to integrate
  • Universal for tension and compression testing

S-types are used inline during loading. They feature threaded mounting holes, providing stability and accuracy in measurement. They are not designed to be used for moving or rotating test objects. S-types are used in individual use cases for testing rigs and machines, as well as OEM solutions embedded into a product for continuous measurement and feedback.

Interface has a wide range of specialized miniature s-type load cells including:

  • Sealed
  • Micro-size
  • Fatigue-rated
  • High-temperature ratings
  • Low height
  • Overload protected
  • Intrinsically safe

You can watch the entire online event here. You will be the first to preview the official launch of the SuperSC and how it is modern design, superior performance, and low cost are ideal for OEM solutions. Randy, Ray and Mark detail tips, FAQs and some innovative applications for s-type load cells.

We record all Interface webinars for your convenience. Be sure to subscribe to our Interface YouTube Channel so that you do not miss an event.

Mini Load Cells 101

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With the miniaturization and compact size of many products and technologies used in today’s market, it is critical that sensors are designed to fit all types of applications both big and small. This is especially true in the medical, aerospace, industrial automation, and automotive industries.

Interface customer’s requirements for miniature load cells has rapidly expanded the diversification of load cell products that are “mini” in capacities as low as 0.11 lbf / 0.5 N and as high as 100 kN. Interface Mini Load Cell solutions include miniature beam load cells, miniature sensors, load buttons, load washers, tension force mini load cells, S-type load cells, and sealed stainless steel load cells.

Interface’s mini load cells are used for customers who are looking for smaller cells, or for those designing for light touch or lightweight products. Our miniature load cells provide exceedingly accurate measurements similar to our full-size load cells, all with proprietary alloy strain gages. Mini’s are available standard and can be modified, as well as completely customized depending on the exact requirements of the client’s project or embedding into original equipment. Decreased size should never equal less accurate measurements. Our customers can expect Interface miniature load cells perform with the exact quality and accuracy as all our larger load cells.

To provide you with more insight, here is a quick overview of some of Interface’s most popular mini load cells and their unique capabilities. You can download the full Interface Mini Load Cell brochure here.

Load Buttons

Interface’s load button cells are designed for customers who require the measurement of forces in a very confined space. They are designed to provide the most accuracy in as little space as possible. The smaller LBM or LBS can fulfill the need for force measurements at a very respectable precision level that is enough for most applications. Diameters range from 1 inch to 3 inches, with heights from 0.39 inch to 1.5 inches. The shaped load button has a spherical radius to help confine misaligned loads to the primary axis of the cell.

S-Beam Cells

This line is designed for customers looking for extremely compact load cells that still offer great accuracy. The SM (Super-Mini) series load cells are a low-cost, yet accurate, cell with a straight-through loading design. The SSM (Sealed Super-Mini) series offers the same benefits as the SM series with a rugged S-Cell with a splash-proof cover. Both series give exceptional results in applications that can be designed to operate the cell in tension. Some caution should be exercised when using these cells if they will be compressed to ensure that the loading does not introduce side loads into the cell.

Bending Beam Cell

With Interface’s bending beam cell, the cell is bolted to support through the two mount holes. The cell is designed to concentrate the forces into the area where the gages are mounted on the top and bottom faces of the beam. Our line of bending beam cells also have a splash-proof sealing cover.

Double Bending Beam Cell

The double bending beam cell from Interface is a useful variation on the traditional bending beam. In general, this configuration is much more user-friendly because of its short vertical dimension and compact design. It is especially useful for applications where the cells could easily be damaged by tension/compression overload. The variation is achieved by forming two bending beams into one cell. This allows the loading fixtures to be attached at the threaded holes on the centerline, between the beams, which makes the sensitive axis pass through the cell on a single line of action.

Interface mini load cells can be ordered in different sizes, with a wide range of capacities. Many of the minis can be used in off-the-shelf applications. We are also happy to work with customers to custom design load cells to fit their exact needs for size, weight, and accuracy.

For more information on Interface’s Mini Load Cells, visit our web product page or review our product brochure below for detailed specifications on every product.

Mini Load Cell Brochure_6-Page

CLICK HERE TO DOWNLOAD