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Interface Solutions for Structural Testing

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Interface products are used in many types of structural tests across industries, including for rockets, aircraft, EV batteries, heavy equipment, and infrastructure projects. Our loads cells provide the accurate and reliable data, which is why our force measurement solutions are a top choice for these complex and highly regulated industries.

Structural testing labs use Interface solutions to perform tensile, compression, bending, fatigue and hardness testing on materials, components, or assemblies. There are a variety of structural tests used for measuring tension of push and pull forces, design proofing, and lifecycle fatigue validation. Each of these tests plays a critical role in verifying the quality and safety of a product, component or materials, and each of these tests relies upon force measurement sensors.

Types of Structural Testing

  • Tensile Testing involves applying a pulling force to measure a structure’s strength and resistance. Load cells are used to measure the applied force and resulting tension from elongation or deformation of the material.
  • Compression Testing uses compressive force to evaluate the strength and resistance of a structure to crushing. Force measurement sensors are used to measure the magnitude of the applied force and the resulting deformation or failure.
  • Torque Testing measures the twisting or rotational forces applied to a structure. Torque transducers are utilized to assess the material’s torsional strength, stiffness, and behavior.
  • Load Capacity Testing determines the maximum load that a structure can withstand before failure. Force measurement sensors and load cells are used to gradually increase the load until failure occurs, enabling the determination of the structure’s load-carrying capacity.
  • Bending Tests assess the flexural strength and behavior of materials under force. Load cells measure forces applied during bending and to determine the bending moment, stress distribution, and deflection of the material within a structure.
  • Fatigue Tests in structural testing labs assess the durability and performance of materials under cyclic loading conditions. Force sensors measure the applied forces or loads helping to analyze the material’s fatigue life through various cycle counts.
  • Impact Testing involve subjecting a structure to sudden and high-intensity forces to assess its ability to withstand rapid loading conditions. This is particularly important for environmental condition testing to structures that endure extreme temperatures, winds, moisture. This type of testing is also important for submersible structures.
  • Shear Testing evaluates the resistance of a material to forces applied parallel to its surface, causing it to slide or deform. Force measurement devices measure the applied shear forces and determine the shear strength and behavior of the material used in a structure.

During the Testing Lab Essentials Webinar, Interface application experts detail various ways our products serve test labs. During this event, the experts detailed top considerations in selecting Interface products that serve test lab engineers in conducting structural tests. 

Structural testing labs use our LowProfile load cells because they are designed to fit into tight spaces and machines, making them ideal for use in small-scale structural applications. High-capacity load cells from Interface are designed to measure large forces and are commonly used in heavy machinery and structural testing. Universal load cells are capable of measuring tension and compression, making them ideal for quality control and structural testing applications.

Multi-axis sensors are valuable force measurement solutions as they provide more data across two, three and six axes during a single structural test. Implementing multi-axis sensors can provide a more complete picture of loads and moments being applied to the DUT providing additional insight for design and verification.

As noted in the webinar, key challenges involved in structural testing include managing and isolating extraneous loads such as off-axis load and bending, understanding which products are most suitable for the type of structural tests you are performing and ensuring the instrumentation you are using is compatible with force solutions. Equally, it is important to define your systems for optimal data collection in the planning phase of any project.

Structural Testing Applications

Performance Structural Loading

Performers and entertainers have special stages built to perform in concerts for their fans. From the largest sports events half-time shows to other complex staging, a force measurement system is needed to ensure the safety for all performers, equipment, and scenery on stage. The stage needs to hold all weight, and also maintain during dynamic movements, such as performers walking on stage. For this challenge, Interface’s A4200 Zinc Plated or A4600 Stainless Steel WeighCheck Load Cells paired with the 1280 Programmable Weight Indicator and Controller is able to measure the individual loads on each load cell, or the entire weight of the performance stage. Results from the 1280 Programmable Weight Indicator and Controller was sent to the customer’s control center. Using Interface’s A4200 Zinc Plated or A4600 Stainless Steel WeighCheck Load Cells as a customizable solution, the customer was able to monitor and weigh the performance stage.

Rocket Structural Test

NASA’s Space Launch System (SLS) core stage will be the largest ever built at 27 feet in diameter and 200+ feet tall. Core components including liquid hydrogen and oxygen tanks must withstand launch loads up to 9 million pounds-force (lbf). Interface load cells attached to hydraulic cylinders at various locations along test stands to provide precise test forces. Strain gages bonded to rocket structure surface and connected to data acquisition system for stress analysis. Using this solution, Engineers are able to measure loads applied at various areas on the rocket structure, verifying the structural performance under simulated launch conditions.

EV Battery Structural Testing

As electric vehicles push advancements in efficiency gains, structural battery packaging is at the forefront for optimization. This drives the need to validate structural battery pack design, both in terms of life expectancy against design targets as well as crash test compliance and survivability. Interface’s solution includes 1100 Ultra-Precision LowProfile Load Cells in-line with hydraulic or electromechanical actuators in customer’s test stand. Also utilized are 6A Series 6-Axis Load Cells to capture reactive forces transmitting through pack structure. Multi-axis measurement brings greater system level insight and improved product success.

Interface is a valued partner to test labs for providing solutions for structural testing.

Additional Resources

Modernizing Infrastructure with Interface Sensor Technologies

Rocket Structure Testing

Rigging Engineers Choose Interface Measurement Solutions

Load Cell Selection Guide

Heavy Truck Test and Measurement Solutions

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Interface is a trusted supplier to the vehicle industry. Manufacturers of vehicles and components rely on our sensor technologies for measuring force, torque, and weight. In the vehicle subsector of trucks, there are three main classifications of this type of vehicle based on weight: light, medium and heavy trucks, sometimes called heavy-duty.

Interface devices are commonly used in heavy-duty truck design and testing for various purposes, from structural to aerodynamic testing. Manufacturers use our load cells, torque transducers and instrumentation in testing labs to ensure vehicles meet regulatory and performance standards. Component and parts makers utilize our sensors and instrumentation for research, design, development and production, whether they are making brake pedals or tires.

Heavy Duty Truck Test and Measurement

  • Structural Testing: Interface products are used to evaluate the structural integrity and performance of truck components and systems. Load cells may be installed at critical points such as suspension mounts, chassis connections, and body attachments to measure forces and stresses experienced during static or dynamic testing. This helps engineers understand the load distribution, identify weak points, and optimize the design for enhanced durability.
  • Brake System Testing: Force measurement devices play a crucial role in assessing the performance and efficiency of a truck’s braking system. Load cells are commonly employed to measure the forces exerted on the brake pedal during braking maneuvers. This data helps evaluate braking performance, optimize braking force distribution, and ensure compliance with safety standards. Wireless load cells are growing in use for these types of tests. See: WTS Brake Pedal Force Testing
  • Tow and Haul Assessments: Determining a heavy-duty truck’s towing and hauling capabilities requires measuring the forces. Interface measurement devices are used to quantify the forces experienced by the vehicle during towing or hauling tasks. Load cells installed at key attachment points, such as trailer hitches or cargo beds, are used to measure the forces applied under different loads. This data aids in establishing safe operating limits and optimizing the truck’s design for maximum payload capacity.
  • Suspension Testing: Strain gage based sensors are frequently utilized to evaluate the performance of a truck’s suspension system and its impact on ride comfort. Load cells or accelerometers may be used to measure forces, vibrations, and accelerations experienced by the vehicle under various road conditions. This helps engineers optimize suspension settings, tune shock absorbers, and design suspension components that provide a balance between load-carrying capacity and ride quality.
  • Crash Testing: High-accuracy load cells and instrumentation are integral to crash testing heavy-duty trucks to evaluate occupant safety and structural integrity. Sensors are used to measure impact forces, accelerations, and deformations during controlled crash simulations. This data helps engineers assess the effectiveness of safety features, such as crumple zones and restraint systems, and improve the truck’s crashworthiness. Read: Vehicle Crash Test Load Cell Wall
  • Aerodynamic Testing: Measurement tools are employed to assess the aerodynamic performance of heavy-duty trucks. Load cells and systems used to measure the forces acting on the vehicle’s body, including drag and lift forces helps optimize the truck’s shape, reduce aerodynamic resistance, and improve fuel efficiency.

Another force that Interface has a great deal of experience measuring and helping our customers to monitor is load pulled or hoisted by components attached to trucks or other heavy machinery. As an example, Interface can measure the load capacity of a truck hitch to test the maximum capacity of an object it is pulling. It can also monitor the hitch in real time to ensure the load combined with the velocity of the vehicle or the gradient of a roadway is not creating a risk of failure.

In addition to testing the vehicles, safety standards exist for large, long and short haul trucks regarding their weight limits for most highway systems. It is why you often see weigh stations across the highway on road trips. Force sensors are often used in these types of weigh stations due to our product’s high capacities, accuracy, and reliability. Adversely, we also measure these types of vehicles capacity prior to hitting the open road to ensure the vehicle is designed to manage the amount of load in transport.

 

Suspension Testing for Heavy Duty Trucks

It is important to heavy duty track manufacturers to thoroughly test suspension. Automotive suspensions require fine tuning for best performance on various roads and conditions. Simulation of bumps, banking and other road conditions result in off-axis loading. Interface’s 1200-series load cell were mounted on top of each post in a 4-, 5-, or 7-post rig, which allowed them to measure forces during simulated driving. Moment compensating design of 1200-series load cells provide accurate readings during off-axis loading. This solution provides highly accurate (0.04%) measurement of loads applied to individual suspension points.

Truck Weighbridge

A customer owns a truck company and needs to record the weight or loads being carried by their trucks. They would like a wireless weighing bridge that is able to transmit, log, and display the results in real time. Interface suggested installing multiple WTS 1200 LowProfile™ Load Cells under a weighing bridge. When the truck drove over it, the load cells transmitted the force results wirelessly to the WTS-BS-4 Industrial Base Station connected to the customer’s PC with provided Log100 software. The WTS-LD2 Wireless Large LED Display also displayed the weight inside for the driver to see in real time. Using this solution, the customer was able to measure, log, and graph the different loads their trucks carried wirelessly onto the weighbridge with success.

Tire Testing for Semi-Trailers

A typical semi-trailer truck consists of a tractor unit with two front wheels and two sets of tandem axles at the rear, each with two wheels, resulting in a total of 18 wheels. By trade, 60,000-pound trailers needed at least three axles and 12 tires. Testing tires and mounting requires precision for these vehicles that are responsible for trucking goods and materials across the interstates and highways. A tire production company wants to put their tires under a stress test to research the dynamic control capabilities of their tires. Interface suggests using the AT105 Contactless Force and Torque Transducer to measure both the lateral force and torque of the tired being tested. Torque and force results can be displayed and graphed when connected to the SI-USB4 4 Channel USB Interface Module. After conducting a stress test on their tires, the tire production company was able to record and log the measurements of the torque and lateral forces implemented on their tires.

These are just a few examples of the types of test and monitoring solutions provides for trucks and other heavy duty vehicles. To learn more about our sensor’s capabilities in the automotive test and measurement markets, visit Automotive and Vehicle Solutions.

ADDITIONAL RESOURCES

Truck Weighbridge

Weighing

Garbage Truck On-Board Weighing App Note

Electric Vehicle Structural Battery Testing

Torque Measurement for Electric Vehicles

AxialTQ Engine Dynamometer App Note

Bluetooth® Brake Pedal Animated Application Note

Interface Powers Smart Transportation Solutions

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Smart transportation refers to integrating advanced technologies and intelligent systems in the transportation sector, including infrastructure and vehicles, improving efficiency, safety, and sustainability.

The transportation industry is getting smarter with advancements in autonomous driving and electric vehicles, unmanned aerial vehicles, electric airborne vehicles, high-speed trains and light rails, and transportation ways. Behind these innovations are critical test and monitoring solutions that help engineers ensure absolute safety and quality during development and in use for real-time monitoring.

Interface transducers measure force, torque, or weight for testing and integration into smart transportation systems. Our load cells, torque transducers, scales, load pins, tension links, and multi-axis sensors provide vital measurement data for design, development, testing, and performance monitoring in various smart transportation applications.

A few examples of smart transportation inventions and use cases that utilize Interface advanced sensor technologies include:

  • Smart Cargo Monitoring: Load cells are installed in trucks, trailers, or shipping containers to monitor the weight and distribution of cargo. These load cells provide real-time data on the load’s weight, ensuring compliance with weight limits and preventing overloading, which can lead to safety hazards and increased fuel consumption.
  • Structural Testing of Vehicles: During physical testing, load cells and torque transducers measure forces and loads applied to vehicle structures. This includes crash tests, structural integrity evaluations, and load capacity assessments. The data obtained helps engineers analyze vehicles’ structural performance and safety characteristics, enabling improvements in design and manufacturing processes for smart transport.
  • Infrastructure Load Data Acquisition: Load cells can be employed in roads, bridges, and other transport infrastructure as part of the load data acquisition systems. These systems measure the dynamic forces and loads experienced by vehicles. By attaching load cells to strategic points on the vehicle, such as suspension components or the chassis, engineers can capture data related to acceleration, braking, cornering forces, and road-induced vibrations. This information aids in vehicle development, durability testing, and optimization of suspension and chassis designs. They also help design durable civil engineering projects and infrastructure.
  • Intelligent Weighing Systems: Load cells can be incorporated into weighing systems at weigh stations or toll booths. By measuring the weight of vehicles passing through, these systems can accurately determine toll fees, enforce weight restrictions, and gather data for traffic management and planning purposes.
  • Smart Suspension Systems: Load cells are integrated into suspension systems of vehicles, such as trucks and buses, to monitor load distribution and adjust suspension settings accordingly. This helps optimize vehicle performance, enhance stability, and improve ride comfort.
  • Load Sensing Axles: Load cells can be installed in axles to measure the weight of individuals or sets of wheels. This information is crucial for load balancing, tire pressure monitoring, and detecting potential axle overload situations.

Since the beginning of “Smart Mobility,” Interface has supplied force-sensing solutions for electric or self-driving vehicles. Specifically in automotive, Interface has developed and supplied precision force and torque test and measurement systems that meet all components’ demands for superior testing requirements. The automotive market is subjected to extremely strict regulations. Therefore, testing and measurement are critical for safety, reliability, durability, and overall smart vehicle performance.

In the context of smart rail transport and railways, force measurement is crucial in testing and evaluating rail vehicles, including locomotives, passenger trains, and freight wagons. Load cells and force sensors are utilized in numerous ways. Load cells are used in braking systems to measure the forces exerted during braking maneuvers. This allows design engineers to assess the effectiveness of automated braking systems and ensure compliance with safety standards. The same types of sensors can be used to measure the vertical, lateral, and longitudinal forces acting on the bogies (wheelsets) of rail vehicles enabling smart operating conditional adjustments.

Smart Transportation Sensors for Stopping Train Derailment

Force measurement systems can measure the contact forces between the wheels and the track. This enables the assessment of wheel-rail interaction, including wheel-rail forces, lateral forces, and rolling resistance. Such data helps optimize track design, wheel profile selection, and maintenance practices to ensure safe and efficient railway operations. Our Pillow Block Load Bearing Load Cell 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 they inflict damage. This is a critically important application as innovators begin to release high-speed trains for cross-country travel.

Smart Trucking Weighing Solution

In this use case, a smart transportation trucking company truck company needs to record the weight or loads being carried precisely. They would like a wireless weighbridge to transmit, log, and display the results in real-time. Interface suggests installing multiple WTS 1200 LowProfile™ Load Cells under a weighing bridge. When a truck drives over it, the load cells will transmit the force results wirelessly to the WTS-BS-4 Industrial Base Station connected to the customer’s PC with the provided Log100 software. The WTS-LD2 Wireless Large LED Display can also display the weight inside of the driver monitor at all times.

Smart Vehicle Crash Walls

Improving vehicle safety is smart. Interface suggests using multiple 3A400 3-Axis Force Load Cells for this use case and attaching them to the back of a cement crash wall. When connected to the BX8-HD44 Interface BlueDAQ Series Data Acquisition System, force result measurements will be recorded and displayed on a computer. The sensors measure the force of impact for all their different vehicle crash testing demonstrations, providing high-accuracy data to make the vehicles safer.

Electric Vehicle Structural Battery Testing

As electric vehicles push advancements in efficiency gains, structural battery packaging is at the forefront for optimization in smart transportation. This drives the need to validate structural battery pack design in terms of life expectancy against design targets and crash test compliance and survivability.  Interface’s solution to this challenge included the 1100 Ultra-Precision LowProfile Load Cells in line with hydraulic or electromechanical actuators in the customer’s test stand. Also utilized were 6A 6-Axis Load Cells to capture reactive forces transmitting through pack structure. Multi-axis measurement brought greater system-level insight and improved product success. The structural tests validated the battery pack’s strong structural design using this solution.

Interface solutions for smart transportation are growing alongside the pace of innovation as we work with industry demands to provide solutions for what comes next.

Read more in our case study Interface’s Crucial Role in Vehicle and Urban Mobility Markets

ADDITIONAL RESOURCES

Making Products Smarter with Interface OEM Solutions

Testing Labs Choose Interface High Accuracy Products

Modernizing Infrastructure with Interface Sensor Technologies

Interface’s Steering Role in All Types of Transportation

Interface Weighing Solutions and Complete Systems

EV Battery Testing Solutions Utilize Interface Mini Load Cells

Bridge Seismic Force Monitoring Solution App Note

IoT Drone Parcel Delivery

Testing for Commercial Drones and Parcel Delivery

 

Why Mechanical Engineers Choose Interface Solutions

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Mechanical engineers play a crucial role in the design, development, and maintenance of mechanical systems that are integral to modern society and industries. They apply tenets of physics, materials science, and engineering to design, test and analyze, fabricate, and maintain mechanical systems in various industries, including automotive, aerospace, energy, robotics, and manufacturing.

Frequently, mechanical engineers use Interface force measurement devices to gather data, analyze performance, and ensure the safety and reliability of mechanical systems. Force measurement technologies help them to quantify the magnitude and direction of forces acting on objects or structures.

Mechanical engineers are active in the research and development of modern technologies and innovations, from small components to large industrial machines. This vital role is typically involved in the selection of materials, manufacturing processes, and quality control to ensure that mechanical systems are safe, dependable, efficient, and cost-effective.

Interface’s quality and accuracy of load cells make them a preferred engineering solution for various use cases. The range of products are used for multiple testing and design applications. The most common products selected by mechanical engineers include:

Engineers use sensors to determine the forces acting on different components or subsystems within a larger system, such as an engine, gearbox, or suspension system, during operation. This information can be used to verify that components are operating within their design limits, identify potential failure points, and optimize performance.

Force measurement devices are used by mechanical engineers in quality control processes to ensure that mechanical systems meet design specifications and performance requirements by performing tests during the manufacturing process, such as checking the tension in bolts, verifying the strength of welds, or measuring the force required for assembly or disassembly of components.

Mechanical engineers use impact force sensors to measure the forces experienced by a vehicle during crash testing, or fatigue testing machines to apply cyclic loads to components or structures to simulate real-world conditions. They participate in the design, development, and optimization of renewable energy systems such as solar power, wind power, hydropower, and geothermal power. Read Interface Solutions for Growing Green Energy.

Mechanical engineers are at the forefront of advancements in robotics and automation, including designing and developing autonomous vehicles, drones, robotic manufacturing systems, and automated processes for industries such as automotive, aerospace, and manufacturing. Advancements in materials science is a key role for many mechanical engineers. As well, these types of engineers play a crucial role in advancing the field of biomechanics and developing medical devices.

IoT and smart systems that integrate mechanical components with sensors, actuators, and control systems to create intelligent and connected systems are a result of the work of mechanical engineers. This includes developing smart buildings, smart appliances, smart transportation systems, and other IoT-enabled devices. Read Interface Sensor Technologies Enables IoT Capabilities

Mechanical engineers use force measurement devices to perform tests and experiments to determine the forces experienced by mechanical systems. Load cells help them to quantify the loads on structural components, such as beams, columns, or joints, to understand their performance under different conditions.

ADDITIONAL RESOURCES

Electrical Engineers Choose Interface Sensor Technologies

Interface Celebrates Engineers

Interface Solutions for Production Line Engineers

Interface Solutions for Material Testing Engineers

Quality Engineers Require Accurate Force Measurement Solutions

Why Product Design Engineers Choose Interface

Why Civil Engineers Prefer Interface Products

Use Cases for Load Pins

Performance Structural Loading App Note

Interface OEM Solutions Process

 

 

Interface Explores Commercial Launch Solutions

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Interface supplies advanced sensor technologies to high-profile companies in some of the most challenging environments, including those that are using their innovations for exploration beyond planet earth.

Aerospace commercial launch programs have a critical role in advancing our understanding of the world around us, as well as in supporting a wide range of industries and applications. Commercial launch is typically defined by engineers and aerospace market leaders as the design, manufacturing, and operation of rockets and spacecraft for commercial purposes. This includes providing launch services to customers such as private companies, governments, and research institutions.

Collaborating with engineers and market leaders at the forefront of the commercial launch industry, Interface is proud to take part in enabling space exploration and satellite deployment for a wide range of use cases. Commercial launch has a big part of our global economic growth for scientific research, environmental monitoring, communications, and national security.

Force measurement devices are critical tools for commercial launch companies, helping ensure the safety and effectiveness of spacecraft and rockets during design, testing, and launch. Interface high-accuracy load cells, torque transducers, load pins and wireless instrumentation are utilized throughout testing phases of aerospace vehicles, small and large. Interface products are used by commercial launch companies for a range of applications, including:

Rocket and Engine Testing: Load cells and force measurement devices are used to measure the thrust and other forces generated by rocket engines during testing. This information is critical for ensuring that the engine is operating safely and as designed. Read

Launch Vehicle Testing: Load cells and force measurement devices are used during testing of the launch vehicle to measure the loads and stresses that it will experience during launch. This helps ensure that the rocket is designed to withstand the forces it will encounter during launch.

Payload Integration: Load cells are used to measure the weight and balance of the payload during integration into the rocket. This helps ensure that the rocket is properly configured for launch and that the payload is secure.

Parachute Deployment: Load cells are used to measure the forces generated during parachute deployment and landing. This helps ensure that the parachute system is designed to deploy safely and effectively. See Parachute Deployment and Deceleration Testing

Spacecraft Separation: Load cells are used to measure the forces generated during spacecraft separation from the launch vehicle. This helps ensure that the spacecraft is safely released from the rocket and that it is on its intended trajectory.

Force measurement plays an important role in space exploration and commercial launches, including vehicle designs, automation of machines that manufacture components, structures used for launch testing, and the actual engineering and building of the spaceships. See our case study, Force Measurement for Space Travel.

With the growing investments in commercial space applications, Interface solutions are in high demand for testing in vehicles in launch environments.  Interface products are used in thrust testing, structural testing, and even force gravity testing.  Every test must be verifiably accurate due to the trustworthiness and safety requirements of moving the ever-increasing valuable payloads, which is beyond stellar communication technologies. It’s now about launching and returning humans, with frequency, in the new era of space travel. Safety is priority number one., Here are a few application examples of Interface solutions utilized by commercial launch market leaders.

Rocket Structure Testing

NASA’s Space Launch System (SLS) core stage is largest ever built at 27 feet in diameter and 200+ feet tall. Core components including liquid hydrogen and oxygen tanks must withstand launch loads up to nine million pounds-force (lbf). Interface load cells were attached to hydraulic cylinders at various locations along test stands to provide precise test forces. Strain gages were also bonded to rocket structure surface and connected to data acquisition system for stress analysis. Using this solution, engineers can measure loads applied at various areas on the rocket structure, verifying the structural performance under simulated launch conditions. Read more about this type of testing here, Rocket Structure Testing

Space Dock Capture Ring Force Testing

A space company wanted to test their spacecraft docking simulator. They wished to test the forces of the actuators used during the “lunge”, when the soft capture ring is lunged forward to latch onto a space vehicle that has been mounted. They also wanted to ensure they are working properly when engaged, and that it does not go past its overload force limit. Interface suggested using multiple WTS 1200 Standard Precision LowProfile™ Wireless Load Cells to be installed to the actuators of the capture ring. Both as wireless solutions, measurements can be recorded through the WTS-AM-1E Wireless Strain Bridge Transmitter Module, which then can transmit to the WTS-BS-1 Handheld Display or the WTS-BS-6 Wireless Telemetry Dongle Base Station for the customer to record, log, and graph on their computer. Interface’s Wireless telemetry system successfully measured the forces of the soft capture ring of the space docking port with overload protection. Learn more about this application here: Space Dock Capture Ring Force Testing

Reduced Gravity Testing

In this application, Interface supplied a Model 1100 Series Load Cell, which was installed in-line with a steel support cable to actively measure the vertical load on the system. A control system was then utilized, (which includes a Model 9870 High Speed High Performance TEDS Ready Indicator), to monitor the load cell output and continuously offload a portion of a human or robotic payload weight during all dynamic motions. Using precise feedback from the load cell, the control system commanded a motor to raise or lower the subject to maintain a constant offload force. During the simulation, the system actively compensated for the subject’s movement to accurately reproduce a microgravity environment. Read more about this test here: Reduced Gravity Simulation.

Commercial launch companies are often driven by market demand and competition, which can lead to innovations in rocket and spacecraft design, manufacturing processes, and launch operations. This in turn can lead to advancements in space exploration, scientific research, and other applications that benefit society. We are proud to play a part of these advancements and discoveries.

Interface is exhibiting again at Space Tech Expo 2023.

ADDITIONAL RESOURCES

Examining Interface Aerospace Industry Solutions

Interface and The Race to Space

Aerospace Brochure

Solutions Provider for Aerospace & Defense

 

 

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.

ADDITIONAL RESOURCES

Interface Celebrates Engineers

Interface Solutions for Production Line Engineers

Quality Engineers Require Accurate Force Measurement Solutions

Interface Solutions for Material Testing Engineers

Why Civil Engineers Prefer Interface Products

Why Product Design Engineers Choose Interface

Ruggedized Test and Measurement Solutions Webinar

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Interface force measurement engineers and solution experts host an online discussion focused on products used to withstand one or more conditions related to temperature, cycling, moisture, environmental stresses. Learn about Interface’s stainless steel load cells, environmentally sealed options, submersible test and measurement products, enclosures, wireless capabilities, load pins, intrinsically safe products. We detail solutions used for all types of applications used in industries that include medical device, aerospace and defense, industrial automation, infrastructure, maritime and general test & measurement. We discuss sensors models, capabilities, features and FAQs. We dive into use cases, tips, measurement know-how and OEM products.

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Taking Flight with Interface Solutions for Aircraft Testing

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As a top supplier of premium force measurement solutions for the aerospace industry, one of our critical areas requiring precision accuracy and high-quality products is for testing airplanes. Interface load cells, torque transducers, and instrumentation are used regularly in testing of all types of aerospace apparatus, components, and machines, along with embedding our force sensors in aircraft for ongoing simulation tests and inflight data acquisition.

Aircraft, spacecraft, military, and defense companies such as Boeing, Airbus, Lockheed, Northrop Grumman, Bombardier, Embraer, Gulfstream, NASA, and Cessna and many others in the supply and production lines utilize Interface load cells for thrust, wing, static, and fatigue testing. While structural test applications use many types of LowProfile™ load cells, Interface also offers a wide variety of load washers, load buttons and miniature tension and compression load cells for test, production, and control monitoring applications for aircraft.

Why do aircraft testing professionals prefer Interface solutions?  One reason is our moment and temperature compensated load cells use proprietary alloy strain gages for extreme accuracy and reliability that is unmatched by other brands. Using eight proprietary strain gages per sensor, our 4mV/V output well exceeds the performance requirements for testing these specialized aerospace vehicles.

In addition, before the airplanes are even assembled, every manufactured part and components must go through rigorous testing. There are hundreds of machines that are used on the production line for the hundreds of thousands of components needed to complete these specialized craft. Interface load cells and torque transducers are found on many of these production and test machines. Our products are used to provide a wealth of insight to guide manufacturers through research, development and final build. Because testing is so inherent for any of these parts, Interface products provide reliability and accuracy when there are no exceptions.

We recently developed several new application notes on ways our products are used to test airplanes. Included below is a preview of a few of the latest additions to our application notes catalog.

Jet Engine Thrust Test

A customer wanted to conduct a static jet engine thrust test that can accurately determine the engine’s thrust, burn time, chamber pressure, and other parameters, providing invaluable data to propellant chemists and engineers. They needed a high accuracy load cell with excellent repeatability to withstand thrust forces in very harsh environments. Interface offered a 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell, which is ideally suited based on their performance for this application. The load cell reacts to the thrust forces produced by the jet engine and the signals are collected and recorded to create a “thrust curve” of the engine. The performance of an Interface LowProfile™ Load Cell allowed the engineers to be confident in the data acquired from the static testing. Additionally, the repeatability of the load cell results in reduced time between tests, making static jet engine thrust testing more efficient. Read the new Jet Engine Thrust Test application note here.

Aircraft Yoke Torque Measurement

An aircraft manufacturer wanted to measure the torque of their aircrafts yoke or control wheel. They also wanted to monitor the torque and forces applied to ensure that the aircrafts controls are operating properly. Interface suggested using the AT103 2-Axis Axial Torsion Load Cell to measure both torque and force within this single sensor. It can be installed inside of the yoke, and can measure the rotation of the yoke, and the forward and backwards movements. Data can be measured and paired with the SI-USB4 4-Channel USB Interface Module and displayed with the customer’s laptop. Using this solution, the customer was able to measure and monitor the torque and force of the yoke control. Read the Aircraft Yoke Torque Measurement application note.

Aircraft Engine Hoist

An aerospace company wanted to test their aircraft engine hoist in order to safely lift, remove, or install engines efficiently and safety. Interface’s solution was to install WTSSHKB-HL Wireless Bow Shackles to the aircraft engine hoist. A heavy load was added to the hooks where the aircraft engine would be. Results from the heavy load are then sent wirelessly to both the WTS-BS-4 USB Industrial Base Station attached to the customers computer or laptop, and the WTS-1-HS Handheld display for single transmitters. With these products, the customer was assured that the aircraft engine hoist was strong and secure enough to lift a heavy engine when installing or removing an engine inside of an aircraft. Learn more about the Aircraft Engine Hoist application here.

Our expert application engineers help our customers by providing technologies that provide exceedingly accurate measurement used in all types of testing, including structural, static and fatigue. For more information on Interface and its solutions designed for airplanes and other aerospace applications, please visit https://www.interfaceforce.com/solutions/aerospace.

Additional Aircraft Testing Resources

Aircraft Wing Fatigue App Note

Aircraft Screwdriver Fastening Control App Note

Aircraft Lifting Equipment App Note

Examining Interface Aerospace Industry Solutions

 

Interface and The Race to Space

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Like many, we are celebrating some incredible milestones in the space industry this year. With every milestone, there is a long path of discovery, invention, and experience that creates these extraordinary moments.

The 53-year history of Interface is rich in experiences supplying force and torque measurement solutions to the engineers and innovators of space vehicles and the structures that support them. For decades Interface has supplied load cells, torque transducers, and multi-axis sensors of all sizes and capacities to the organizations that put the first man on the moon and to those that are pursuing the commercialization of space travel and colonization of other planets.

Our legacy as a reputable provider of sensor technologies has created a reliance on Interface products and expert calibration services. Our products have been and are used today in the development and flight qualification for the ascent and now descent of spacecraft, with rapid expansion and frequency. As we enter a new era of recoverable spacecraft, we are seeing more dependence on Interface as the supplier of the measurement devices used by these remarkable innovators, builders, and test engineers.

Why Interface? It comes down to reliability and accuracy, two extremely important measures of success in the launch and recovery of spacecraft.  These measures are also critical factors given the acceleration in space travel for both valuable cargo and with greater occurrences, humans.

Beyond the performance factors of precision force and torque measurement solutions that Interface engineers and manufactures, we are chosen by the steadfast leaders and new entrepreneurs in the space industries because of quality and our ability to customize our products to exact specifications.

You will find Interface products used in thrust testing, structural testing and even force gravity testing.  Every new test and launch inspire the Interface team to keep doing what we do. In fact, you can find our high-capacity and miniature load cells in use with future engineers and astronauts at universities around the world that are inventing new planetary exploration vehicles and rockets.  Learn more here.

Interface provides products that accurately measure thrust, which is critical in cargo lifting. Every test must be verifiably accurate due to the trustworthiness and safety requirements of moving the ever-increasing valuable payloads, which is beyond stellar communication technologies. It’s now about launching and returning humans, with frequency, in the new era of space travel.

Interface load cells are also commonly used in the production and development of launch structures.  These structures must withstand incredible forces during liftoff and return.

You can also find the Interface blue and stainless-steel load cells in the designs and for testing structures and aerodynamics for payloads of all types.

NASA’s Space Launch System (SLS) core stage is 27 feet in diameter and 200+ feet tall. Core components including liquid hydrogen and oxygen tanks must withstand launch loads up to 9 million pounds-force (lbf). Interface 1200 High-Capacity Standard Precision Low-Profile™ Load Cell Model 1260 for 600,000 lbf capacity, Model 1280 for 1,000,000 lbf capacity and Model 1290 for 2,000,000 lbf capacity were used in the design and testing of the structure.

Load cells were attached to hydraulic cylinders at various locations along test stands to provide precise test forces. Strain gages bonded to rocket structure surface and connected to data acquisition system for stress analysis. Read more here: /solutions/aerospace-industry/rocket-structural-testing/.

Exploring the possibilities of what you can measure?  Interface is here to support your vision and mission. Contact our experts to help you get exactly what you need to accurately measure your designs.