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Outlining Force Solutions for Structural Outrigging

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Across a wide variety of industries, heavy machinery, maritime, construction, and other infrastructure often need additional structural support. This includes support that prevents equipment, vessels, and buildings from falling over, capsizing or collapsing.

Typically, the solution to provide this critical structural support comes in the form of an outrigger. For vehicles, both land and maritime, an outrigger is a projecting structure, with specific meaning depending on types of vessels, or the legs on a wheeled vehicle that are folded out when it needs stabilization.

For buildings, outriggers are interior lateral structural systems provided to improve the overturning stiffness and strength of high-rise buildings. It is a lateral load resisting system that is located within the building. The whole system consists of a core structure connected to the perimeter columns of the building.

These types of structural supports became popularized in the 1980s as an addition to high-rise buildings as they are effective up to 150 floors due to its unique combination of architectural flexibility and structural efficiency. Outrigging has been adapted for large vehicles and boats, such as large cranes that are extremely top heavy and can create balance problems, or yachts that need to be stabilized when stored out of water.

With the addition of these supports, various forms of testing need to be done to ensure the outrigger can support the vehicle or structure it is installed upon. This is where Interface’s force measurement testing and monitoring products are utilized in different outrigging applications.

Interface load cells are used by outrigging engineers, civil engineers and heavy equipment manufacturers, oil and gas, construction industry and marine equipment companies. Read more why Rigging Engineers Choose Interface Measurement Solutions.

The role of force measurement sensor technologies in outrigging is to provide high accuracy measurement of the outrigging equipment in test and actual use. The applications range from integration of sensors into outrigger equipment, to load cells for real-time monitoring of the physical structure using outrigger supports.

The most common Interface products used for outrigging include:

For example, Interface load shackle cells are used to measure the forces during outrigger testing as well as on the outrigger equipment that support the structure. The data from the sensor is critical information used to assess the structural integrity of the outrigger or structure and to identify any potential weaknesses.

Interface load cells, such as our load shackles or load pins, are typically placed in strategic locations on the outrigger or structure where the force is expected to be greatest. The load cell is then connected to a data acquisition system (DAQ) or indicator that records the force readings. The data can then be analyzed to determine the maximum force applied to the outrigger or structure, as well as the distribution of force over the structure.

Load cells can also be used to monitor the performance of outriggers or structures over time. This can be helpful in identifying any changes in the structural integrity that may be caused by wear and tear, environmental factors, or other factors. Utilizing instrumentation with alarm capabilities is helpful, as well as a tool for maintenance.

Load cells are an important safety feature in outrigging equipment. They can help to prevent accidents and ensure that the equipment is used safely. A load cell is used to prevent a crane collapse during the construction of a high-rise building in a large congested metropolitan city. The crane is used for lifting a heavy beam. The load cell alerts the operator when the load is too heavy.

Ultimately, force measurement provides several benefits to testing and monitoring different outrigger applications, including:

  • Increased safety: By measuring the force applied to the outrigger, a load cell can help to prevent overloading and damage to the outrigger. It is also valuable for continuous monitoring during lifting use cases, such as with a crane or heavy machinery.
  • Improved efficiency: By monitoring the performance of the outrigger, a load cell can help to identify any potential problems early on, which can help to prevent costly downtime.
  • Reduced risk: By providing accurate data on the force applied to the outrigger, a load cell can help to reduce the risk of accidents and injuries.

Examples of how force measurement is used to test outrigger solutions in a variety of industries:

  • In the oil and gas industry, load cells are used to test the outriggers of offshore drilling rigs. This helps to ensure that the rigs are safe to operate in high-wind and wave conditions.
  • In the construction industry, load cells are used to test the outriggers of cranes and other lifting equipment. This helps to ensure that the equipment is safe to use and that it will not overload the outriggers.
  • In civil engineering, load cells are used to test the structural integrity of bridges and other structures. This helps to ensure that the structures are safe to use and that they will not collapse underload.

Outriggers play a critical role in the safety and support of vehicles, infrastructure projects and massive structures. Interface force measurement products also play a necessary role in safeguarding outriggers and the operators. If you have an outrigging use case and are wondering which products are best suiting for your specific requirements, contact Interface Application Engineers for help.

Construction Brochure

Interface Measurement Solutions Support Smart Cities

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Various Interface load cell products are used in the development of smart cities. What is a smart city? A smart city is a municipality that uses data and interconnectivity to improve sustainability and quality of life.

According to the Smart City Index of 2023, London is leading the way in the development of its smart city infrastructure. Other top contenders for the lead are Zurich, Oslo, Barcelona, Taiwan, Singapore and New York. There are estimates are there are more than 140 smart cities today in various stages, and the number is growing. They are also showing tremendous potential to transform the way we live, consume, move and work. Most smart city infrastructure is in the early and mid-stages of development.

From research to engineering and building to maintenance, Interface force measurement solutions are being actively used in the design and testing of components used in smart city projects and systems. Force measurement data is valuable for assessing and improving the overall efficiency and sustainability of a city. Learn more by visiting our smart cities solutions here.

Load cells can be used to measure a variety of parameters in smart city design, development of infrastructure and resource management.

  • Interface LowProfile and Mini Load Cells are used to measure the force applied to a structure or object. This information can be used to assess the structural integrity of a building or bridge, or to optimize the design of a new product used in the smart city infrastructure.
  • Interface torque transducers provide data on the rotational equivalent of force. This information can be used to monitor the performance of heavy duty machinery and construction equipment, or to ensure that products are assembled correctly when building.
  • Specialized load cell technologies, like load pins, load shackles and tension links can be used to measure tension, lifting actions and weight, which is the force of gravity acting on an object. This information can be used to weigh products, to monitor the loading of transport vehicles, or to ensure materials or people are not overloading lifting equipment. Go to our Lifting Solutions and Weighing Solutions to learn more about the range of products available for smart city applications.
  • Interface wireless and Bluetooth solutions support the advance ICT (communications) requirements to easily capture accurate data without the cable. Our complete line of wireless telemetry systems and Bluetooth options support the advancements in digital optimization and feedback required for real-time data management.

By using sensors, data, and communications to improve human conditions of our cities, we can create more livable, sustainable, and equitable communities for the future.

SmartInfrastructure_InfographicPoster

How Load Cells and Sensor Devices are Used in Smart Cities

Load cells are versatile and essential tools for a diverse range of smart city applications. They provide accurate and reliable measurements that can be used to improve safety, resource management, and sustainability. Here are some examples of how force measurement solutions are used in smart cities.

  • Improving traffic management: Data acquired from load cells and sensors can be used to monitor the weight of vehicles on bridges and roads. This information can be used to optimize traffic flow and to prevent overloading of infrastructure. Force measurement data can also be used to monitor the movement of people and vehicles. This information can be used to identify potential hazards and to prevent accidents. Read: Interface Powers Smart Transportation Solutions
  • Smart waste management: Force measurement outputs can be used to monitor the weight of waste in bins. This information can be used to optimize waste collection routes and to reduce the amount of waste that is sent to landfills. Learn more in our IoT Waste Management Container Weighing App Note
  • Structural health monitoring: The data from load cells, torque transducers and multi-axis sensors can be used to monitor the structural integrity of buildings and bridges. This information can be used to identify potential problems before they lead to failure. Check out our post Interface Solutions for Structural Testing.
  • Smart farming and agriculture: Data from force measurement solutions can be used to monitor the weight of crops and livestock. This information can be used to optimize irrigation, fertilization, and harvesting. Learn more in our post Solutions to Advance Agriculture Smart Farming and Equipment.
  • Smart transportation: Creating a system of public transportation options, electric vehicles and bicycles, along with autonomous deliveries are part of smart city development projects around the world. Interface force measurement devices are critical in the development, testing and management of smart transportation.
  • Air quality systems: Force measurement data collected in real-time can be used to monitor the emission of pollutants from vehicles and factories. This information can be used to reduce pollution and improve air quality in smart cities.
  • Resource and energy management: Measurement data is important in production and optimization of critical resources like renewable energy and water, as well as for reducing waste and improving efficiency. Force measurement data can be used to monitor the energy consumption of buildings and infrastructure. This information can be used to identify opportunities for energy savings.

Smart cities use various Interface sensors technologies and other data collection instrumentation devices to track the use of resources and transportation. Overall, force measurement solutions are a valuable tool for improving the efficiency, sustainability, and safety of smart cities. As the use of sensors and other data collection devices continues to grow, we can expect to see even more innovative applications for force measurement data in smart city applications.

Keep watch of our smart city applications, as we learn more about how our products are being used in very smart and innovative use cases.

ADDITIONAL RESOURCES

Modernizing Infrastructure with Interface Sensor Technologies

The Rise in Digital Force Measurement Solutions

Why Civil Engineers Prefer Interface Products

Interface Powers Smart Transportation Solutions

Smart Pallet Animated Application Note

Making Products Smarter with Interface OEM Solutions

Solutions to Advance Agriculture Smart Farming and Equipment

Interface Solutions for Heavy Equipment

Vertical Farming for Sustainable Food Production on Earth and Beyond

Innovative Interface Lifting Solutions

 

How Load Cells Are Transforming the Construction Industry

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The construction industry is one the most universal, growing, and dangerous industries in the world. Interface force measurement solutions are used for all types of construction applications from bridge and high-rise building projects to foundation load tests and structural monitoring. Our sensors and instrumentation are used in crane and heavy lifting operations, material testing and equipment calibration.

Accuracy and quality of all measurement products used for design, testing, monitoring, and equipment evaluations is imperative in protecting the project’s assets and workers. One of the leading causes of construction accidents is overloading equipment. When equipment is overloaded, it can fail, leading to serious injuries. It is essential to utilize high accuracy load cell technologies to measure the amount of force being applied to construction equipment.

Interface force measurement solutions can help to prevent overloading accidents by using the measurement data to ensure that equipment is not being extended beyond its safety capabilities. Force measurement solutions can also be used to monitor the performance of equipment and identify potential problems before they lead to an accident.

Interface offers a wide variety of sensor solutions for construction equipment and material testing. Our load cells offer precise measurements of applied forces, furnishing essential data regarding the structural response under various load circumstances. This data plays a critical role in evaluating structural integrity, detecting potential vulnerabilities, and optimizing design to guarantee the safety and dependability of infrastructure.

Interface force measurement solutions can help to improve efficiency and productivity in the construction industry in all areas including engineering, testing and maintenance. By monitoring the performance of equipment, construction companies can identify areas where they can improve efficiency.

It is common to find Interface load cells, including load pins, load shackles, miniature and even jumbo load cells in use for various forms of construction projects, equipment and tools. These products, as well as torque transducers, instrumentation and wireless systems are frequently used in the testing and monitoring of the machinery, rigging and lifting devices, gear, and heavy duty vehicles that are used in various stages of building.

Interface provides various sensors for a range of construction use cases around the world, including:

  • Residential and commercial buildings
  • Infrastructure programs
  • Industrial construction
  • Material testing machines
  • Civil engineering projects
  • Mining and tunneling
  • Environmental remediation
  • Heavy equipment manufacturing
  • Vehicle OEMS
  • Cranes and lifting equipment


Construction is an ever-present and ever-growing industry estimated to reach nearly $13T in global spending with broad and diverse use of measurement solutions. From single dwelling construction tools to heavy machines used to move concrete slabs, measurement is fundamental in construction. Included below we have provided a few examples of how our sensors are being used in construction.

Construction Reach Stacker

A reach stacker is a vehicle used in construction site to lift, move, and stack heavy containers. A force monitoring system was needed to ensure the safety of surrounding personnel, and if the reach stacker can lift heavy loads. Interface’s WTSLP Wireless Stainless Steel Load Pins were installed into the corners of the lifting mechanism of the reach stacker, where heavy loaded containers are lifted and moved. The force results were then wirelessly transmitted to both the WTS-BS-1-HS Wireless Handheld Display for Single Transmitters, or directly to the customer’s PC with the WTS-BS-6 Wireless Telemetry Dongle Base Station. Using this solution, the customer was able to monitor their reach stacker with Interface’s Wireless Telemetry System and ensure its ability to lift heavy loads on site.

Bridge Construction Wind Monitoring

Wind monitoring is a necessary operation during bridge constructions. Strong winds can destroy a bridge under construction since it is a work in progress with poor structural design. Monitoring these winds in real time is much more accurate than using predicted weather forecasts. Interface suggested installing the WTS-WSS Wireless Wind Speed Transmitter Module on the highest point of construction, such as a crane. Wind speed results were wirelessly transmitted to the customer’s PC through WTS-BS-4 Wireless Base Station with USB Interface in Industrial Enclosure. It was transmitted to the WTS-BS-1 Wireless Handheld Display for Unlimited Transmitters Data can be displayed, logged, and graphed with supplied Log100 software. Interface’s WTS-WSS Wireless Wind Speed Transmitter Module combined with Interface’s Wireless Telemetry System was perfect to monitor the wind speed in real-time during the bridge’s construction.

Metal Bending Force Material Testing for Construction

A construction material supplier wanted to know how much force it takes to bend different grades of steel metal used for building and infrastructure projects. They use their metal bending machine to create different metal hardware and wanted to record the amounts of force it takes to bend the metal used for their projects. Interface suggested using a wireless method, so cables do not interfere with the machine. The WTS 1200 Standard Precision LowProfile® Wireless Load Cell was attached to the head of the hydraulic operated steel bender. Results were wirelessly transmit to the customers PC through the WTS-BS-4 Wireless Base Station with USB Interface, where data can be displayed, logged, and graphed with supplied Log100 software. Using this solution, the customer was able to record the force results of his metal bending machine with Interface’s Wireless Telemetry System.

Interface is adept at providing solutions suited for use in construction projects, equipment and ongoing monitoring programs.  If you have questions about what products are suited for your specific project, equipment or testing programs, contact us. We are here to help.

ADDITIONAL RESOURCES

Force Measurement Solutions for the Construction Industry

Interface Solutions for Heavy Equipment

Gantry Crane Weighing

Lifting Heavy Objects

Rigging Engineers Choose Interface Measurement Solutions

Innovative Interface Lifting Solutions

Modernizing Infrastructure with Interface Sensor Technologies

Interface Solutions for Structural Testing

Why Civil Engineers Prefer Interface Products

Innovative Interface Load Pin Applications

 

 

Testing Labs Choose Interface High Accuracy Products

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Specialists focused on testing applications work in a variety of testing lab environments. In each lab, technicians rely on the tools to collect and report on data that is used to make products safer, guarantee performance, ensure quality, and to meet the strict industry standards and requirements. Accuracy in testing data is dependent on the precision measurement devices and instrumentation used to capture the results.

We supply lab engineers with high-accuracy sensor technologies used to complete rigid test requirements. Interface is the top provider of test and measurement products used for structural and material testing, static and fatigue testing, torsion effects, tension tests, calibration testing, and environmental testing. Read more in Types of Force Measurement Tests 101.

Our standard high precision load cells, torque transducers, multi-axis sensors, and instrumentation are used on every continent for T&M. Based on our quality and performance, we are the chosen supplier to calibration and testing labs. We see our products used today for continuous improvement programs, advancements in smart manufacturing and new product designs.

If it must be measured, Interface has a solution. Our products are designed for small and large testing facilities, including calibration-grade load cells, load frames and test stands, along with data acquisition systems. The wide variety of our force measurement solutions designed for testing labs means we play a role in every industry that is making a physical product and the test labs that validates the products performance.

Testing Labs and Types of Testing Using Interface Solutions

General Automotive Test Labs:

  • Component and Sub-Component Level Testing
  • Suspension Testing
  • EV Battery Testing

Automotive Driveline Testing:

  • Engine Performance and Durability Tests
  • Motor Efficiency Testing
  • Power Analyzation (Electric)

Aerospace Testing:

  • Full Scale Structural Static Testing
  • Component Fatigue Test
  • High Precision Thrust Testing
  • Simulators
  • Wind Tunnel Testing

Geotechnical and Civil Testing

  • Concrete or Asphalt Core Testing
  • Soils Testing

General Structural and Component Testing

  • General Push and Pull
  • Design Proofing
  • Life Cycle Fatigue Validation

Medical Device Testing:

  • Prototyping
  • PPAP Validation and FDA Certification
  • Device Lifecycle Testing

Consumer Product Testing Labs:

  • Design Validation
  • Material Testing
  • Fatigue and Failure Tests

Interface recently highlighted testing lab applications in our Test Lab Essentials Webinar. Here you can see the lab use cases and products as they are reviewed by our applications experts.

Each of these testing types requires different force testing equipment, and our experts work directly with testing lab professionals to determine the products or systems they need for single and ongoing test requirements.

As testing technologies becomes increasingly complex, off-the-shelf products may not meet the needs of every Interface customer. We lend engineers expertise in test and measurement to support unique and custom requirements to get the right sensor, instrument, and system in place.

Since our first load cells were designed five decades ago, we have built millions upon millions of load cells and torque transducers used in testing labs around the world. Our products are built to withstand the rigor and requirements needed for high quality and reliable data collection in test and measurement. Our test customers depend on us for proving accuracy, consistency, and reliability in performance.

ADDITIONAL RESOURCES

Interface and Testing Lab Applications

Testing Lab Essentials Webinar

Engine Dynamometer App Note

Consumer Product Testing Case Study

Interface Solutions for Safety and Regulation Testing and Monitoring

Metrologists and Calibration Technicians 101

Motor Test Stand

GS-SYS04 Gold Standard® Portable E4 Machine Calibration System

Electric Vehicle Structural Battery Testing

Furniture Fatigue Cycle Testing App Note

Regular Calibration Service Maintains Load Cell Accuracy

 

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

 

Aerospace and Defense Industry Solutions

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Among the many applications Interface products are used for across multiple markets, there may be none that require the highest levels of accuracy, quality and reliability as does the aerospace and defense industry.

By classification, aerospace largely comprises of those engaged in producing and servicing of commercial aircraft. The defense market is defined as those providing military weapons and systems designed to operate in the air, in the sea or on land.

The aerospace and defense industries are global markets that continue to expand their use of precision sensor technologies for advancing innovations in autonomous vehicles and flight systems, electric and hydrogen engines, as well additive manufacturing applications. Interface proudly serves the world’s largest manufacturers and suppliers in the aerospace industry by providing world-class force and torque measurement solutions for these types of requirements, as well as for their future inventions.

Over the past two years, the trends in the global commercial space ecosystem along with defense needs have created unique requirements that benefit from our five decades of being a premium provider for A&D equipment manufacturers and testing labs. We are able to meet these trending demands through our standard, engineered to order and completely custom force, torque and systems. These solutions are being utilized in testing of all types of vehicles, on the ground, in the water, and for flight.

A&D is a unique industry because of the complex needs of many applications. When we develop applications for other industries, we’re typically focused on solving a few specific challenges, whether it’s related to cost, safety, performance, environment, or other engineering specified design requirements. In aerospace and defense, every one of these factors needs to be addressed, as well as some special needs. Applications in the aerospace and defense industry cannot fail. If they do, it can put people, both military and civilians, in danger. That’s why force products in the defense industry need to be of the highest quality in all key factors.

Below are a few applications for force measurement in the defense industry. Each demonstrates the criticality of proper force testing, as well as the complexity of the projects Interface has been involved in.

SLS Tank Test

As outlined in NASA’s article on the SLS Tank Test, NASA’s goal was to push the very limits of a test version of the world’s largest rocket fuel tank. The project put incredible flight test strain on the tank to try and push it to its breaking point. After five hours of testing and more than 260% of the expected flight load, the tank finally buckled. Doing this helped engineers gather data on the tank to help intelligently optimize the final rocket ship.

In this application, load cells played the key role of collecting the flight force data. The extreme nature of the flight tests meant that the load cells needed to be incredibly durable and provide accurate data all the way through the breaking point.

Structural Testing

For the many hundreds of thousands of commercial and military vehicles on the market, especially those that fly, there are numerous force tests involved to validate a design and ensure they’re safe and of the highest quality to move into production. Load cells and torque transducers are used across a wide variety of vehicles for structural testing. The torque of the helicopter rotor is measured and validated using a torque transducer, or the wings and hull of an airplane are put through wind tunnels and other stress tests with load cells installed to collect data. All of these force applications are critical to ensuring that these vehicles can last beyond their intended breaking point and offer complete peace of mind to operators and passengers. There are a million different things that a military pilot is thinking about – the structural integrity of his or her aircraft should never be one of them.

Custom Sensors

Another area that has grown in recent years as technology pushes the aerospace and defense market forward is custom sensors. Test has gotten more sophisticated as the move to big data becomes more prevalent, and Interface has addressed this by working directly with customers to develop custom sensors that address unique challenges.

One of the biggest areas where we have seen a growing need for custom sensors is on test stands in thrust application. Test stands are often used in field testing on rocket or plane engines. In certain field applications, the test stand is outfitted with numerous load cells that must be custom designed with features like weatherization, multiple bridges, very-high precision, and more. The reason for this is because the cost of a thrust test in fuel alone can be incredibly high. You usually only get one shot at a successful thrust test. If there are any issues with the sensor, it’s going to be costly.

Interface has deep experience developing custom sensors for our aerospace and defense partners. We understand their needs and work closely with their engineering team to ensure they get it right the first time. If you’re interested in learning more about Interface and our solutions for the aerospace and defense industry, please visit us at www.interfaceforce.com/solutions/aerospace.

For additional references, check out our A&D related case studies and application notes:

Launching Into Orbit with Interface

Force Measurement for Space Travel

Interface’s Crucial Role in Vehicle and Urban Mobility Markets

Aircraft Wing Fatigue Test

Rocket Structural Test

Wind Tunnel Testing

Contributor: Elliot Speidell, Interface Regional Sales Director

Driving Force in Automotive Applications

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Among the most highly regulated industries in the world, automotive is up there with the likes of medical and defense. Every component and system needs to be thoroughly tested and deliberately analyzed to ensure that the final product is safe for the driver, other vehicles and pedestrians. Any mistakes or failures can cause catastrophic damage and put lives at risk.

There are hundreds of thousands of different tests that car parts and software go through before they are approved for the road. Among them is force measurement testing. Force and torque tests are integral to the structural and mechanical design and build of the car. Gathering data on the build quality and safety of materials and components found within cars, trucks and more is done through a wide variety of different force measurement testing.

Interface has been a partner to the automotive industry for more than 50 years, from the major OEMs to smaller parts manufacturers and test labs. We build force and torque sensors and acquisition devices designed to provide automotive engineers and manufacturers with high-quality data to monitor and confirm the design and in-action processes of a wide variety of vehicles.

Force testing applications for the automotive industry involve everything from structural, engine, brake, seat belt and suspension tests, all the way down to individual lug nut torque testing.

Recently, Interface has also been supplying solutions to those in the growing electrical vehicle (EV) market. EV cars and other motor vehicles present a wide variety of unique challenges for engine torque and battery technology testing.

As an example of some of the products we offer to the industry, we are highlighting Interface expertise in different automotive applications. This will include specific examples of work we’ve done for our customers recently or in the past.

BRAKE PEDAL TESTING

One of the largest areas of automotive test and measurement we are involved in is brake pedal testing. Our customers need to ensure that applying certain amounts of force to the brake will slow and stop the vehicle as intended.

In this application note, Interface supplied our customer with a BPL-300-C Brake Pedal Load Cell, which was installed on the brake pedal. As the user depressed the brake pedal, force data was transmitted by our BTS-AM-1 Bluetooth Low Energy (BLE) Strain Bridge Transmitter Module to the BTS Toolkit Mobile App and displayed on a mobile device. This allowed our customer to view and graph the data in real-time.

Read the application note for Brake Pedal Testing here.

EV BATTERY TESTING

In the EV market, one of the most integral pieces of technology is the battery used to run every piece of hardware and software in the car. One of the critical tests that’s performed on EV batteries in compression testing. As an EV battery is charged and stores more electrons, it swells. If the packaging that houses the batteries is not intelligently designed to compensate for this swelling, you could have a major problem.

For this challenge, Interface can supply the popular WMC Miniature Load Cell. The load cell will measure compression force as a battery goes through charge cycles on a test stand to determine the force given off as the battery swells. This allows our customers to design the proper packaging for the batteries.

Read more about Interface’s role in the The Future of Automotive is Electric.

SUSPENSION TESTING

A personal favorite of the Interface team is a suspension test we performed on a race car. As you can imagine, race car components need to be finely tuned for optimal performance. The suspension is one of the most significant factors in the tuning process.

Using an Interface Model 1200 Standard Load Cell, we were able to measure simulated motions of a racetrack including bumps, banks and other track conditions. This allowed the customer to gather highly accurate (0.04%) measurements of loads applied to individual suspension points. This type of suspension testing technology can also be performed on a regular commercial automobile, but the race car example is much more fun!

View the race car suspension testing application here.

MOTOR TESTING

In this motor test stand application, it was used in the quality control lab of a major automotive manufacturing customer that needed to test, record and audit the torque produced by a new motor design under start load.

Interface supplied a Model AxialTQ Rotary Torque Transducer that connected between the motor and the differential, on the drive shaft, which could measure and record these torque values. Based on the data collected using the AxialTQ, AxialTQ Output Module, and customer laptop, the test engineer was able to make recommendations to optimize the amount of torque created by the new motor design.

You can read more about the AxialTQ in this post.  

The wide variety of applications for automotive force testing that Interface has been involved in is significant. We have many published application notes beyond those highlighted, including Seat Testing, Engine Head Bolt Tightening and one for an Engine Dynamometer (dyno for short) use case. The examples listed above just scratch the surface.

Interface is a preferred partner to the automotive industry.  To review some of the automotive application notes we have published, please check out our website at /solutions/automotive-vehicle/. You can also give us a call to learn more about the various solutions we offer for customers in the automotive industry at 480-948-5555.