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Fitness Equipment Makers Require Extreme Accuracy

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Interface’s specialty is building solutions for the testing and monitoring of parts and total systems that move and create force. One of the industries where this is critical is the fitness industry. Equipment and fitness machines, whether designed for in-home use or in professional athlete training facilities, needs to perform safely and accurately.

Utilizing Interface sensors and instrumentation, the performance of different fitness apparatus is measured in various testing protocols throughout the product’s lifecycle. Rigorous tests are performed during each phase: R&D, design, manufacturing, and after-market use. These tests look at performance data, as well as measure reliability, durability, fatigue, and safety of the equipment. Manufacturers of fitness devices also utilize feedback from sensors to monitor user experiences in real-time. This means they need accurate data for all types of user profiles, strength variability, weights, and experience levels.

The global fitness market also needs a testing solutions partner as the industry is looking at solid growth over the next few years. In fact, Allied Market Research predicts that the fitness market will reach $14.8 billion by 2028, registering a CAGR of 3.3% year-over-year during this assessment period.

Interface recently captured a series of use cases for how our test and measurement products are used in the fitness industry for testing and in OEM applications. You can read the entire case study here: Interface Measures Fitness Equipment with Extreme Accuracy.

Addressing Challenges in Making Fitness Equipment

In the development of fitness equipment, a lot goes into the manufacturing and engineering process to ensure equipment is safe and reliable for users. Taking a treadmill as an example, the wheels that move the running surfaces must withstand varying speeds and levels of force over extended periods of time. This requires torque and stress testing. Additionally, the sensors on the handrails that send out a pulse to measure the user’s heart rate needs to provide accurate data in health and wellness uses. Manufacturers are looking to install sensors into their equipment that measure various forces and provide fitness data to the user, or data that doctors can use to monitor patients while working out. These makers and product designers for fitness equipment need sensors that can be easily designed into the product or customized to fit into existing products to enable smart functionality and IoT capabilities.

Interface Fitness Equipment Test & Measurement Solutions

Interface provides a variety of measurement solutions used by manufacturers and testing engineers in the fitness equipment sector. This includes our load cells, torque transducers, multi-axis sensors and miniature load cells, along with the popular wireless products and instrumentation. Our products have been used across a wide variety of fitness applications, including elliptical, leg press, rowing machines, bicycles both mobile and stationary, and physical training and therapy equipment. Interface sensor technologies are preferred by product design engineers in this field because of the precision, accuracy, range of options, and quality.

The following application notes examples provide an overview of how Interface serves the fitness industry:

Designing Fitness Equipment and Machines

A fitness machine manufacturer wanted multiple load measurement systems for their different fitness machines such as the elliptical, leg press, rowing machine, and the cable machines used in gyms of all types. The goal of designing sensors into the equipment is to ensure the machines are functioning properly to prevent injuries. The sensors can also be used for trainers who want to conduct strength and endurance tests. Interface provided a combination of products including the WMCFP Overload Protected Sealed Stainless Steel Miniature Load Cell, SSB Sealed Beam Load Cells, and AT103 Axial Torsion Force and Torque Transducers. Paired with Interface’s proper instrumentation, the forces can be measured, graphed, and displayed during the testing stage. Interface’s products all effectively measured forces needed for those working out or undergoing athletic training regiments. Not only did it ensure the designed machines were working properly, but it also helped those using them to track their endurance performance and consider future design enhancements based on consumer use. Read more about this use case.

 

 

Treadmill Rehabilitation

A medical device maker wanted a force measurement system for their experimental rehabilitation treadmill for patients that have pelvic mobility difficulties. For example, patients who have had strokes tend to have difficulty walking. Their goal was to measure the forces applied on the pelvis when the patient is walking on the treadmill and catch any pelvic deviations. The treadmill had a special harness with two actuators on either side of the patient when in use. Interface suggested installing two WMC Sealed Stainless Steel Miniature Load Cells to the actuators, which will measure the forces applied on the pelvis of the patient. Force results would be measured using the SI-USB4 4-Channel USB Interface Module, which could also be graphed and logged on the customer’s computer with supplied VS3 software. Using this solution, the medical company was able to catch different pelvic deviations in their experimental rehabilitation treadmill using Interface’s products. Learn more here.

Bike Power Pedals

A bike manufacturer wanted to evaluate the functionality of their power pedals. They needed a reliable system to measure how much force the cyclist pushes down onto the bike pedals, and they preferred a wireless system that can be paired with their computer to review data results. Interface suggested four Model SML Low Height S-Type Load Cells installed within the bike’s pedals. The four SMLs are paired with two WTS-AM-4 Wireless Strain Bridge Transmitter Modules, which will transmit the force data from the cyclist to the WTS-BS-6 Wireless Telemetry Dongle Base Station Dongle connected to the customer’s computer. The products Interface provided allowed the bike manufacturer to measure the pedal power applied by the cyclist. Read more here.

Interface load cells, torque transducers, and data acquisition systems are ideal for many fitness applications, especially those designed for IoT connectivity. Interface offers products that measure all types of force across the necessary fitness applications. Additionally, if we don’t have a product that works for your exact challenge, our custom solutions team will work alongside your design and test engineers to create the most effective and efficient solution based on the unique specifications.

ADDITIONAL RESOURCES

Bike Frame Fatigue Testing Application Note

E-Bike Torque Measurement

Why Product Design Engineers Choose Interface

Golf Club Swing Accuracy

Golf Ball Tee

Industry Leader in Test and Measurement

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Interface was founded as a supplier of cutting-edge test and measurement industry solutions in 1968. It’s in our DNA and fundamental to what we’ve been engineering, manufacturing and selling for more than five decades. What started out as first to market with a pancake-style LowProfile load cell, has expanded into a broad mix of world-class test and measurement products and calibration services that enable T&M professionals full access to complete systems, from sensors to instrumentation.

Our mix of load cells, torque transducers, multi-axis sensors, calibration systems and other force measurement solutions allow engineers, product designers and manufacturers access to industry-leading testing devices that provide the most accurate and reliable data possible.

Whether that is testing the torque when applying a screw via robotics or verifying touch screen force for the latest 5G consumer hand-held device, we provide the sensors that test the machines, tools, and actual products before and in-market.

Interface is steadfast in ensuring the test and measurement professionals have more than quality sensors. We also provide T&M solutions to maintain and service testing equipment and devices used in labs and facilities throughout the world. The range of products we offer are from standard precision use to calibration-grade. Whether we are supplying our 1800 Platinum Standard Load Cell or a Verification Load Frame, Interface supports all types of T&M pros. Or as we like to call them, ForceLeaders.

Test and measurement use cases are growing due to the demands for miniature load cells, more data for intelligence gathering and automation functionality.  It is estimated that more than $27B is spent in the production of test and measurement equipment globally. And the market is growing due to professionals seeking advancements in equipment and sensor technologies for use in new products, maintaining equipment and sustaining usability with data and proven testing rigor.

Interface sensors are involved in a wide range of T&M applications across a multitude of industries, with increased visibility into new markets like IoT and smart data-drive technologies.

Trends in test and measurement that are fueling the greatest growth:

  1. Medical and healthcare devices using miniature and wireless sensor technologies
  2. Activation of sensors into real-time data monitors and feedback tools
  3. Networking and communications use with 5G and wireless sensor capabilities
  4. Robotics and industrial automation machines and equipment
  5. Safety and regulation equipment with performance sensors
  6. Consumer electronics durability and usability
  7. Environmental exposure and changing conditions, from submersible to extreme temperatures

Read more about the trends in test and measurement in 2022 Test and Measurement Industry Trends.

The reason Interface is the industry-leading provider is because T&M requires precision and reliability. Interface sensors are known for being the most accurate in the industry. From structural and material testing to static and fatigue testing, our products provide key data for manufacturers, engineers and testing professionals to ensure their products and services will hold up under designed loads and performance standards.

From our Ultra Low Capacity series measuring forces in mere grams to our LowProfile™ load cells with capacities up to 2 million lbf, our solutions can meet the needs for any test profile required when it comes to force.  In regard to torque testing, Interface can supply torque transducers with ranges as low as 0.005 Nm and up to 340K Nm to meet the needs of your test. Our overload protected low capacity load cells and torque sensor provide the most accurate results in the industry. In fact, T&M experts measuring torsion effects, tension tests, mass and kinetic energy are utilizing our products. Watch the video below to see some popular Interface Test and Measurement Product Solutions.

Interface provides an overview of solutions for the T&M industry, detailing our capabilities and providing an overview of some of recent applications. Of course, there are hundreds of use cases every year that depend on Interface, so these are just a couple highlights we thought you would find interesting below. Download the T&M Industry brochure at https://bit.ly/37q3Bnx. E-Bike Torque Measurement

An E-Bike manufacturer needed to test the torque on their electronic bicycles. They needed a torque sensing system that measures how much force the bike rider is pedaling onto the pedals, because this determines how much electric power the bike’s motor generates. Interface suggested installing the Model T12 Square Drive Torque Transducer where the pedal assist sensor would normally be. The T12 Square Drive Torque Transducer’s results can be recorded, graphed, and logged using the SI-USB4 4 Channel USB Interface Module when connected to the customer’s PC. Using this solution, the E-Bike manufacturing company successfully tested the torque on their electronic bicycles with Interface’s products and instrumentation. Read the full E-Bike app note here.

Proving Theoretical Cutting Forces of Rotary Ultrasonic Machining

Rotary ultrasonic machining is a hybrid process that combines diamond grinding with ultrasonic machining to provide fast, high-quality drilling of many ceramic and glass applications. This new method has been theoretically proven using computer models. Rotary ultrasonic machining generates forces of a very small magnitude. To prove this theory, any load cell used for measurement must be sensitive, while at the same time retaining high structural stiffness within a compact, low-profile envelope. Interface’s 3A120 3-Axis load cell is installed in the rotary ultrasonic machine to measure the forces being applied to a sample part. With clear signals and minimal crosstalk, the applied forces are recorded and stored using an the BSC4D Multi-Channel PC Interface Module. The 3-Axis load cell provides excellent data helping uncover the relationship between machine cutting parameters and the forces applied on the component. Using this knowledge, the machining process can be reliably optimized for new materials and operations. Learn more about this machining T&M app note here.

You can learn more about all types of T&M applications in our Applications Catalog, demonstrating the diversity and range of T&M solutions and ingenuity of our customers.

Additional Resources:

Interface Solutions for Testing Tools

Insights in Torque Testing Featured in Quality Magazine

 

Fueling Global Demand for Interface Solutions

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Increasing demand for quality, accurate and reliable sensor technologies is global.  Interface products are used on every continent and across all types of industries. As manufacturers and product innovators make advances in what they build and test, there is a direct correlation to the growth in precision test and measurement tool requirements we supply.

The overall sensor market in 2022 is expected to continue its fast past growth, estimated between 8-12% across all types of sensors. In force measurement, this pace is consistent with the experience in the global markets we serve in Africa, Asia, Australia and Oceania, Europe, Middle East, South and North America.

Represented by hundreds of sensors experts around the world, Interface distributors continue to experience growth in market share and Interface product users.  In fact, Interface’s fastest growing markets are represented in our global network.  Solutions that utilize our precision load cells, torque transducers, multi-axis load cells and instrumentation are all experiencing high growth worldwide.

What is impacting the greatest international growth for all types of sensors technologies?  According to market analysis and based on Interface’s experience, it’s being fed by:

  1. Miniaturization of Products and Sensors Used in Testing and OEMs
  2. Industrial Automation and Robotics
  3. Innovation in Aerospace and Automotive
  4. IoT – Internet of Things

Our direct experience in demand for Interface solutions outside of the US is related to these areas and specifically new products and expanding use cases. First, we recently launched our Global G Series products to meet this demand. This specialty product is sold exclusively outside the US. These products are designed and manufactured in the International System of Units (SI), with the same precision and accuracy of all Interface products.

The Global G Series is a global standard product line that is designed for applications that require miniature load cells and for OEM solutions used for automation of machines and components.  The markets that are experiencing the highest growth internationally include:

For example, innovative markets like electric vehicles and hydro-electric energy are growing rapidly domestically and in international markets. These industries rely on force testing to optimize these new technologies.

The Asia-Pacific market is currently our fastest growing market. Interface provides products for this market across all industries including automotive, aerospace, test and measurement and more. As mentioned above, the alternative energy, aerospace and electric vehicle market is a big area for Interface and the Asia-Pacific plays a big role in these areas.

Electric vehicle design and manufacturing requires a precise level of accuracy to improve energy efficiency, minimize weight and maximize vehicle range. For instance, battery technology is a major global focus; therefore, maximizing power output using force testing is the key to improving vehicle design. To achieve this, test and measurement solutions need to be as accurate as possible. Interface also provides high accuracy torque transducers, load cells, load washers and more for two areas of electric vehicle testing: laboratory testing to optimize system performance and production testing to ensure product quality.

Another application for force measurement in Europe is force testing on off-shore hydro-electric power plants. This is a great fit for Interface because we have developed an entire lineup of load cells and other products that are submersible. For this project specifically, we provided submersible WMC load cells. This is one example of an innovative application for renewable energies, and this is another market that is growing rapidly both domestically and internationally.

One of the consistent top selling products in both regions and industries are wireless load cells. In our 2022 Test and Measurement Industry Trends blog, detailed some of this growing demand for wireless force measurement solutions. Wireless systems are helping manufacturers simplify the integration process and create a cleaner safer test environment with far less wiring. It is especially helpful in industries like aerospace or automotive, where large factories want to transmit data across the facility without needing a mess of wires getting in the way.

For wireless needs, Interface supplies its Wireless Telemetry System (WTS) which offers sensor transmitters, receivers, and displays. High accuracy, high quality measurement is interfaced with simple yet powerful configuration and monitoring software and gives sensor manufacturers and integrators the complete flexibility to build their own sensor modules around it. The system easily replaces wired systems, reducing installation and maintenance costs.

One area that Interface is also investing in internally is recalibration services to serve all customers across the world. Many of our customers are becoming more aware of and utilizing these services, as we are continuing to grow this capability amongst international customers who are utilizing Interface products for the first time.

Interface’s presence in the international market is growing quickly. Interface is looking forward to seeing where and how we can supply the best in force measurement solutions to enable innovation around the world.

Source: Tyler Pettit, Application Engineer International Markets

2022 Test and Measurement Industry Trends

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Interface continues to experience significant growth in demand and fulfillment of our precision measurement products and services. Despite the ongoing challenges in supply and overall health and economic concerns, our focus has remained steadfast to serve customers with innovative solutions, facilitated requests for specialized engineering and production requests and expeditiously working to meet the delivery schedules aligned to our customers’ requirements.

As the overall T&M industry grew, so did the demand for engineers and manufacturers across all industries to have proven solutions from their test and measurement equipment, expanded capabilities from sensor technologies, as well as explore new ways of optimizing products with real-time, accurate measurement.

As we look ahead to 2022, we are also investing in new and existing trends and exploring how they will shape the overall market next year and beyond. To help prepare our customers, here are our predictions for the new year, along with what is hot and trending in force measurement. The following provides some insights from our experts on how Interface is prepared to address these trends, while continuing to serve our customers at the highest level of satisfaction. Here is Interface’s viewpoint on market trends and predictions for 2022 and beyond.

Big Data Continues to Rule Product Design and Test

Over the last few years, we’ve shared our view on the Industry 4.0 revolution and how Interface customers are demanding more data from their T&M tools to give exactness in accuracy and all-encompassing performance data at the earliest phases of product design. Not only will this continue, but it will expand rapidly. In the force measurement world, Interface has responded by serving our customers with new innovations in multi-axis sensors that provide more force data on more axis. Interface offers a wide variety of multi-axis sensors including 2, 3 and 6-axis sensors. We certainly anticipate a continued growth in demand for multi-axis sensors as our product line expands to meet the requirements.

In addition, Interface is seeing more requests from manufacturers and product designers to embed sensors and measurement capabilities within their products. To enable continuous improvements and advancements in smart manufacturing and product designs, sensors are being used to provide real-time feedback on machines, components, equipment, and consumer products. These sensors are often designed in or embedded into the OEM product to predict the health in each type of use case, as well as notify users when a repair or adjustment is needed for safety, user satisfaction, and controlled maintenance. In the manufacturing applications, this capability significantly reduces facility downtime. To meet this demand, Interface is investing in more automation capabilities within our own manufacturing facilities to produce high volume sensor solutions for OEM customers. This market is growing rapidly, and Interface is working hard to meet the needs of our customers that need our products in volume.

New Advancements in Strain Gages

Another trend that Interface is actively investing in is new strain gage technologies and manufacturing techniques to better serve the high-production and OEM markets. Interface uses proprietary strain gages for all products we manufacture. When OEMs are making high-volume product orders and need sensors that fit their exact needs without breaking their budget, Interface is ready to meet the demand. One of the ways that force sensor manufacturers can meet OEM cost needs is through innovation in strain gages, the heart of any measurement device. Interface deploys a team of resources to design and build custom strain gages when a unique solution is part of the design requirements. Interface has expanded our specialization and expertise in mechanical engineering, chemical engineering, and metallurgy to meet this specific trend and need. We are currently undergoing critical R&D to find new ways to develop these components and working directly with customers to meet their data requirements. Check out this post on strain gages.

Growing Demand for Wireless Solutions

Another trend that is continuing to gain momentum is the growing need for wireless measurement solutions. Wireless systems are helping manufacturers simplify the integration process and create a cleaner safer test environment with far less wiring. Wireless communication is also playing a major role in advanced manufacturing and smart products. By connecting systems wirelessly, users can monitor testing and in OEM applications, review the health of a system, from a central point. This includes for components used in the field, underwater or via remote locations for assembly and test.

These wireless systems also help improve accuracy significantly. Wireless technology has gotten to the point where we can receive more accurate readings when converting from an analog to a digital signal. This is especially important in highly complex and regulated industries like aerospace, energy, or medical. Wireless solutions will continue to grow, and Interface continues to develop new wireless total system solutions for our various product lines.

Faster, More Efficient Calibration Services

One of the most critical facets of working in manufacturing and technology is meeting the demands of our clients in an extremely timely manner. Innovation, advancements and testing demands slows down for no one, and our customers are no exception. This also requires regular maintenance and servicing of our devices. Interface recommends annual calibration services to ensure your force and torque measurement products are performing as designed. We understand they need our products and services fast. As part of our commitment to customers, Interface provides high quality calibration services that are key to long lasting and accurate force sensors. This service has grown rapidly alongside the force measurement industry and we’re receiving more re-calibration orders than ever before. To meet this demand, Interface is investing heavily in both people and technology to further expedite this process and meet our promise of expeditious turnaround times for calibration services. Read more about calibration here.

Complete Systems

Sometimes out-of-the-box meets the exact requirements, sometimes it’s in the box.  Interface continues to expand our product mix to include advanced instrumentation, accessories, sensors and unique housing for full systems due to growing demands. Our team of solution engineers partner with our customers to identify the specifications and understand the application to build completely custom solutions, from single sensors to complete systems. These systems can be used within lab testing environments or as remote testing solutions.  Learn more about the capabilities of our custom solutions team here.

These are just a few of the many trends occurring in test and measurement into 2022 and beyond. Technology is progressing at a rapid pace. Our customers need more data, that’s abundant and accurate. Our sensors are seeing new application and use cases, ranging from testing unmanned space vehicles to smart agriculture components.

Rest assured, Interface is deeply invested in addressing these trends and serving our customers in the new year and beyond with critical innovation. It’s what we’ve been doing since 1968. We see an abundance of opportunities and possibilities in working with our customers to get the best products for their projects, programs, and OEM products. Whether they need our standard, engineered-to-order, and custom solutions, we are here to serve and ready for 2022. How can we help you?

Additional Resources

Interface Multi-Axis Sensor Market Research

Interface All-In-One Custom Test Systems

Additional Interface Calibration Grade Solutions

 

Where to Find 50 New Force Measurement Application Notes

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One of the advantages we have at Interface is that our application engineers and solutions experts are constantly recommending Interface load cells, torque transducers, instrumentation and accessories for a wide range of projects and programs.  In this fortunate position, it enables our team to explain why and how these solutions work through a series of illustrative application notes. We detail the problem statement, the products required to achieve the desired outcome, and the measurable results in every Interface application note.

The purpose of our app notes is to show the range of capabilities for products we offer, as well as inspire product designers, engineers, and testing professionals to expand how they use sensor technologies. We also increased our industry solutions to highlight a growing interest of how our products are used in agriculture, maritime and infrastructure force and torque measurement projects.

In 2021, Interface produced a record 50+ new application notes.  We have so many application notes, we even produced a first ever complete Interface Applications Catalog.  The type of applications we detailed this year range from space docking to golf swing testing, with everything in between. You can find applications for livestock weighing, crash wall testing, crane safety regulation and even commercial fishing line tests.

Every application note includes a graphic that highlights how the test project is designed and how the products work together. All our illustrated application notes can be found here.  We also have a collection of animated application notes you can watch here.

So if you didn’t keep up with every application note we added this year, here is a quick reference:

AUTOMOTIVE AND VEHICLE

Automotive Head Rest Testing

Pre-Installation Sealing Sensor Testing

Automotive Window Pinch Force Testing

Airbag Connector Testing

Vehicle Crash Test Load Cell Wall

Torque Measurement for Electric Vehicles

TEST AND MEASUREMENT

Garbage Truck On-Board Weighing

Bike Helmet Impact Test

Bike Handlebar Fatigue Testing

Mobile Force System

Gaming Simulation Brake Pedal

Mountain Bike Shocks Testing

Spring Compression Testing

Proving Theoretical Cutting Forces of Rotary Ultrasonic Machining

Fitness Equipment and Machines

6-Axis Load Cell Solutions using Raspberry Pi

Mouse Touch-Pad Force Testing

Treadmill Force Measurement

Veterinary Weighing Scales

E-Bike Torque Measurement

Bike Power Pedals

Bike Load Testing

Bike Frame Fatigue Testing

Golf Club Swing Accuracy

Golf Ball Tee

INDUSTRIAL AUTOMATION

Commercial Food Processing

6-Axis Force Plate Robotic Arm

INFRASTRUCTURE

Aerial Lift Overload Control

Concrete Dam Flood Monitoring

Hydraulic Jacking System Testing

AGRICULTURE

Tractor PTO Torque Testing

Silo Grain Dispensing

Poultry Feeder Monitoring

WTS Equine Bridle Tension System

BTS Equine Bridle Tension System

Livestock Weighing System

Tractor Linkage Draft Control

Chicken Weighing

Silo Monitoring and Weighing

MEDICAL AND HEALTHCARE

Tablet Machine Hardness Tester Calibration

Dental Handpiece Torque Check

Interventional Guidewire Quality Inspection

Tablet Hardness Testing

AEROSPACE AND DEFENSE

Space Dock Capture Ring Force Testing

Aircraft Yoke Torque Measurement

Aircraft Screwdriver Fastening Control

Landing Gear Joint Testing

Aircraft Engine Hoist

Rescue Helicopter Hoist Test

MARTIME

Mooring Quick Release Hooks (QRH)

Commercial Fishing Wire Rope Testing

Mooring Line Tension Testing

Crane Block Safety Check

Crane Capacity Verification

Crane Force Regulation

We would like to send a special thank you to our illustration and design team of Lauren O’Hagan and Scott Whitworth for all their work in creating this array of illustrations, along with a special shout out to Ken Bishop and Keith Skidmore that help us create all these application stories.

What’s new in 2022? Stay close to our Interface IQ Blog and watch our updates on the homepage and solutions for new inspirations and unique examples how engineers and product designers are thinking about using our sensors,

Insights in Torque Testing Featured in Quality Magazine

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With the explosive growth in industrial automation and advanced manufacturing, torque measurement is a hot topic for test and measurement applications across a multitude of industries. We see demand rising due to the use in electric and autonomous vehicle testing, as well as in building components used in robotics and for spacecraft. Demand for torque transducers is so popular, Quality Magazine asked Interface’s product and custom solutions expert Keith Skidmore to contribute an article all about torque testing and how to get the most out of the transducer’s testing data.

Interface has a deep line of innovative torque transducers used where torque measurement is critical to the success of engineering and manufacturing products and components. We provide both an extensive array of standard transducers and custom torque solutions to be used in applications as large as rocket ships, to as small as measuring the torque on a bolt wrench.

Included below is a brief overview of Keith Skidmore’s contributed article in Quality Magazine outlining the basics of torque testing and providing examples of real-world applications of Interface products used to test and measure torque.

Getting The Most Out of Torque Testing

Torque is defined as the rotational equivalent of linear force. It’s a measure of how much a force acting on an object causes that object to rotate. This is one of the key measurements for engineers doing design, test, and manufacturing across a wide variety of industries where machines, vehicles, components and parts include a spinning or rotating motion. It’s critical to understand how to measure torque if you’re doing product development with these types of systems such as engines, crankshafts, gearboxes, transmissions, and rotors.

The incredibly wide variety of torque transducers, different types of devices and tests and the accompanying accessories necessary for different projects can make it difficult to determine what is needed for each individual application. For instance, torque tests are often used in the automotive industry to assess engine torque and speed, but the products used can differ between a typical gas vehicle and newly introduced electric vehicles. Torque is also frequently used to test the tightness of a variety of lug nuts and screws, which is an entirely different measurement solution.

This article provides a brief overview of the key considerations when planning for a torque test. It includes the different types of torque testing, the different torque sensor styles, accessories, mounts, and other tips and tricks. It also provides a brief overview of the potential applications of torque tests with pictures.

The article goes on to provide the basics of torque testing, as well as providing real world applications of torque test and measurement. Here is a preview of one of the applications included in Keith’s contribution to Quality Magazine. To read the article in its entirety, please click the link here.

Engine Dynamometer Testing

In this application example, a rotary torque transducer is used to measure the speed and torque of an engine. This rotary transducer can sense the torque of the engine with high precision and provide an electrical output that is converted from an analog to a digital signal. A rotary transducer is necessary due to the spinning element involved in the engine. It’s paired with a very high-quality coupling and is mounted in a fixed position. Both are necessary to account for the high speeds used in the test. This application would allow the user to measure both torque and speed of the engine simultaneously, which will provide valuable data in confirming the design of the engine or determining if it needs to be adjusted for the vehicle it will drive.

To see the range of torque products offered by Interface, download our Interface Torque Transducers brochure.

Additional Resources

New Twist on Torque Webinar

Torque Measurement for Electric Vehicles

Dental Handpiece Torque Check

OEM: Torque Verification

AxialTQ™ Wireless Rotary Torque Transducer

 

Interface Sensor Mounting and Force Plates

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Test and measurement systems are defined by the sensor, instrumentation, and mounting hardware. Mounting considerations are crucial when designing your system. Utilizing best practices in mounting is also extremely important, especially if you are utilizing multi-axis sensors. Deflections in the system can introduce errors and apparent crosstalk into the sensor measurement.

Mounting plates are used to secure sensors during use. The plates should emulate how the sensor was calibrated, so if it was calibrated on stiff plates these characteristics should be duplicated when using the sensor. Plates should be stiff in design, as a flimsy plate secured on corners can introduce errors, such as off-axis loading, due to bending.

Interface mounting plates are made from the best grade alloy and stainless-steel, machined to the tightest specifications, and are designed exclusively to maintain the performance of the sensor in your application.

Interface Mounting Plates Features and Benefits

  • Designed to work with Interface products
  • Made with the highest quality components and processes
  • Created to maintain the specification of the sensors
  • Distributes the load over the foundation of the supporting structure
  • Provides a prepared surface for the load cell
  • Eliminates the requirement for expansion assemblies in most installations
  • Available in standard and custom options

Mounting instructions are specific to each sensor model. Interface offers complete product datasheets and drawings to locate the features for mounting. We also publish mounting instructions for our torque transducer models, as highlighted in our recent Inventive Multi-Axis and Instrumentation Solutions webinar. The instructions we offer include model, material, capacity, mounting holes, threads and dowel pins and pilot specifications, for both live and dead-end use.

Plates must deflect uniformly to minimize local deformation at the mating surfaces. You may need to use a double plate mounting arrangement, also known as a sandwich mount. In this case, they need to be suitably thick. They must be flat and smooth and the same material as the sensor for thermal matching.

Interface offers top plates and bottom plates for load cells. Mounting Plates for Low Profile™ Load Cells are used in the installation of a compression load cell under a weigh bridge, tank, or other structure normally requires that mounting plates be used. The bottom plate is designed to mate with the load cell and is fabricated of mild steel. It distributes the load over the foundation or supporting structure and provides a prepared surface for the load cell.

The top plate distributes the load to the weighing structure and provides a hard surface for the load button. The top plate will move on the button due to thermal expansion, load shifting, wind loading, and other side loads. The high side load capacity of the Interface load cell eliminates the requirement for expansion assemblies in most installations. Mounting plates are suitable for compression loads only; they will not properly support a universal load cell used in tension.

Interface has recently introduced force plates. Interface Force Plates are a system of multiple multi-axis sensors mounted between two plates. They are ideal for larger capacities than single 6-Axis sensors and can react high moments. Results dependent on characteristics of the plates and other system components and for load introduction and bigger sensors, you should consider in-situ calibration.  Force plates are used for applications such as robotic arms. When secured at the base of the arm, the four sensors are providing feedback during use.

You can learn more about force plates and mounting plates for multi-axis sensors in our latest webinar. Learn more by watching the multi-axis webinar here.

Interface offers mounting plates in our accessories product line. For custom applications, such as our force plates or multi-axis mounting plates and systems, contact our Application Engineers today.

Additional Resources

3A Mounting Instructions

 

Evolving Urban Mobility Sector for Test and Measurement

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Every day it seems we are inching closer to the Jetson’s utopia of flying cars, floating cities and robot butlers. Technology is evolving to the point where robotics and computers control most aspects of travel and mobility. That requires a lot of testing and dependency on accurate measurements for what is on the road and what is flying up above.

Interface has been long been working with leading manufacturers and suppliers of all types of vehicles traveling on the ground, across the skies, and into aerospace. As innovations are removing old boundaries, one thing that remains constant is the need for test and measurement programs.

In the urban mobility sector, we are seeing growth related to rigorous T&M projects for everything from autonomous vehicles to manned rockets, as well as unmanned aircrafts and drones. Interface is proud to be a solutions provider to the engineers and innovators of these growing applications and sectors.

Arizona, the home to Interface’s headquarters, is considered a hub for new technologies and inventions in urban mobility, including autonomous automobiles, alternative-fueled vehicles, rockets and unmanned vehicles. There are dozens of companies with testing and research facilities located throughout Arizona, with countless self-driving vehicles testing and mapping streets throughout the state. In fact, the Institute for Automated Mobility (IAM) in partnership with Intel, Arizona State University, Northern Arizona University, University of Arizona, and other public and private organizations, is collaborating on state-of-the-art research in Arizona. The goal of IAM is to advance all aspects of autonomous vehicles from science to safety to policy.

Nearly every company currently testing and innovating autonomous vehicle technology in Arizona is a customer of Interface. We are providing everything from instrumentation to torque transducers, along with a large range of our standard precision load cells for all types of testing projects. Our custom solutions team also has been working with leaders in these markets.

Being on the forefront as a solutions provider for this sector gives us visibility into many of the applications. What we have learned is demand is related to advancing urban mobility to solve for increasing congestion and diminishing inner-city air quality. The 2019 Urban Mobility Report published by The Texas A&M Transportation Institute with cooperation from INRIX notes:

“Connected vehicles “talking” to each other, such as traffic signals and other systems, and providing this information to decision‐makers will provide unprecedented data and insights to identify and fix mobility problems. Newer model vehicles sense and adjust to their surroundings, increasing the safety and efficient movement of goods and people. Other technologies, such as The Internet of Things (IoT), 3D printers, Blockchain, and Artificial Intelligence (AI) will impact transportation systems of the future.”

As technology leads the way in urban mobility, the safety and performance of the vehicle are of utmost importance. There is no room for failure. The point is, the advancement of robotics, sensor technology, and computing power are becoming a driving factor behind a fully autonomous world in terms of how people and products move about the world.

Another area of increased T&M product demand at Interface is coming from the application of our force measurement products for moving objects in unmanned vehicles above ground. The advancement of drone technology for commercial purposes is seen through the adoption across diverse applications such as mapping, logistics, and surveillance. Interface load cell technologies have been used for flight and wing testing, load testing and a variety of force measurement projects. The drone market, for commercial applications,  is expected to grow to more than $7B through 2022.

Interface is well known throughout key global industries as the premier manufacturer of the most accurate and reliable force measurement products on the market. For urban mobility, accuracy is critical to maintaining safe, pilot and driverless, vehicles and with the advancement of high-quality robotics.

Our load cells and torque transducers are used to test and measure key data points such as balance and weight distribution, thrust and lift, and to optimize movement on robotic arms and legs.

Here are a couple of application examples where Interface is providing critical components to advance innovation in urban mobility

Aerospace and Defense

The aerospace and defense industries are among the earliest adopters of urban mobility technology. The defense sector has utilized drones for surveillance, tactical advantage and battle since the advent of the technology. Aerospace manufacturers have also implemented autonomy into many of their commercial and defense planes. Interface has been a longtime partner of the aerospace and defense sector, working with some of the largest OEM’s across the U.S., as well as internationally. Some of the capabilities of our products in the aerospace and defense industry include thrust tests, wing and fuselage balance, weight distribution and fatigue testing, landing gear tests and parcel delivery weight testing for drones.

Automotive

In the automotive industry, autonomous vehicles have been a critical focus for the past 10 years. The technology really exploded onto the scene over the past five years with key players like Google, Tesla, GM, and others making significant investments in the development and testing of autonomous vehicles. Interface products are used by most of the major automobile OEM’s throughout the world. In 2018, we released one of our most advanced products to date, the Axial TQ™, which includes capabilities uniquely designed for autonomous vehicle testing. Our services in automotive include bolt fastening, brake pedal force testing, engine torque testing and more.

Here are a couple of application notes and a case study that outlines how Interface products are used in this sector:

As the urban mobility sector continues to grow, more advanced travel and delivery systems will require precise weight and torque testing to ensure unwavering reliability. The less control humans have over land and air vehicles, the more we need to trust the construction and design of these vehicles using proper force testing. Interface will continue to grow as a key player in the space as more OEM’s turn to our services to optimize the development of drones, autonomous vehicles, and other urban mobility innovations.

Contributor: Kim Williams, Interface Business Development Manager

Interface Solutions for Medical Devices and Healthcare

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There is a reason that the most highly regulated industries in the world turn to Interface for force measurement equipment used for medical device and healthcare product design, development and testing. The industry must trust the data they are using to optimize or validate product design because the slightest errors can have devastating results.

In the medical industry, the dependence on accuracy and reliability increases tenfold. Not only are medical devices and healthcare products some of the most complex and delicate technology in the world, the regulations and certification standards they need to meet are stringent. And most importantly, any design flaws or failures could present serious health risks and or worse. Interface has been a trusted partner to medical OEMs and healthcare technology providers around the world for decades.

Our test and measurement products are crucial in the development of numerous medical and healthcare tools, technology, medical devices and equipment used in labs and hospitals alike. Interface has been part of remarkable innovations and test and measurement projects of products implanted inside of the human body and used for prosthetics.

“To serve our customers who need high-quality force and torque measurement testing data, Interface is the provider of choice for accurate, reliable and customizable force measurement products and systems.”  Elliot Speidell, Regional Sales at Interface

Engineering and building load cells, along with supplying the best torque transducers, digital instrumentation and accessories all plays a critical role in the evolving needs within the healthcare industry. Interface load cells that can measure capacities as low as 0.11 lbf / 0.5 N have been used to measure the smallest weight change in medical bags. Our multi-axis sensors are used to measure multiple axis of force in the development of prosthetics.

Here are a few applications that showcase different Interface products for healthcare and by medtech OEMs:

VASCULAR CLAMP FORCE

Using an Interface High Speed Data Logging Indicator and Model LBS Load Cell, the customer was able to test multiple clamps, recording the force measurements for each. By using this accurate data, they were able determine the best one to use during surgery. READ THE MEDICAL APP NOTE HERE.

BALL AND SOCKET MED DEVICE

A medical device OEM needed to test a new design for an artificial hip joint. This test needed to validate load consistency, and the durability of their design. Using a 6-Axis Load Cell mounted to the manufacturer’s test machine, they were able to simulate actual use. A Model BX8 was connected to the sensor to collect data. READ THE MEDICAL APP NOTE HERE.

SURGICAL STAPLER FORCE VERIFICATION

A large medical manufacturer required a load button load cell to verify the amount of force needed to activate the surgical stapler. Along with precision measurement, the load cell requirements were it needed to be small, easy to mount, and accurate. Interface’s LBMU Compression Load Button was mounted to the surgical stapler to enable force verification, and then connected to a 9820 Load Cell Indicator to record output. READ THE MEDICAL APP NOTE HERE.

PROSTHETIC FOOT PERFORMANCE

In this use case, Interface supplied products to help our customer test how a prosthetic foot performed during different positions and stances. The products used in this test were the Interface Model 3A120 3-Axis Load Cell, which was installed between the leg socket and the prosthetic foot and the Model 3A120 which was connected to customer’s portable data acquisition system. READ THE MEDICAL APP NOTE HERE.

When standard precision solutions need a custom application, Interface’s solutions team and engineers work directly with medical device manufacturers to deliver specialized products, systems and software that meet evolving needs and innovation.

To provide additional information on the medical customers we serve and the solutions we develop, Interface has created our medical industry case study. The case study provides details on the force measurement needs of the industry, as well as various examples of solutions we have developed for medical devices and equipment from heart medtech devices to some of the machinery used to manufacture medical products.

Click Here to Read the NEW Interface Medical Industry Case Study

You can view some of these medical and healthcare application use cases here.

Contributor:  Elliot Speidell, Regional Sales Director at Interface