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Interface Load Cells for Press Machines

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Press machines are designed to measure and apply force for various reasons. Hydraulic presses can be used to shape materials or crush objects. Stamping presses make a visible impression or stamp onto materials, such as a pharmaceutical tablet or logo on a food product. Even sandwich presses follow many of the characteristics of more industrial presses.

Press machines are used across automotive, aerospace, construction, consumer goods, medical, agriculture, mining, and other industries.  The presses produce consistent, cost-effective quality parts, tools, and products. No matter what kind of press machine, it must undergo rigorous testing during the machine-building process. During operation, there must be continuous monitoring of the press force used in each application.

NEW! Interface Solutions for Machine Builders

Interface load cells are critical to designing, testing, and using accurate and reliable press machinery. Interface load cells come in various shapes, dimensions, and capacities, allowing press machine builders and engineers to find the best solution for their specific machinery use case. Whether selecting a miniature load button load cell for a small press test or our WMC Load Cell to integrate into the machine, Interface has a range of products for press machine applications.

Benefits of using load cells in press machines:

  • Enhance Operator Safety
  • Prevention of Overloading
  • Improve Consistency
  • Avoid Damage to Equipment
  • Reduce Waste and Scrap
  • Increase Quality and Consistency of Work Product
  • Improve Process Control
  • Extend the Life of the Machine’s Operation
  • Increase Productivity

In a press machine test, the load cell is typically placed between the ram of the press and the die, where it can measure the force being applied to the object. The load cell is usually connected to a readout or display showing the operator the force applied to the part or material. This readout may be a simple analog or digital display, depending on the specific press and load cell being used in the machine. Review our Instrumentation Selection Guide to find the best option for your press.

There are numerous options for the types of load cells used for press machine applications. Hydraulic presses are some of the most common presses that use load cells. These machines are often built to form metal parts, such as gears, shafts, and bearings. The construction industry uses presses to assemble and test concrete structures. These presses are designed to crush and process minerals and ore in mining.

Mechanical presses are typically used for high-precision applications, such as metal stamping and forming. Miniature load cells are used in more precise applications that require smaller measurements. These use cases are often reserved for the medical or consumer goods industry, where the goal is to provide a stamping force for medicine or candy to label the product without crushing or damaging it. A precision Interface load cell ensures that the force applied to the material is consistent and accurate.

Another type of press using a sensor is known as a screw press which forms and compacts materials such as plastic and rubber. These press machines are found in chemical, food, and waste processing facilities.

Depending on the measurement capacity needed in the machine’s application, two popular Interface options are the Rod End Load Cells and Mini WMC Sealed Stainless Steel Load Cells. A rod end load cell is typically installed at the end of the piston or ram, where it can measure the tension or compression force being applied during the pressing operation.  These load cells provide accurate and reliable force measurement in various presses.

Press Forming and Load Monitoring

Press forming is a method to deform different materials. For instance, materials such as steel can be bent, stretched, or formed into shapes. A force measurement solution is required to monitor the forces being applied by the press-forming machine. This ensures quality control and traceability during the production process. Interface recommended installing the 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell for large press forming machines. When the material is placed under the punch plate to form a shape, the 1000 series load cell measures the force applied. The captured force results were sent to the INF-USB3 Universal Serial Bus Single Channel PC Interface Module, where results could be graphed and logged on the customer’s PC using the provided software. Interface’s force measurement products and instrumentation accurately monitored and logged the force results of the press force machine, ensuring zero-error production performance.

Tablet Forming Machine Optimization

A pharmaceutical tablet producer wanted to monitor the forces the tablet forming machine applied to understand the relationship between raw material, die set, form, force, and the motor’s cycle speed. The goal was to improve the productivity and efficiency of the tablet-forming process while reducing losses (i.e., cracked tablets or voids) by adding a dimension of feedback that could be used to assign specific press adjustment criteria for given inputs. An Interface Model WMC Sealed Stainless Steel Mini Load Cell (10K lbf Capacity) was mounted in the section of the downward press bar. The machine was modified to accomplish this. The load cell was then connected to a Model 9320 Portable Load Cell Indicator to collect the needed data. After analyzing the data, the tablet producer could quantify adjustment levels by monitoring which forces produced optimal results for a given cycle speed, die set, and raw material. The enhancement of the data feedback significantly improves productivity and efficiency.

Candy Stamp Force Testing

Manufacturers of hard-shell candies often stamp text or logos on the candy shells. Stamping too hard breaks the candy shell and stamping too light results in an uneven or incomplete imprint. Using a test apparatus with an Interface Model WMC Mini Load Cell attached to hydraulic actuators was discovered to be an accurate way to measure the compression force required. Engineers determined the specific force needed to properly apply the imprint without breaking the candy shell using this solution.

Using Interface load cells on a press machine is a valuable investment that can help to improve the quality of the products being produced, extend the life of the press machine, and reduce the risk of accidents.

ADDITIONAL RESOURCES

Press Forming and Load Monitoring

Press Load Monitoring App Note

Hydraulic Press Machines and Load Cells

Metal Press Cutting Machine

Interface Solutions for Machine Builders

Force Measurement Sensors are Essential to Modern Industrial Machinery

 

ForceLeaders Summit Arizona

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Interface ForceLeaders Summit 2024 in Arizona happens on Tuesday, January 16, Our force measurement solutions engineers and experts will share valuable tips and experience using load cells, torque transducers, multi-axis sensors, and advanced instrumentation. Register to join the live conversation, ask your questions, and learn from industry professionals. The event takes place at ASU SkySong.

Read more

Fatigue Testing with Interface Load Cells

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Engineers rely on fatigue testing to ensure the safety and reliability of their product designs and structures. By understanding how materials behave under repeated loading, engineers can design components resistant to fatigue failure.

Fatigue testing requires accurate and reliable force measurement. Interface uses ‘fatigue-rated’ as an exact specification that defines a special class of load cell design and construction. Interface fatigue-rated load cells are designed to withstand the rigors of repeated loading, which makes them ideal for even the most demanding high cycle count fatigue testing applications.

In a typical fatigue testing setup, Interface fatigue-rated load cells are attached to the test specimen or the test machine, and the cyclic loading is applied according to the test protocol. The load cells continuously record the applied forces or stresses, allowing engineers and researchers to monitor how the material responds to repeated loading.

By analyzing the data from Interface load cells, researchers and material engineers can determine the material’s endurance limit, fatigue life, and stress-strain behavior. This information is invaluable for optimizing material selection, design, and manufacturing processes to enhance product performance and reliability while identifying fatigue and potential failure risks.

The use of fatigue-rated load cells and data logging instrumentation is necessary for most test and measurement applications, particularly when materials, parts, or assemblies are tested for destruction. This is true because an accurate record of the forces at every moment of the tests is the only way an engineer can analyze the stresses that occurred in the moments just before the ultimate failure. Read more about fatigue testing in our Interface’s Technical Library.

Interface Fatigue-Rated Load Cells

1000 Fatigue-Rated LowProfile® Load Cell

1000 High Capacity Fatigue-Rated LowProfile® Load Cell

1500 Low Capacity LowProfile® Load Cell

1208 Flange Standard Precision LowProfile® Load Cell

Profile of a Fatigue-Rated Load Cell

  • Design stress levels in the flexures are about one-half as high as in a standard LowProfile load cell.
  • Internal high-stress points, such as sharp corners and edges, are specially polished to avoid crack propagation.
  • Extraneous load sensitivity is specified and adjusted to a lower level than in a standard LowProfile load cell.
  • All Interface fatigue-rated load cells have a specified service life of 100 million fully reversed, full-capacity loading cycles.

No one can accurately predict exactly when the failure will occur, nor which part of an assembly will be the weakest link that eventually will fail. This is why high cycle count testing is the best way to measure fatigue life. To read more about fatigue testing and fatigue theory, consult Interface’s Load Cell Field Guide.

Fatigue Testing Applications

Interface fatigue-rated load cells are used in various industries, including aerospace, automotive, civil engineering, and manufacturing. They are used to test various products, from aircraft wings and landing gear to furniture and industrial machinery.

How Interface fatigue-rated load cells are used in fatigue testing:

  • Aerospace: Interface fatigue-rated load cells test the durability of aircraft wings, landing gear, and other aerospace components. This helps to ensure that aircraft can withstand the rigors of repeated takeoffs, landings, and flights. These load cells test the materials used for structures and even rockets.
  • Automotive: Interface fatigue-rated load cells test the fatigue life of engine components, chassis, and suspension systems. This helps to ensure that vehicles are safe and reliable and that they can withstand the stresses of everyday driving.
  • Civil engineering: Interface fatigue-rated load cells test the fatigue resistance of bridges, buildings, and critical infrastructure. This helps to ensure that these structures can withstand the loads they are designed to carry and are safe for the public.
  • Manufacturing: Interface fatigue-rated load cells test the fatigue life of industrial machinery, tools, and consumer products. This helps to ensure that these products are reliable and can withstand the demands of everyday use.

Watch how Interface load cells are used in this bike frame testing application.

Interface has specialized in fatigue-rated load cells and their applications since our founding in 1968. Our LowProfile® fatigue-rated load cells provide up to 100 million duty cycles, and the gaged sensors in every load cell are individually inspected, tested, and certified to meet our rigid performance standards.

It is imperative to choose the right load cell for your fatigue testing application. Load cells come in various sizes and capacities, so it is vital to choose one that is right for your fatigue testing application. Ensure you know the maximum load that will be applied to the load cell, the type of loading, the accuracy requirement, and the environmental conditions for testing. Consult with Interface application engineers to find the suitable load cell for your testing requirements.

ADDITIONAL APPLICATIONS AND RESOURCES

CPG Bike Handlebar Fatigue Testing

Interface Specializes in Fatigue-Rated Load Cells

Prosthetics Load and Fatigue Testing App Note

Furniture Fatigue Cycle Testing App Note

Aircraft Wing Fatigue App Note

 

How Does Tensile Testing Work?

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Tensile testing, also known as tension testing, is a type of mechanical test used to determine how a material responds to a stretching force. This test helps evaluate the mechanical properties of an object, such as metals, polymers, composites, and various other materials.

Performing a tensile test applies a load to specimen, and gradually increasing the load sometimes until failure or destruction. The tensile data is analyzed by using a stress-strain curve.

Interface stain gage load cells are commonly used in tensile testing due to their high precision and sensitivity. They work by measuring the strain in a material, which is directly related to the applied force. This strain data is then converted into force measurements. Learn more in Tension Load Cells 101.

Tensile testing is fundamental in test and measurement. It is used by researchers, testing labs, and engineers across industries including infrastructure, medical, manufacturing, aerospace, consumer goods, automotive, energy, and construction.

How Tensile Testing Works

Tensile testing is essential in materials science and engineering to understand the material’s behavior under tension and to ensure its suitability for specific applications.

First, a specimen of the material is prepared with a specific shape and dimensions. This sample is carefully controlled to meet testing standards based on the test plan.

Interface supplies a variety of load cells for these tests. The load cell is typically mounted in a tensile testing machine. The tensile test machine has two separate jaws, one of which will move away from the other at a controlled rate during the test. As it moves away, it is pulling on the material, stretching it until it the test is complete, or it breaks. This is also referred to as testing to failure or destruction. The controlled rate is called the strain rate, and materials will behave differently under different strain rates.

The specimen is then securely mounted in a testing machine, which is usually called a tensile testing machine or universal testing machine. The load cell is positioned in such a way that it bears the load applied to the specimen during the test.

Load cells are commonly used in tensile testing to measure and record the force or load applied to a specimen during the test. These sensor devices are crucial for accurately determining the mechanical properties of materials under tension.

The testing machine applies a pulling force (tensile force) to the specimen along its longitudinal axis. The force is gradually increased at a constant rate, causing the specimen to elongate.

As the tensile testing machine applies a pulling force to the specimen, the load cell measures the force in real-time. This force measurement is typically displayed on a digital instrumentation device or recorded by a data acquisition system.

The recorded data, including the applied force and the corresponding elongation or deformation of the specimen is usually plotted on a stress-strain curve for analysis. The stress-strain curve provides valuable information about the material’s mechanical properties, including its ultimate tensile strength, yield strength, Young’s modulus, and elongation at break.

Engineering Checklist for Tensile Test Plans

  • Identify the Purpose of the Tensile Test
  • Select the Material and Test Standard
  • Define the Mechanical Properties
  • Determine the Specific Mechanical Properties for Evaluation
    • Common properties include tensile strength, yield strength, modulus of elasticity (Young’s modulus), elongation, reduction in area, stress-strain curve characteristics
  • Establish Test Conditions
    • Include temperature, strain rate and testing environment
  • Define Sample and Specimen Requirements
  • Determine Measurement Accuracy Requirements
  • Prepare Instrumentation and Equipment
  • Plan for Data Recording and Reporting
  • Review Compliance Requirements and Safety Standards
  • Document Test Plan
  • Publish Verification and Validation Processes
  • Report Results

Defining measurement requirements for tensile tests by specifications is a crucial step in ensuring that the tests accurately and reliably assess the mechanical properties of materials.

Tensile Testing Terms to Know

Stress: Stress is the force applied per unit cross-sectional area of the specimen and is usually denoted in units of pressure. Stress is calculated by dividing the measured force by the cross-sectional area of the specimen. The load cell’s force measurement ensures that the stress values are accurate and precise. Simply, stress is the amount of force applied over a cross-cross-section.

Strain: Strain represents the relative deformation of the material and is the change in length (elongation) divided by the original length of the specimen. Strain is the amount of elongation in a sample as it is stretched or squashed.

Elastic Region: In the stress-strain curve, the initial linear region where stress is directly proportional to strain is known as the elastic region. Here, the material returns to its original shape when the load is removed.  As soon as a material is placed under any load at all, it deforms. Visually, the deformation may not be noticeable, but right away, the material is deforming. There are two types of deformation: elastic (not permanent) and plastic (permanent).

Yield Point: The yield point is the stress at which the material begins to exhibit permanent deformation without an increase in load. It marks the transition from elastic to plastic deformation.

Ultimate Tensile Strength (UTS): UTS is the maximum stress the material can withstand before breaking. It is the highest point on the stress-strain curve. If the material is loaded to its UTS, it will never return to its original shape, but it can be useful in engineering calculations, as it shows the maximum, one-time stress a material can withstand.  Load cells can detect the exact moment of specimen failure, such as fracture or breakage. This information is crucial for determining the ultimate tensile strength and other mechanical properties of the material.

Elongation at Break: Elongation at break is the amount the specimen stretches before it breaks, expressed as a percentage of the original length.

Load cells can also be used for real-time monitoring and control during the test. Test operators can set specific load or strain rate parameters to control the testing machine’s operation and ensure the test is conducted within specified conditions.

Load cells play a safety role by providing feedback to the testing machine’s control system. If the load exceeds a certain threshold or if the load cell detects an anomaly, the testing machine can be programmed to stop or take corrective actions to prevent damage to the equipment or ensure operator safety.

To discuss Interface products and experience in tensile testing, be sure to reach out to our global representatives in the field or contact us. We are always here to help!

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

Force Measurement Testing Improves Products and Consumer Safety

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Across every industry, force measurement solutions are utilized to improve product performance, safety and quality. Sensor technologies are used every day to test various consumer products’ weight, torsion, tension, compression, fatigue, impact, and materials.

Force measurement testing is used throughout the product development lifecycle, from concept and R&D, through engineering and testing, to manufacturing and distribution, leading to eventual utilization. Interface load cells are commonly integrated into actual consumer products for activation and to measure performance during use.

Interface force measurement solutions are also used in the testing of equipment, machines, and tools used in the production of all types of products and goods. Our products are used in industrial automation robotic arms as well as within lifting equipment deployed to move materials around a facility.

The key to all force measurement testing is accuracy and reliability of data, as well as selecting the right type of force sensor for the specific product being testing.

Types of Product Testing Applications Using Interface Measurement Solutions

  • Weighing Applications: Interface miniature load cells are often for product testing to measure the exact weight of consumer products, such as food, beverages, and electronics. This information is critical R&D, as well on the production line and to meet the exact product specifications. Our load cells help to ensure that the products are not underweight or overweight, and comply with regulations. Read more about Load Cells for Smarter and More Efficient Weighing
  • Material Applications: Interface LowProfile load cells are often found in product testing labs to assess the strength of materials used in consumer products such as plastics, metals, and mixtures of composites. The measurements gathered during the product testing safeguards consumers and confirms the product’s durability. Read Interface Solutions for Material Testing Engineers
  • Force Applications: Interface load cells, torque transducers, and instrumentation are used in complete test systems that examine the usability of products such as exercise equipment, appliances and electronics. The data acquired in shear, tensile and force testing is important to understand if the product meets design specifications, is easy to use and does not require excessive force to work.
  • Safety Applications: One of the most important product use cases for Interface measurement solutions is to test the safety of products such as furniture, toys and automobile features. It is a requirement for every maker of products that are not hazardous and will not cause injury to consumers. Read Interface Solutions for Safety and Regulation Testing and Monitoring

To give you a better idea of how our load cells and instrumentation are utilized in distinct types of product tests, we have included a few application notes below outlining real-world examples of force testing projects.

Bicycle Helmet Safety and Impact Product Testing

A high production bicycle manufacturing facility set up a product testing lab to measure the impact of the safety of their helmets when dropped from different heights onto a flat surface such as an anvil. This test is necessary to ensure consumer safety and that the products are made with the highest quality materials to protect the rider. Interface suggests installing the 1101 Compression-Only Ultra Precision LowProfile® Load Cellat the bottom of an anvil. The bike helmet is then dropped from multiple heights and at multiple angles onto the anvil. The measurements from impact are then recorded and logged throughout the product testing using Interface’s INF-USB3 Universal Serial Bus Single Channel PC Interface Module with supplied software. Every design or material change runs through the same rigorous testing protocols using these high accuracy measurement solutions.  Read CPG Bike Helmet Impact Test

Product Weighing of Consumer Water Bottles

A manufacturer of glass bottled water needs to dispense the exact amount of fluid into each bottle and then weigh the water bottle to ensure it is at the labeled weight on the product packaging. The product testing of the manufacturing equipment is used to minimize waste and to meet the weight requirements to ensure consumer satisfaction. Interface suggests using the MBP Miniature Beam Load Cell and attaching it under a plate or platform where the water bottle is placed on while it is being filled with fluids. The force weight is measured by the MBP Miniature Beam Load Cell and connected to the 9870 High Speed High Performance TEDS Ready Indicator where results are captured, displayed, and logged for quality control. Read CPG Water Bottle Dispensing and Weighing

Product Test Lab Conducts High Volume Tensile Force Testing

A product test lab is constantly requested to conduct a series of tensile force tests on different samples and materials until failure. These materials include plastic, steel, or woven fabric, and are utilized in the design and manufacturing of several consumer products. The lab professionals want to measure tensile strength, yield strength, and yield stress for every submitted product material sample. For the tensile test stand, we recommend using Interface’s 1200 Standard Precision LowProfile™ Load Cell be installed into the test frame. As the tensile test is conducted, force results captured by the load cell and extensometer are synchronized through the SI-USB4 4 Channel USB Interface Module. The results are displayed on the customer’s computer with supplied software. Learn more by reading Material Tensile Testing.

Interface’s high precision force sensor technologies used in robotics have revolutionized the manufacturing of consumer products. With automated assembly lines and robotic arms taking charge, these machines work efficiently to mass-produce consumer goods. Quality control of all the products we provide you for testing is one of the main focuses of Interface, as we want to keep your customers happy and safe.

Interface’s experienced team are renowned specialists in force, torque and weight measurement manufacturing and technology. Our depth of knowledge and wide range of capabilities create custom solutions of all types, whether special transducers made to your exact specifications or complete customized sensor, instrumentation, and software systems. We collaborate with you to ensure the product specifications you need are designed to match your precise requirements.

ADDITIONAL RESOURCES

Introducing the Interface Consumer Product Testing Case Study

Interface Solutions for Consumer Products

Force Measurement is Reducing Waste and Automating the Consumer Packaging Industry

Applications for Consumer Products and Packaging

Load Cells for Consumer Product Applications

Why Product Design Houses Choose Interface

Testing Labs Choose Interface High Accuracy Products

Interface Solutions for Material Testing Engineers

Force Measurement Enables Precision Drone Aerial Displays

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Many of the largest outdoor celebrations around the world are utilizing drone technologies quipped with LED lights working in complete unison to create amazing displays. From coronations and holidays to world sporting events, these incredible lighted airborne spectacles are growing in scale, design and capabilities.

The use of drones for aerial displays are on the rise. Swarms of drones offer new possibilities for creating captivating light shows and visual displays that can accompany or even replace certain aspects of traditional fireworks. They offer a unique aerial perspective by flying at various altitudes and angles. They can be programmed to create specific patterns, shapes, and movements in the sky, allowing for more intricate and tailored displays. Drones can also be equipped with different lighting effects and colors, offering a wide range of visual possibilities.

Drone shows provide stunning visuals and add a new dimension to sky visual arts; however, safety is still primary in design and use. Though drones can be programmed to fly predefined paths and execute specific maneuvers, ensuring that they stay at a safe distance and do not provide risk or harm is critical to use.

Safety and regulation of a flying object is determined by the location and governing bodies. As increased visual arts using drones grows, testing and design is paramount to ensure these objectives are met and held to standards for sake of the manufacturer, operator and the viewing public.

How does Interface take part? Sensor technologies have a big hand in making drone and areial displays due to the necessity of force measurement in designing and evaluating the drones for the launch, precision movements, lighting effects and descent. Interface products are used by drone manufacturers to design these flying machines to conduct different tasks, from deliver packages as well as for testing motor torque and center of balance.

Due to Interface’s experience in supplying measurement devices for aerospace, automotive, industrial automation, we have several load cells, miniature transducers and instrumentation solutions perfect for use in drone application. Our wireless sensors and digital instrumentation are particularly attractive to drone makers because they eliminate the need for wires and facilitate real world testing. For more unique applications, Interface also offers custom solutions and can work with the original equipment manufacturers to understand their specific needs and deliver a sensor suited for those needs.

The use of drones for creating light shows has become a safe and more environmentally friendly alternative to fireworks, often being used at big venues across the country. Force sensors are used in the testing of these types of drones to ensure they can manage the weight of the equipped LEDs.

Drone Show Application

Drone fireworks have become increasingly popular in recent years. During drone firework and light shows, drones are equipped with LED lights, flying in synchronized patterns to create displays in the night sky. A force measuring and monitoring system is needed for the weight of the LED or the forces generated by fireworks explosions.

Interface suggested four of its WMC Sealed Stainless Steel Miniature Load Cells, which were installed to the necessary propeller motors measure the attached LED lights. Each were connected to a WTS-AM-1E Wireless Strain Bridge Transmitter Modules. The WMC’s measure the weight of the LED lights to monitor weight shifting or any uneven weight distributions. Data results were wirelessly transmitted directly to the customer’s laptop through the WTS-BS-4 Wireless Base Station, or to the WTS-BS-1-HA Wireless Handheld Display for Multiple Transmitters. The four WMC load cells accurately measured and monitored the weight of the attached LED light and maintained stability of the propeller motors to when the drone was in air performing the fireworks show.

Interface, a US manufacturer of force measurement solutions, will be closed on July 4th. We will resume our normal business hours the following day.

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 and Testing Lab Applications

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Test and measurement impacts nearly every industry.  At Interface, we classify Test and Measurement (T&M) as it’s own solutions market. Though testing is generally a service, the accuracy and quality equipment and tools that are required for performing these T&M services has created an industry in itself.

Throughout the Test and Measurement industry, there are several different classifications and testing lab types. Each of these different testing labs provide unique equipment for different forms of testing depending on the application, system or component. These different types test labs include:

  • Structural testing labs perform tensile, compression, bending, fatigue and hardness testing on materials, components, or assemblies.
  • Environmental testing labs evaluate the impact of environmental factors on products, components, or materials performing temperature, humidity, salt spray, and vibration testing.
  • Electrical testing labs determine the electrical properties of components or products using insulation resistance, electrical continuity, and dielectric strength testing.
  • Chemical testing labs determine the composition and purity of materials using chromatography, spectroscopy, and elemental analysis.
  • Product safety testing labs ensure that products meet safety and regulatory standards with flammability, toxicity, and durability testing.
  • Calibration testing labs ensure that measuring instruments and equipment are accurate and reliable. Common disciplines include force, torque, pressure, temperature and physical calibration. Read more: Interface Calibration 101
  • Non-destructive testing labs evaluate the integrity of materials with ultrasonic testing, magnetic particle inspection, and radiography.

Here at Interface, we are deeply ingrained in supplying nearly every type of testing lab out there with precision T&M devices, from the world’s best force measurement sensors to advanced instrumentation. Interface offers one of the most diverse force, torque, and weight related force sensor product lines in the market. It is why labs prefer Interface. In addition to our expanding line of  data acquisition systems, software and accessories, T&M engineers and lab pros find Interface as a one-stop-shop for simple and complex testing projects.

Testing Lab Applications Using Interface Products

Material Testing Lab – Press Form Monitoring

Customer Challenge: Press forming is a method to deform different materials. A force measurement solution is required to monitor the forces being applied by the press forming machine to ensure quality control and traceability during the production process.

Interface Solution: For large press forming machines, Interface recommended installing the 1000 High Capacity Fatigue-Rated LowProfile™ Load Cell. When the material was placed under the punch plate to form a shape, the force applied was measured and results were sent to the INF-USB3 Universal Serial Bus Single Channel PC Interface Module, where results can be graphed and logged.  Read: Press Forming and Load Monitoring

Medical Testing Lab – Specimen Research Linear Test Stand

Customer Challenge: Medical experts need the best equipment during research of multiple specimens. In this case, a medical researcher needed to monitor the load force of their linear actuator that uses a needle to collect material from the desired specimen.

Interface Solution; Interface’s SuperSC S-Type Miniature Load Cell was easily installed into the linear test stand. A needle with a gripper on the end was installed on the lower end of the SuperSC. As the needle is pushed to collect material of the specimen, the load feedback is captured using the 9330 Battery Powered High Speed Data Logging Indicator.  Read: Specimen Research App Note

Safety Test Facility – Bike Helmet Impact Test

Customer Challenge: A company wanted to test the impact of a bike helmet when dropped from different heights, onto a flat surface such as an anvil. This test is necessary to ensure consumer safety, and that their products are made of the highest quality until sold to the public.

Interface Solution: Interface suggested installing our 1101 Compression Only Ultra Precision LowProfile™ Load Cell at the bottom of an anvil. The bike helmet was then dropped from multiple heights, at multiple angles, onto the anvil. The measurements from impact were then recorded and logged using our INF-USB3 Interface Module.  Read: CPG Bike Helmet Impact Test

Product Test Lab – Touch Screen Force Testing

Customer Challenge: Touchscreen kiosks used in restaurants, retail and entertainment venues all need various tests to be performed to ensure functionality and sensitivity. One of those tests are force tests that touch screens to withstand high use by all types of consumers.

Interface Solution: Interface’s SMTM Micro S-Type Load Cell was installed on the customer’s force testing machine. The touchscreen was laid flat under the machine, and force tests were conducted in different locations of the touchscreen. With supplied BlueDAQ software, results are captured and reviewed using the 9330 Battery Powered High Speed Data Logging Indicator through an SD card.

These are just a few examples of where Interface products are involved in a wide variety of different testing labs and how T&M engineers are utilizing them. To learn more, check out our new Testing Lab Essentials webinar, which can be found here.


ADDITIONAL RESOURCES

Testing Lab Essentials Webinar Recap

Introducing the Interface Consumer Product Testing Case Study

Interface Solutions for Safety and Regulation Testing and Monitoring

Electric Vehicle Structural Battery Testing