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Stainless Steel Load Cells 101

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Different materials are used in designing and building force sensing products based on the environmental conditions. The choice of materials is important when considering specifications, test and measurement environment, and use case. One of the best metals for keeping environmental factors away from the electronics of a load cell is stainless steel.

The three main metals used in making load cells and other force sensing products is aluminum, steel, and stainless steel. The output signal performance for stainless steel load cells is in the middle of steel and aluminum standards.

The main benefit of stainless steel is the fact it is the best material to use in a corrosive environment because of the metal’s environmental resistance properties. The downside to stainless steel is that it is a bit more difficult to machine; however, it does only require a simple heat treatment process. It is also the most expensive metal of the three and has the highest hysteresis.

Why choose stainless steel over the more cost-effective steel and aluminum options, especially when it is not the strongest or provide the best signal output? Interface recommends stainless steel when the user needs to collect data from a load cell in a hazardous environment or under harsh conditions.

Interface offers stainless steel sensors as part of our hermetically sealed ruggedized load cell product lines. We make stainless steel load cells of all sizes and capacities, including stainless steel miniature load cells, load washers, and customized load pins. Using stainless steel not only keeps users safe, but it also allows for high-quality, accuracy and reliability in extreme environments.

These specialized load cells and force measurement solutions are designed and manufactured so that our products are safe for use in hazardous gas and dust environments when installed per applicable installation instructions. These components play an integral role in the safety of those working in dangerous environments in particular industries like oil and gas, mining, aerospace, automotive and more.

Some of our stainless-steel load cell options include:

To help keep individuals and workplaces safe, manufacturers create tools and equipment that are protected from the elements in these environments and will not expose electronics to hazardous environments. Interface’s contribution to this is our ruggedized load cells, many of which are made with stainless steel materials due to its strength in these harsh environments. We also carry a specialized line of intrinsically safe products.

There are hundreds of thousands of engineers and manufacturers that design solutions for or work in hazardous environments. Whether its operating inside of facilities with large machines with intricate moving parts, working hundreds of feet in the air repairing a bridge, or deep within a mine shaft, these professionals put themselves in danger every day by the nature of their work. The solutions they use to measure force must provide the type of specifications that are suited for these types of conditions.

To learn more about these products, join the conversation Ruggedized Solutions for Test & Measurement, where we discuss:

  • Defining Ruggedized
  • Environmental Stresses and Harsh Condition Categories
  • Standards and Ratings
  • Structural and Material Options
  • Ruggedized Test and Measurement Devices
  • Sealed Products and Enclosures
  • Extreme Temperatures and Cycling
  • Exposure to Moisture and Submersibles
  • Test and Measurement Applications Using Ruggedized Products
  • Do’s + Don’ts
  • FAQs

This is a live event that takes place Tuesday, November 15, 2022. To register or get a copy of the recorded event, go here.

 

Back to School Force Measurement Essentials

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Interface has a long history of collaborating with colleges and universities around the world. From individual engineering students testing the force of launching miniature rockets to supplying onsite test labs with load cells and equipment for R&D, we are a resource for higher education learning and experimentation.

In our view, innovation and exploration have no boundaries. What validates new ideas and manifests problem solving requires modern and reliable tools that support student’s projects and activities. Its key to any program’s success. It is also why we are proud to be known around the globe as a leader in building and designing force measurement products that facilitate these initiatives through higher learning.

It is very inspiring to see new engineering students, future metrologists, and soon-to-be graduates designing new medical devices, creating new spacecraft and interplanetary vehicles, testing materials used for miniature consumer products and of course, building plenty of new robots and AI machines.

In our view, every university or college should have Interface force measurement products on hand to support these types of educational test and measurement research projects. Here is a simplified list of basic sensor products to get started.

Force Measurement Essentials for Higher Learning

  • Precision load cells in diverse designs and capacities
  • S-type load cells (load beams)
  • Miniature load cells and load buttons
  • Multi-axis sensors
  • Calibration grade equipment
  • Instrumentation
  • Wireless sensor technologies
  • Rotary and reaction torque transducers
  • Verification load frames

Our investment in supporting educational programs runs deep into our history as a company. You will find our founder’s name on the Richard F. Caris Mirror Lab at The University of Arizona. Following in his commitment to education, the Richard F. Caris Charitable Trust II continues to support STEM programs including sponsorship of the International Science and Engineering Fair (ISEF).

We drive to ensure that students who have a passion for science, technology and engineering have access to the best force measurement sensor technologies. It is why we offer a standard discount to all students and education institutions. You can learn more about our education support here. We know that learning requires the best tools, and we want to make sure that every student has the most accurate, quality and precision load cells available today.

As with all inquisitive minds, we thought it would be interesting to share what are other university and colleges buying for their learning programs and campus labs.

Top 10 products for testing projects and campus lab studies:

  1. 1200 LowProfile Load Cells are our most popular load cell, available in standard and high-capacity features.
  2. 1010 Load Cell model is a fatigue-rated low profile load cell in our 1000 product family, offering various capacities and functions.
  3. 2420 Load Cell is one of our stainless-steel standard and high-capacity load cells in our 2400 model series.
  4. 1500 Low-Capacity Load Cell designs are common requirements for applications where low sensitivity to eccentric load is important.
  5. WMC Sealed Stainless Steel Miniature Load Cell has an environmentally protected construction that comes in a variety of model capacities and configurations. It is great for small spaces and industrial applications.
  6. 3-Axis Load Cells are extremely popular multi-axis sensors designed to provide more testing data and often paired with BSC4 instrumentation. They are ideally suited for aerospace, robotics, automotive, and medical research testing applications.
  7. 6-Axis Load Cells are growing in popularity, for cost benefit and their unique ability to simultaneously measure Fx Fy Fz Mx My Mz.
  8. SSM Miniature Load Cells are one of many popular general-purpose s-type designed load cells. You call learn more about all our s-type models here.
  9. Torque Transducers of all types are used by university programs, engineering departments and metrology labs. There are many different options including rotary and reaction torque solutions. For all options, start here to choose the right one.
  10. Load Washer Load Cells are used because of the unique through-hole designs. They come in various models and dimensions, along with capacity options.

As with any project, the questions of what you want to measure, the applications, and where you are sending the data, are all core to choosing the sensor and instrumentation that is best suited for the learning environment or program.

Speaking of where to send the data for performance monitoring and analysis, the five most favorite types of instrumentation selected by university students and engineering labs include:

  1. DMA2 Signal Conditioner
  2. 9840 4-Channel Intelligent Indicator
  3. 9825 General Purpose Indicator
  4. BX8-AS BlueDAQ Series Data Acquisition System
  5. SGA AC/DC POWERED SIGNAL CONDITIONER

If you are heading back to school and thinking that it is time to revamp the testing lab or need new force measurement equipment, be sure to reach out to our education application engineers. They have years of experience and can help you get exactly what you need for your project and programs.

Be sure to tune into our Load Cell Basics, for answer to common questions about using these highly accurate sensors for your test and measurement projects. You can find all our Interface videos on our YouTube channel here.

If you are looking to explore more technical resources, be sure to go to our online support area and subscribe to our blogs for weekly updates.

ADDITIONAL EDUCATIONAL RESOURCES

Types of Force Measurement Tests 101

Torque Transducers 101

Multi-Axis Sensors 101

S-Type Load Cells 101

Mini Load Cells 101

Force Measurement Instrumentation 101

Load Washers 101

Couplings 101

Load Shackles 101

Load Pins 101

Tension Links 101

Load Button Load Cells 101

Strain Gages 101

Load Cell 101 and What You Need to Know

Calibration Systems 101

Force Measurement Accessories 101

TEDS 101

Shunt Calibration 101

 

Force Solutions for Medical Tablet Forming Machines

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In the medical and healthcare industry, accuracy is an absolute imperative in the devices used in every stage including diagnosis, surgery, health monitoring and even after care. This also applies to the specialized equipment used by pharmaceutical manufacturers, in both design and maintenance, when producing medicine and other healthcare related products.

When it comes to product development in the United States, not only do med devices and pharmaceuticals need to pass rigorous FDA regulations, but they must also be proven to serve patients and doctors safely. This results from robust test and measurement data requirements before seeking clearance. These same types of fundamental safety requirements of testing are also standard in most developed countries when seeking approvals before release.

Medical industry manufacturers turn to Interface because our force measurement solutions are designed for high performance test and measurement, in both accuracy and reliability. There is also a high demand for Interface’s ability to customize solutions to meet the exact requirements of these sensitive applications.

In a variety of medical device applications, one noted example is Interface’s role in providing various miniature beam and in-line load cell solutions with ten times the overload protection to protect against accidental shock loads. Our torque transducers provide rotary and reactive measurement to accurately track light movements required to control prosthetic fatigue testing, surgical equipment, knee or hip replacement and other medical devices. Other Interface solutions include multi-axis sensors for multiple channels of measurement in one housing. Read more about these types of medical applications here.

Interface provides force measurement solutions for a wide variety of products and machines that help biotechnology and pharmaceutical product engineers to design, test and manufacturer devices of all shapes and sizes. When it comes to equipment used in the manufacturing of medicine, Interface products are used to optimize production and reduce waste.

TABLET HARDNESS TESTING

In this application, a pharmaceutical tablet producer wanted to test and monitor the hardness of the tablets being created in their tablet forming machine. Interface’s SML Low Height S-Type Load Cell was mounted to the hardness device inside the tablet forming machine. The SML Low Height S-Type Load Cell was then connected to the 9870 High-Speed High Performance TEDS Ready Indicator to record the force measurements.

TABLET FORMING MACHINE OPTIMIZATION

For a tablet forming machine optimization project in Europe, a pharmaceutical tablet producer wanted to monitor the forces applied by the tablet forming machine in an effort to understand the relationship between raw material, die set, forming force, and motor cycle speed. The goal was to improve productivity and efficiency of the tablet forming process, while reducing losses such as cracked tablets or voids, by adding a dimension of feedback that could be used to assign specific press adjustment criterion for given inputs. An Interface Model WMC Sealed Stainless Steel Mini Load Cell 10K lbf 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.

TABLET MACHINE HARDNESS CALIBRATION

Our partners in Germany also had the opportunity to work on a calibration project for a device that tested the hardness of tablets, such as a medicine in tablet form. The reason for this type of device is because medical tablets are overly sensitive to compression force when being formed and when ready to be shipped. If the tablets hardness isn’t tested properly, consistency in size and shape is nearly impossible. The need for force testing is because the device must provide very minimal and accurate forces to the tablet for product consistency. When this is applied to tablets that are used in medicine, accuracy in dosage is fundamental and an absolute necessity.

The customer required a unique solution to properly re-calibrate the device. They needed a mini-load cell the size of a sugar cube that replaces the tablets and fits horizontally in the tablet test-box. A special cable exit was also critical for the compression only calibration application.

Interface provided an MCC Miniature Compression Load Cell which can measure forces on its side with a special cable exit on the flat side that attaches to a calibration indicator, such as the Interface battery powered handheld indicator and datalogger Model 9330. The MCC load cell calibration set compares the applied forces with the hardness tester to make sure that the tablet hardness tester uses the correct force for future tablet hardness tests. The BlueDAQ software included in our indicator helps to log and compare the data of the MCC reference load cell.

In the past, the customer’s medical tablet machines had to be rebuilt for calibrations, or a complex mechanism had to be integrated to enable vertical calibration. With Interface’s new solution, the customer successfully verified and calibrated the tablet hardness tester machine horizontally to conduct accurate hardness testing on tablets in the future. Interface’s MCC Miniature Compression Load Cell was perfect due to its small size, and convenience in measuring the forces on its side.

Read more about these healthcare and medical applications in these posts:

Interface Solutions for Medical Devices and Healthcare

Interface Load Cells in Medical Applications

Interface Ensures Premium Accuracy and Reliability for Medical Applications

To see more of Interface’s solutions designed for the medical device industry, visit our solutions page at www.interfaceforce.com/solutions/medical-healthcare/.

Interface Solutions Designed for Infrastructure Challenges

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All infrastructure, big and small, needs to be designed with safety and durability in mind. Take for instance the massive amount of design, engineering and quality control that goes into a suspension bridge requires testing before and after it’s built. Not only does it need to be constructed with supreme accuracy, but it also needs to be tested and monitored constantly to ensure it’s safe for use, especially as often infrastructure projects are exposed to extreme elements.

Among the various tools and technologies used to build and test infrastructure designs, sensors play a substantial role. Interface has served infrastructure industry suppliers and customers since our founding more than 50 years ago. Force and torque measurement products including Interface load cells, torque transducers, load pins, load shackles, tension links and instrumentation are involved in a wide variety of infrastructure applications including construction and maintenance of bridges, roads, transportation systems, communication structures, water and electrical facilities, and numerous inventions that are used to build, test, support, maintain and monitor performance of these critical projects around the world.

Accuracy and reliability of Interface solutions are a key factor in measuring structures and components that are exposed to hazardous or weather-related conditions, heavy loads and constant use. Our precision load cells, rugged load pins, wireless and digital instrumentation, along with multi-axis sensors and robust torque transducers are a top choice for those engaged in infrastructure engineering projects and testing.

A few examples of how Interface products have been used on infrastructure applications over the years are noted below. The following examples are also found with many others here /solutions/infrastructure/. 

Concrete Dam Flood Monitoring

A customer was looking for a solution to monitor a concrete dam and be notified when it reached high flooding levels. Interface provided WMC Miniature Sealed Stainless Steel Load Cells with multiple WTS-AM-1E Wireless Acquisition Modules connected to the load cells. This solution proved to be small enough and perfect for measuring compression and tension on the dam. The WMC Modules are installed on the arch of the dame and transmit data and notify the customer through Interface’s Wireless Telemetry System when flooding occurs. Check out the application here.

Hydropower Turbine Generator Monitoring

When a customer wants to monitor and detect turbine generator faults in their hydroelectric power plant located on a river, Interface can provide a T2 Ultra Precision Shaft Style Rotary Torque Transducer and attach it to the turbine generator with Interface’s Shaft Style Torque Transducer Couplings. When water from the river pushes through the penstock to the outflow, it moves the turbine blades, creating electricity through the generator shaft. Torsion measurements can be graphed and logged with the 9850 Torque Transducer and Load Cell Indicator catching any unusual fluctuations and vibrations. Using this solution, the customer can monitor, graph, and log the torque measurement results of the turbine generator. Learn more here.

Bridge Seismic Force Monitoring Solution

A customer wanted to monitor seismic activity that occurs to a bridge using force sensors to continuously monitor activity before, during and after earthquakes. They also wanted a wireless solution to avoid running long cables on the bridge. Interface provided an LP Load Pin custom made to fit the need. The load pin was used in conjunction with our WTS Wireless Telemetry System to monitor the force on the load without cables. Using this solution, the customer was able to monitor continuously, log results to the cloud and review the data. Read more here.

This is just a brief example of the applications throughout the infrastructure industry that Interface supports. A long list of additional applications that use Interface products includes:

Highways and Bridge Construction and Monitoring

Concrete Dam Measurement and Flood Monitoring

Transportation Heavy Equipment Testing

People Movers for Airports

Train Brakes Testing

Power Generation Equipment

Geotechnical Monitoring

Road Load Tests

Weight Bridges and Transportation Scales

Truck and Aircraft Weighing

Housing Mainframe and Skyscraper Construction Monitoring

Building Foundation Capacity Measurement

Bridge Seismic Force Monitoring

In-Motion Rail Weighing

Cranes and Heavy Object Lifting

Structural Testing and Telecommunication Structures

Conveyor Belts

To learn more about Interface and our solutions for Infrastructure and other key industries, please visit our solutions page at www.interfaceforce.com/solutions/.

Trending at Interface

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As in years past, the Interface team looks at trends in what products caught the greatest interest of our customers, along with those that are top sellers throughout the year.

We’ve gathered our key findings based on searches and purchases by industry-leading engineers, product designers, testing labs, manufacturers and T&M pros using Interface solutions. Here is a summary of the trends over the past 12 months.

TRENDING PRODUCT CATEGORES IN 2020

#1 LOAD CELLS – There is no surprise that topping the 2020 list is what we are best known for, our precision load cells. When quality, accuracy, and reliability matter Interface Models 1000, 1100, 1500 and 1600 in various capacities ranked highest in interest. What’s the top seller? The 1200 Standard Precision LowProfile® Load Cell ranks number one, with the 1000 Fatigue Rated Load Cell in second place.

#2 TORQUE TRANSDUCERS – Torque is definitely trending, taking the number two spot. Hot picks are the MRT Miniature Flange Style Reaction Torque Transducer, T8, T25 and our proprietary AxialTQ. Read Torque 101 here.

#3 INSTRUMENTATION – One of the most popular adds to any purchase is instrumentation like the DMA2, SGA, 9320 or 9840.

#4 MULTI-AXIS SENSORS – Watch Dimensions of Multi-Axis Sensors to learn more about why multi-axis is trending, including the popular 3AXX 3-Axis Force Load Cell.

#5 MINIATURE LOAD CELLS – Interface’s expertise for engineering force measurement applies to a wide range of capacities and sizes, including Interface Mini best sellers: SSM and SSM2 Sealed S-Type Load Cells, SM-S Type and SMT Miniature Load Cells followed closely by MB, MBP, WMC Stainless Steel Miniature Load Cell and SMTM models.

#6 CALIBRATION SYSTEMS – These Interface systems are growing in popularity. Read why here.

#7 CALIBRATION SERVICES AND REPAIR ­­­– Our customers can depend on us for our services. Click here to request service today.

#8 DIGITAL INSTRUMENTATION – Interface has expanded our line of digital instrumentation based on growing demands. See what’s hot here, like our BX8.

#9 LOAD PINS, LOAD SHACKLES AND TENSION LINKS – A new entry to the trends list this year based on the high interest for these specialty products including the wireless options.

#10 LOAD BUTTON LOAD CELLS – Robotics, automation and testing in confined and compact spaces has raised greater interest in highly-accurate load button load cells, including our new ConvexBT and our popular LBM and LBS models.

Based on feedback and our analysis of trends, we know that getting exactly what you want is as important as the product category selection. Engineered to order, custom solutions and complete systems are rapidly growing in demand as Interface customers evaluate ways to embed sensor technologies into products or utilize advances sensor technologies, along with wireless and Bluetooth communication capabilities.

Take a look at why Interface Engineered to Order Solutions continue to be in high demand by helping our customers get exactly what they need.

Interface has played an important role in shaping the test and measurement industry and though we know our standard catalog is robust, we are always here to get the exact product for our customer’s exact requirements. How can we help you get what you want in 2021 and beyond?  Reach out and let’s start the conversation now.

Interface Load Cell Indicators 101

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At Interface, our claim to fame is that we offer the most accurate and reliable force measurement devices on the market, from load cells to torque transducers and everything in-between. However, no test is complete without the system used to gather the data to evaluate performance results. That’s why we provide a wide variety of instrumentation solutions that include signal conditioners, output modules, high speed data loggers, portable load cell indicators, and weight indicators to complete any testing system.

Among the Interface instrumentation products, the most frequently purchased with a force measurement devices are our load cell indicators in various models including handheld, digital, wireless, multichannel, programmable, output modules, analog and bidirectional.

What is a load cell Indicator?

A load cell indicator is a high-accuracy device connected to the output of a load cell to amplify and display the value of the measured load force and weight. Load cell indicators are often needed where the force, load, or weight measurement needs to be visually displayed for the user and displaying the results on a PC is not feasible or desired in the testing environment. For example, testing in the field or confined spaces can make it impossible to connect directly to a PC. In these situations, indicators are used to quickly review and capture force data in real-time.

A few key benefits of load cell indicators include that they provide stable excitation voltage and converts force measurement sensor signals to a digital display. Commonly available features include analog or digital output, selectable digital filtering, peak and valley monitoring and set-point outputs. Additionally, each load cell indicator can be used to connect to four (or more) digital load cells and can display individual readings or the sum of all connected load cells.

Need a load cell indicator?

Interface offers a wide variety of load cell indicators in multiple configurations. Interface indicators come in single to multi-channel weight transmitters and can be found in handheld and portable designs. Things to consider when selecting an indicator are internal sample rate and update rate of the output. A few of our most popular indicators include:

9890 Strain Gage, Load Cell, & mV/V Indicator

Model 9890 is a powerful multipurpose digital load cell meter ideal for weight and force measurement applications. With a max current of 350 mA at 10 V, it can support up to 12 load cells making it perfect for multipoint weight measurement purposes. The dual-scale capability allows for displays in two different units of measure. See a demonstration video here.

9320 Battery Powered Portable Load Cell Indicator

Model 9320 is a bipolar 7-digit handheld meter featuring two independently scalable ranges, peak and valley monitoring, display hold, mV/V calibration, and a power save feature. Typical battery life exceeds 45 hours of continuous use and 450 in low power mode. IEEE1451.4 TEDS Plug and Play compliant.

482 Battery Powered Bidirectional Weight Indicator

Model 482 is battery powered, bidirectional, and comes in a NEMA 4X stainless enclosure. Standard options include 523,000 internal counts, 0.8-inch LCD 6-digit display and a measurement rate that goes up to 40 Hz. Available options include analog and relay outputs.

1280 Programmable Weight Indicator and Controller

The Interface 1280 Series programmable digital weight indicator with color touchscreen, web server view and multiple protocol types delivers uncompromising speed for today’s operations and expansive options for tomorrow’s requirements.

INF4-Ethernet IP Weight Transmitter and Indicator

The Interface INF4-Ethernet IP weight transmitter and indicator has a six-digit red LED display (8 mm height), space-saving compact design, four buttons for the system calibration, and a six-indicator LED.

See all the indicator options here.

Load Cell Indicator Application Note

The application note below provides an example of the benefit of a load cell indicator in real-world use within the medical industry.

A pharmaceutical tablet producer wanted to monitor the forces applied by the tablet forming machine to understand the relationship between raw material, die set, forming force, and motor-cycle speed. The goal was to improve productivity and efficiency of the tablet forming process while reducing losses, such as 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.

The indicator was selected as the data collection device because a laptop could have interfered with the test cycle due to space restrictions. The output of the load cell was connected to the 9320 Portable Load Cell Indicator and set aside so that the cable did not interfere with the cycle and no snagging would occur. A cable tie was used to stow aside the cable and to ensure there was enough clearance for the entire cycle.

After analyzing the data, the tablet producer was able to quantify adjustment levels by monitoring which forces produced the most optimal results for a given cycle speed, die set, and raw material. Productivity and efficiency were greatly improved by the enhancement of the data feedback.

To learn more about Interface load cell indicators and for a complete list of products, you can download our instrumentation brochure here. You can also read more about instrumentation options in test and measurement in this post.

Force Measurement Solutions for Mobility Markets

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One of the tenets in addressing urban mobility is innovation.  As populations grow around the world, addressing how people get from here to there is part of a challenge and opportunity.  Investments are growing in this sector, as experts and designers look to how to increase efficiency and performance in vehicle markets.

Interface has long been a supplier of test and measurement solutions to industries that play a critical role in mobility, from vehicle manufacturers to infrastructure planners and builders. In our latest case study, we look at some of the innovative ways our solutions are being used to advance technologies and capabilities in transportation.

If something moves, it likely needs force and torque testing for reliability, safety and performance. With the evolving trends in urban mobility, Interface is working with makers and builders of all types of transportation solutions for unmanned vehicles like drones and autonomous vehicles, as well as alternatively fueled and electric vehicles.

READ OUR NEW CASE STUDY: INTERFACE’S CRUCIAL ROLE IN VEHICLE AND URBAN MOBILITY MARKETS

Interface customers utilize our standard and custom products in the vehicle and mobility markets to:

  1. Test the force and torque of components for validation or for design improvements
  2. Integration of sensor technology into a component or product for functional real-time performance data

These products include Interface load cells, mini load cells and subminiature load button load cells, rotary and reaction torque transducers, instrumentation, and accessories. For the growing trends for digital requirements in testing and OEM solutions, our wireless and Bluetooth solutions are commonly used in these markets.  Interface is also frequently engaged on specific customer requests for engineer-to-order products and customized solutions.

Here are four use case scenarios of Interface solutions used in the vehicle and mobility markets:

Brake Pedal Testing

Interface’s Brake Pedal Load Cell BPL-300-C was installed on a brake pedal and then connected to a BTS-AM-1 Bluetooth Low Energy Strain Bridge Transmitter Module, which collects and transmits data to our BTS Toolkit Mobile App. This solution allowed the customer to record and review data from a mobile device while out on a test track. READ MORE HERE.

Drone Delivery Systems

Interface supplied four WMC Sealed Stainless Miniature Load Cells to measure the payload weight and  for the detection of in-motion shifting and uneven distribution of the package weight. As the load cells detect this data, it provides a signal to the propeller to increase RPMs on the propellers and adjust balance and weight distribution inflight. WATCH HERE.

Electric Vehicle (EV) Battery Testing

Compression testing performed on EV batteries is critical for performance and safety. As an EV battery is charged and stores more electrons, it swells. If the packaging housing the batteries does not compensate for this swelling in the design, failure is likely. Interface can supply a WMC miniature load cell. The load cell will measure compression force as a battery goes through charge cycles on a test stand to determine the force given off as the battery swells. This allows our customers to design the proper packaging for the batteries. Read more about the future of EV markets and testing here.

Engine Performance Testing

Force and torque sensors are used with a dynamometer, which isolates the engine’s power output to help quantify its overall performance.  In this application, a  precision SSMF Fatigue Rated S-Type Load Cell is attached to a torque arm to “feels” the torque from an engine loading system. The fatigue rating on the load cell allows it to accurately measure performance for extended cycles. A signal conditioner is used to connect out from the load cell to a computer to ensure clear transmission of data to accurately measure torque being produced by the engine. Engineers analyze power transfer through the data output to tune the engine performance. Check out this engine dynamometer application note here.

Contact our experts to learn more about these types of testing applications, use cases and products used in urban mobility projects.

Testing for Commercial Drones and Parcel Delivery

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Drone parcel delivery, and the use of drones in general, has expanded rapidly throughout the world. A technology that was once relegated to science fiction and imagination is becoming a real-world asset and making a huge impact on many commercial use applications in military and defense, consumer goods, logistics and inventory management, industrial automation, construction, security, agriculture, healthcare, imaging and surveying, as well as shipping and fulfillment.

To give you an idea of the impact of drones, take a look at recent numbers published by the FAA on registered drones in the U.S.:

  • 1,710,159 Drones Registered
  • 495,909 Commercial Drones Registered
  • 1,210,751 Recreational Drones Registered
  • 195,346 Remote Pilots Certified

There is a significant role for test and measurement as well as embedded sensors in this growing industry, which is expected to reach of $6B in size in the next few years. Load cells play a huge part in the design and development of this specialized aircraft technology and ongoing monitoring while in flight. Drones are classified as unmanned aerial vehicles. Basically, an aircraft without a human pilot. Successful operation of a UAV is dependent on a system, including the vehicle, a ground-based controller, and communications components, all of which must pass rigorous performance testing standards and constant data feedback.

The knowledge and tools we apply to test and measure airplanes and spacecraft performance can be transferred at a smaller scale to drones. Drone OEMs need to collect data points on thrust and velocity in test, and they also need to collect real-time sensor data on drones in-use. In fact, a large variety of sensor types are used for drone applications, including: force sensors, gyroscopes, barometers, and accelerometers.

Most recreational drones have passed significant testing during the engineering and design phase to ensure safety for anyone on the ground. Early applications and adoption sparked immediate regulation and safety requirements. We are now seeing the fastest expansion of this technology into commercial use. The future of drone technology for wide-scale business use has several of the world’s largest companies engaged in expansive development and deployment in use of UAVs for package delivery, including Alphabet (Google), Amazon, UPS, CVS and Walmart.

Commercial applications require substantially more rigorous testing in all use cases, in particular for transportation of objects. Most developed countries have defined commercial use requirements and regulations, such as the FAA in the U.S. Not only is the safety of those on the ground important critical, so is protecting the value of the goods in transport.

In demonstrating how force measurement solutions are used with drone technology, Interface created animated application note showcasing how a force solution is necessary for real-time monitoring of drones used in the shipping and fulfillment markets. Testing beyond flight, there is a level of complexity present when you introduce the weight of a package to a drone.

DRONE TESTING USE CASE

Customer Challenge:

A customer approached Interface to deliver a force solution capable of weighing a “payload” and using that data in real-time to tell the propeller motors to compensate for weight shifting or uneven weight distribution. The purpose of the force solution was to help the drone lift the payload and fly normally to reach its destination.

Interface Force Measurement Solution:

To solve this challenge, Interface supplied four WMC Sealed Stainless Steel Miniature Load Cells, which were used to measure the weight of the payload and detect weight shifting and distribution in flight. As shifting and uneven distribution occurred, the load cells send a signal to the necessary propeller motors to compensate.

How it Works:

The four miniature load cells are connected independently to each of the four landing gear legs. The load cells are then connected to the drone’s processor, which allows the load cell to communicate the weight of the payload and store the information. As the drone flies and weight shifts, the load cell can then relay the information to the processor in real-time so that the individual motors increase in RPM to balance the shifting weight.

Subscribe to Interface’s YouTube Channel to see our latest animated application notes. This new series of animated application notes give viewers a better sense of how force measurement products are applied to real-world challenges to collect and analyze data. So far, we have produced three animated application notes, which we have linked below:

 

Driving Force in Automotive Applications

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

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

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

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

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

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

BRAKE PEDAL TESTING

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

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

Read the application note for Brake Pedal Testing here.

EV BATTERY TESTING

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

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

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

SUSPENSION TESTING

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

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

View the race car suspension testing application here.

MOTOR TESTING

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

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

You can read more about the AxialTQ in this post.  

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

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