By embedding dynamic force sensors in the machine and matching them with analysis software, it provides an intelligent solution for the machine. Expand the scope of application, increase production capacity and reduce waste in the customer's manufacturing process, thereby reducing energy consumption and moving towards energy saving and waste reduction.
How is the Force Sensor Applied?
A force sensor is responsible for measuring the force acting on an object. Tensile and compressive forces as well as elastic deformation should be measured simultaneously. Furthermore, there are different variants in which force can be measured and determined by sensors. The more precise the required value, the smaller the measuring range and the higher the acceptance of the force sensor.
Types of Force Sensors:
- Simple Pressure Sensors - These are mechanical pressure sensors. In general, they are not suitable for precise measurements but are good for detecting force.
- Strain Gauge Force Sensors – These use simple principles and are mostly used in robotics research. The two forms of strain gauge force sensors are multi-axis force sensors and uniaxial load cells.
- Multi-axis force sensors use different strain gauges to detect each force applied to the sensor in the 6 axes. On the other hand, uniaxial load cells are common in some fields such as physics and mechanical engineering. They use a single strain gauge to measure the force on 1 axis.
How do Force Sensors Work?
The working principle of a force sensor is that it responds to an applied force and converts that value into a measurable quantity. Most force sensors are created by using force-sensing resistors. This sensor consists of electrodes and a sensing membrane. Force-sensitive resistors are based on contact resistance. They contain a conductive polymer film that predictably changes its electrical resistance once a force is applied to the surface. The film includes non-conductive, micron-sized, and conductive particles arranged in a matrix. If a force is applied to the surface of the membrane, tiny particles contact the sensor electrodes, changing the resistance of the membrane. The amount of change can change the resistance value that provides a measure of the applied force. To improve the performance of force-sensitive resistors, several methods are used in different efforts such as reducing the drift of the polymer electrode configuration being tested with the sensor.
Dynamic Force Sensing Module:
The piezoelectric dynamic force sensing module has the characteristics of high dynamic response and high reliability. It monitors the stamping process of the equipment in real time through the sensor signal and diagnoses the health of the machine in real time. Improve the reliability of the sensor, and have a patented reading circuit, which prolongs the release time of the charge, ensures that the sensing output signal is not distorted, and improves the accuracy of the sensing signal.
Dynamic Pressure Measurement:
The ability to measure small pressure fluctuations at high static pressure levels is a characteristic of piezoelectric pressure sensors. With an ICP amplified output, these sensors are ideal for continuous operation in underwater and long cable field testing applications. No special low-noise cables and charge amplifiers are required. These sensors are ideal for virtually all dynamic pressure applications with a sensor temperature range of -196 to +135°C. For higher temperature applications, charge output sensors are available up to +650°C.
Although piezoelectric pressure sensors are primarily recommended for dynamic pressure measurements. Some quartz pressure sensors have long discharge time constants that extend low-frequency capabilities, allowing static calibration and quasi-static pressure measurements in seconds measurement.
Measuring the Direction of the Strain Sensor:
The measurement methods of the micro force sensor are mainly pressure and tension. When used on the production line, the measured value can be used to ensure that the execution process is smooth and the force can be accurately controlled. The high-rigidity sensor has a high-resolution detection force corresponding to 100N or more and is most suitable for force measurement in precision machining or precision stamping. The measurement directions are mainly horizontal and vertical, and can also correspond to single-axis and dual-axis measurement directions.
What Benefits of Force Sensors?
orce sensors are beneficial in various industries. These have different fields of application at work. In manufacturing companies, force sensors are often used to determine forces in weight measurements or production processes. But industrial use covers only a part of force measurement. In road traffic, dynamometers play a crucial role, enabling precise determination of axle loads for effective and fast monitoring.
Different force sensors are used in cars to understand the trailer load and to determine static information related to dynamic driving behavior on the road. This means the control technology within the vehicle can react more quickly and efficiently behind the wheel. Force sensors have a variety of applications in the railway industry. They determine the cargo weight and pulling capacity of passenger vehicles or towbars. All collected information will be gathered to ensure smooth and safe operation within recommended parameters. Force sensors are not only used in railways but also in the area of track systems. This sensor determines the number of wheels driven on a track section and releases or blocks the track section and improves future rail traffic safety. In the field of bridges and cranes, the use of force sensors has a positive impact on user safety and technology. Structural problems or damage can be detected at an early stage, increasing safety at every step. For cranes, different force sensors are used not only to calculate the center of gravity of the crane but also to check the weight of the trailer. Heavy equipment ensures more efficient performance and greater job safety.