Force Sensors

Key Takea­ways

  • Defi­ni­tion and Appli­ca­ti­ons: Force trans­du­cers, also known as force sensors or load cells, measure the force applied to an object and are used in manu­fac­tu­ring, quality control, rese­arch and deve­lo­p­ment, as well as safety monitoring.
  • Func­tion­a­lity: They typi­cally operate with strain gauges that detect the defor­ma­tion of the metal struc­ture under force and convert it into an elec­tri­cal signal corre­spon­ding to the applied force.
  • Designs and Measu­re­ment Prin­ci­ples: Various designs such as load cells, ring force trans­du­cers, and load pins exist, each selec­ted based on the speci­fic appli­ca­tion and requi­red precision.

In this article we explain how force sensors work, the various types available and their applications.

What is a Force Sensor?

A force sensor is a tool used to measure the force applied to an object.

Given the criti­cal rele­vance of precise measu­re­ment of tension and compres­sion forces in various appli­ca­ti­ons, force sensors are used in count­less diffe­rent working areas.

Among them are:

  • Manu­fac­tu­ring
  • Quality control
  • Rese­arch and development
  • Safety moni­to­ring
  • Opti­miza­tion of devices and machines

Diffe­rent terms

Force sensors are also known under a variety of diffe­rent terms such as load cell, force trans­duc­tor or simply as force measu­ring device.

This is how Force Sensors work

The func­tion­a­lity of speci­fic force sensors can vary based on the measu­re­ment prin­ci­ple but the inten­tion remains the same.

To deter­mine the force acting on an object in diffe­rent direc­tions, a force measu­ring device is atta­ched or integrated.

Within the force measu­ring device, a strain gauge with an arran­ge­ment of sensors on a metal struc­ture is installed.

Func­tion­a­lity

As soon as force is applied to the struc­ture, the sensors measure the strain and produce an elec­tri­cal signal corre­spon­ding to the applied force.

The elec­tri­cal signal is then regis­tered and proces­sed on specia­li­zed devices or computers.

Gene­rally, force sensors are very precise and capa­ble of measu­ring both small and large forces.

Howe­ver, varia­ti­ons may occur.

Accu­racy class

This is why manu­fac­tu­r­ers provide an accu­racy class in the data­sheet, defi­ning the poten­tial maxi­mum devia­tion of the measu­re­ment in percen­tage terms.

As with other instru­ments used for test­ing, the regu­lar inspec­tion and cali­bra­tion of force sensors are essen­tial to ensure accu­rate measurements.

Want to cali­brate your devices directly with us?

No problem thanks to our accre­di­ted lab!

Cali­bra­tion at DSM

Diffe­rent Types of Force Sensors

Force sensors used to achieve opti­mal force trans­mis­sion, where a force should act predo­mi­nantly in the measu­ring direc­tion without inter­fe­rence from late­ral forces or bending moments.

This requi­re­ment leads to various designs utili­zing diffe­rent measu­re­ment prin­ci­ples such as:

  • Load cells
  • Ring force trans­du­cers / Donut load cell
  • Force measu­ring tabs
  • Load pins
  • Thread force sensor

Often the force sensors need to be minia­tu­ri­zed to ensure an easy inte­gra­tion into machines.

They are charac­te­ri­zed by a flat­ter design and a smal­ler diame­ter.

There are nume­rous varia­ti­ons, including:

  • Tension bars
  • Measu­ring rings
  • Load cells
  • Bending bars

Importance of appli­ca­tion area

In many cases, the appli­ca­tion area deter­mi­nes the most suita­ble form to deli­ver opti­mal results.

Depen­ding on the needed force sensors, prices can vary significantly.

While in some cases a stan­dard model is suffi­ci­ent, in other cases only custom-made ones can meet all the needed requirements.

Measu­re­ment Prin­ci­ples in Force Sensors: Table and Applications

The most common force sensors and their measu­re­ment prin­ci­ples are summa­ri­zed in the follo­wing table:

Name Measu­re­ment Principle Suita­bi­lity
Strain Gauge or Spring Body Force Sensors Strain Gauge force sensors utilize a support plate equip­ped with thin metal foils. The applied force deforms the metal, leading to a measura­ble change in resistance. Among the most common types of force sensors, they excel in high accu­racy and good long-term stability.
Piezo­elec­tric Force Sensors (Piezo) Piezo force sensors incor­po­rate crys­tals that gene­rate elec­tri­cal char­ges when subjec­ted to force. The elec­tric charge forms the basis for calcu­la­ting the force. Parti­cu­larly suita­ble for measu­ring dyna­mic tension and compres­sion forces.
Hydrau­lic Force Transducers Measu­re­ment invol­ves the compres­sion of liquids in a cham­ber subjec­ted to pres­sure. Evalua­ting the pres­sure increase allows for the calcu­la­tion of force. Capa­ble of measu­ring various types of forces, such as late­ral or compres­sion forces. They are robust and highly relia­ble in diffi­cult weather condi­ti­ons or when tempe­ra­ture fluc­tua­tions occur.
Magne­toela­s­tic Force Sensors The measu­ring body consists of ferro­ma­gne­tic mate­rial connec­ted to a coil. The effect of force is detec­ted through a change in induction. Cover a wide measu­ring range and are suita­ble for mass produc­tion due to their cost-effectiveness.
Induc­tive Force Sensors Induc­tive force sensors measure the change in distance that occurs when force is applied to two points. Often used in labo­ra­to­ries due to high sensitivity.

For simul­ta­neous, multi-axis measu­re­ment of more than one force, multi-compo­nent force sensors are used.

All press-in units of the DSM SMP and XMP series are equip­ped with digi­tal force sensors to guaran­tee the highest precis­ion possible.

Frequently Asked Ques­ti­ons (FAQ)

1. What is a force sensor and how does it work?

A force sensor is a device that measu­res mecha­ni­cal forces such as tension, compres­sion, or pres­sure and converts them into elec­tri­cal signals. These signals are used to moni­tor and control proces­ses across various industries.

2. How do force sensors enhance effi­ci­ency in indus­trial applications?

Force sensors improve effi­ci­ency by provi­ding real-time data on applied forces, enab­ling precise control, redu­cing mate­rial waste, and ensu­ring consis­tent product quality.

3. In which indus­tries are force sensors commonly used?

Force sensors are widely utili­zed in manu­fac­tu­ring, robo­tics, auto­mo­tive, aero­space, medi­cal devices, and consu­mer elec­tro­nics for tasks requi­ring accu­rate force measu­re­ment and control.

4. What types of force sensors are available?

Common types include strain gauge sensors, piezo­elec­tric sensors, capa­ci­tive sensors, and force-sens­ing resis­tors, each suited for speci­fic appli­ca­ti­ons based on sensi­ti­vity, range, and envi­ron­men­tal conditions.

5. Can force sensors be inte­gra­ted into exis­ting systems?

Yes, many force sensors are desi­gned for easy inte­gra­tion into exis­ting machi­nery and control systems, often featuring stan­dard inter­faces and compa­ti­bi­lity with various data acqui­si­tion systems.

6. What factors should be conside­red when selec­ting a force sensor?

Key conside­ra­ti­ons include the requi­red force range, accu­racy, envi­ron­men­tal condi­ti­ons (such as tempe­ra­ture and humi­dity), sensor size, and compa­ti­bi­lity with exis­ting systems.

7. How do force sensors contri­bute to predic­tive maintenance?

By conti­nuously moni­to­ring force data, sensors can detect anoma­lies or devia­ti­ons from normal opera­tion, allo­wing for early inter­ven­tion and redu­cing unplan­ned downtime.

8. Are force sensors suita­ble for dyna­mic force measurements?

Certain types, like piezo­elec­tric sensors, are well-suited for measu­ring dyna­mic or rapidly chan­ging forces due to their high-frequency response capabilities.

Note: This FAQ is inten­ded for gene­ral infor­ma­tio­nal purpo­ses and does not replace perso­na­li­zed advice. For speci­fic inqui­ries, please consult a quali­fied specialist.

Über den Autor

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