The requirement was to design and manufacture a simple beam to fit into a very confined space and meet a stringent budget.  Following several months of design, development and creation the final product is manufactured from a high grade alloy steel requiring minimal additional machining.  A single strain gauge containing a full Wheatstone bridge is bonded to the beam in a specific position to maximise the sensitivity and accuracy.

During development a bespoke calibration system was also built to ensure that each beam was accurately positioned and loaded for consistent quality.

Following the successful acceptance trials and approval by our customer, the product has been put into full production, which is expected to exceed 2000 pieces per year.

This is a typical example of our design, development and manufacturing capabilities in the field of bonded strain gauge technology.

The plant was experiencing severe chain wear problems causing loss of production.  It was suspected that this was due to excessive tension at certain points in the system.  The challenge was to identify these areas, which could only be done effectively in a live running situation.

Applied Measurements Ltd were supplied with a standard link from the chain, this was modified to enable strain gauges to be bonded to the structure.  The transformation of the link into a load cell was completed by terminating with a four core screened cable, environmental protective coatings and calibration.

The link was then installed in the standard process chain and fitted with a portable data logger, this enabled the special link to map the forces around the system allowing adjustments to be made where required to ensure even tension, reducing chain wear and system stoppages.

The overall tension in the system is controlled by a spring mechanism against an idler wheel.  Some form of load measurement was required, but it had to fit into the existing system, which did not allow space for a standard off-the-shelf load cell.

Applied Measurements Ltd designed and manufactured a custom load cell based on the CCG load cell concept, but to exactly fit the existing mechanical dimensions.  It had to be annular to allow the tensioning system to fit through the centre and to be extremely low in height to replace an existing washer.

To complete the system each load cell was supplied calibrated with a digital indicator containing 4 changeover relays.  Each system operated from a 240Vac supply, giving the system operators a visual reference of the tension in the system, plus the relays controlled an early warning alarm system allowing preventative maintenance.

The application required the design of a custom built load cell to enable the customer to determine the ratio between gripping force and friction coefficients of various materials. The length and overall diameter of the finished transducer were stipulated by the customer and it was important that the load cell could be gripped at any point along its length without compromising the sensitivity and accuracy.

This was achieved by utilising the basic single point load cell principles but adapting them to meet the dimension specifications.  To enable transducer to be used in a variety of locations, it was calibrated to UKAS Standards with our portable battery powered PD100 Indicator.

From the initial consultation through design and manufacture took only 6 weeks.  This is a typical example of our design and manufacturing capabilities for custom specials.