A PROJECT REPORT ON

Force measuring transducer

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

DIPLOMA IN MECHANICAL ENGINEERING..

SUBMITTED TO MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,

MUMBAI

SUBMITTED BY

1. Akanksha Mohan Lokhande

2. Rupali Prasad Chilgar
3. Yogesh Prakash Agav
4. Ravi Gangadhar Ambhore

GUIDED BY ( kamble Madam)

 GOVERNMENT POLYTECHNIC JINTUR
DISTRICT - PARBHANI
CERTIFICATE
Sr.no Name of Student Enrollment no. Seat No.
1. Akansha Lokhande
2. Rupali Chilgar
3. Yogesh Agav
4. Ravi Ambhore

In partial fulfilment of the requirements for the award of the Diploma in

Mechanical engeneering and submitted to the Department of Mechanical Engineering of
Government Polytechnic, Jintur. Work carried out during a period for the academic year
2023-2024 as per curriculum.

Name of Guide Name of HOD Principal

(Kamble Madam) (Y.D.Sarate Sir) (R.T.Pachkor Sir)
 ACKNOWLEDGEMENT

This project is done as a part course title "Perform Comparative study of various
non contact sensor" We are really thankful to our
Prof. Kamble Madam, Principal and Y.G Sarate Sir Head of Department, Department
Of Mechanical Engineering, Government Polytechnic, jintur for his valuable
guidance and assistance, without which the accomplishment of the task would have
never been possible. We also thank (Kambale Madam) for giving this opportunity to
explore into the real world and realize the interrelation, without which a Project can
never progress. We are also thankful to our supporting staff of computer department,
parents, and friends for providing us relevant information and necessary
clarifications, and great support.

Sr no. Name of Candidate Signature of Candidate

1. Akansha Mohan Lokhande

2. Rupali Prasad Chilgar
3. Yogesh Prakash Agav
4. Ravi Gangadhar Ambhore
 INTRODUCTION
In the realm of engineering and technology, microprojects
represent an opportunity to delve into specific areas of interest with
focused objectives and limited resources. One such intriguing
microproject revolves around the development or enhancement of
force measuring transducers. These tiny yet powerful devices play a
crucial role in converting mechanical force into electrical signals,
facilitating precise measurements in a wide array of applications.
This microproject aims to explore innovative approaches, design
improvements, or miniaturization techniques within the realm of
force measuring transducers, fostering hands-on learning and
practical experimentation.
 FORCE MEASURING TRANSDUCER
A force measuring transducer, also known as a force sensor or
load cell, is a device designed to measure the magnitude and direction
of applied forces. These transducers are crucial components in various
industrial, scientific, and commercial applications where accurate
force measurement is essential. Here's some fundamental information
about force measuring transducers:

Principle of Operation: Force measuring transducers operate based

on various principles, including strain gauge, piezoelectric, capacitive,
and electromagnetic. Each principle utilizes different mechanisms to
convert mechanical force into an electrical signal that can be
measured and analyzed.

Types of Force Measured: Force measuring transducers can measure

tension, compression, or shear forces, depending on their design and
application. They are used to measure forces exerted by machinery,
materials, structures, or biological systems.

Components: A typical force measuring transducer consists of

several components, including a sensing element (such as strain
gauges or piezoelectric crystals), a housing or body to protect the
sensing element, and electrical connections for signal transmission.

Calibration: Calibration is essential to ensure the accuracy and

reliability of force measurements. Transducers are calibrated using
known forces applied under controlled conditions to establish a
relationship between the applied force and the electrical output signal.
Applications: Force measuring transducers find applications across
various industries, including:

Industrial Manufacturing: Monitoring and controlling forces in

manufacturing processes such as assembly, pressing, and forming.

Automotive: Testing and validation of vehicle components, including

suspension systems, brakes, and engine mounts.

Aerospace: Structural testing, flight testing, and component testing to

ensure the integrity and safety of aircraft and spacecraft.

Biomechanics: Measuring forces exerted by the human body for

ergonomic studies, rehabilitation, and sports performance analysis.

Material Testing: Determining material properties such as tensile

strength, compressive strength, and elastic modulus in materials
testing laboratories.

Accuracy and Resolution: Force measuring transducers are available

in a range of accuracies and resolutions to suit different applications.
High-precision transducers with low measurement uncertainty are
used in demanding applications such as aerospace and scientific
research, while lower-cost transducers may suffice for less critical
applications.

Environmental Considerations: Factors such as temperature,

humidity, and vibration can affect the performance of force measuring
transducers. Specialized designs or environmental sealing may be
required to ensure reliable operation in harsh or demanding
environments.
 TYPES OF MEASURING TRANSDUCERS
1. Strain Gauge Transducers: One of the most common types of
force measuring transducers is based on strain gauge technology.
These transducers consist of a metal or semiconductor element that
deforms under the application of force, causing changes in electrical
resistance. Strain gauges are bonded to a flexible substrate and
arranged in a Wheatstone bridge configuration to measure the strain
induced by the applied force. As the strain changes, the electrical
resistance of the gauge changes proportionally, allowing the applied
force to be determined.

2.Piezoelectric Transducers: Piezoelectric force measuring

transducers utilize the piezoelectric effect, where certain materials
generate an electrical charge in response to applied mechanical stress.
Piezoelectric crystals, such as quartz or certain ceramics, are
commonly used in these transducers. When subjected to force,
piezoelectric materials generate a voltage proportional to the applied
force. Piezoelectric transducers are often used in dynamic force
measurement applications due to their fast response times.

3.Capacitive Transducers: Capacitive force measuring

transducers utilize changes in capacitance to measure applied forces.
These transducers typically consist of two parallel plates separated by
a small gap. When a force is applied, the distance between the plates
changes, altering the capacitance. By measuring the change in
capacitance, the applied force can be determined. Capacitive
transducers are known for their high sensitivity and low hysteresis.
4.Electromagnetic Transducers: Electromagnetic force
measuring transducers utilize the principle of electromagnetic
induction to measure forces. These transducers consist of a conductor
(such as a coil) and a magnet. When a force is applied, the movement
of the conductor relative to the magnetic field induces an
electromotive force (EMF) or voltage. The magnitude of the EMF is
proportional to the applied force. Electromagnetic transducers are
often used in high-force applications due to their robustness and
ability to withstand harsh environments.

5.Signal Conditioning: The electrical output signals from force

measuring transducers are typically weak and require amplification
and conditioning before they can be accurately measured and
analyzed. Signal conditioning circuits may include amplifiers, filters,
and analog-to-digital converters (ADCs) to improve signal quality and
resolution.

6.Calibration Standards: Calibration of force measuring

transducers is essential to ensure accuracy and traceability of
measurements. Calibration standards, such as weights or known
forces, are used to calibrate transducers over their operating range.
Calibration certificates provide documentation of the transducer's
performance characteristics and traceability to recognized standards.

7.Integration with Data Acquisition Systems: Force

measuring transducers are often integrated with data acquisition
systems for real-time monitoring, data logging, and analysis. Data
acquisition systems capture and process the electrical signals from the
transducers, allowing engineers and researchers to analyze force data
and make informed decisions.
8.Future Trends: Advancements in force measuring transducer
technology are focused on improving accuracy, miniaturization,
wireless connectivity, and compatibility with Internet of Things (IoT)
platforms. Emerging technologies such as fiber optic sensors and
MEMS (Micro-Electro-Mechanical Systems) sensors hold promise for
further enhancing the capabilities of force measuring transducers.

Overall, force measuring transducers continue to evolve and play a

critical role in a wide range of industries and applications, driving
innovation and enabling precise measurement of mechanical forces.

How does a Force Transducer work for Measuring

Force?
Firstly, we need to understand the underlying physics and material
science behind the force sensor working principle, which is the strain
gauge (sometimes referred to as Strain gage). Metal foil strain gage is
a sensor whose electrical resistance varies with applied force. In other
words, it converts (or transduces) force, pressure, tension,
compression, torque, weight, etc… into a change in electrical
resistance, which can then be measured. Strain gauges are electrical
conductors tightly attached to a film in a zigzag shape. When this film
is pulled, it — and the conductors — stretches and elongates. When it
is pushed, it is contracted and gets shorter. This change in shape
causes the resistance in the electrical conductors to also change. The
strain applied in the load cell can be determined based on this
principle, as strain gauge resistance increases with applied strain and
diminishes with contraction.
Structurally, a load cell sensor is made of a metal body (also called
flexure) to which foil strain gauges are bonded. The sensor body is
usually made of aluminum or stainless steel, which gives the sensor
two important characteristics: (1) provides the sturdiness to withstand
high loads and (2) has the elasticity to minimally deform and return to
its original shape when the force is removed. When force (tension or
compression) is applied, the metal body acts as a “spring” and is
slightly deformed, and unless it is overloaded, it returns to its original
shape. As the flexure deforms, the strain gage also changes its shape
and consequently its electrical resistance, which creates a differential
voltage variation through a Wheatstone Bridge circuit. Thus, the
change in voltage is proportional to the physical force applied to the
flexure, which can be calculated via the load cell circuit voltage
output.
Fig. 2: Strain gauge deformation in both tension and compression.

These strain gauges are arranged in what is called a

Wheatstone Bridge Circuit (see animated diagram). This means that
four strain gages are interconnected as a loop circuit (load cell circuit)
and the measuring grid of the force being measured is aligned
accordingly. The strain gauge bridge amplifiers (or load cell signal
conditioners) provide regulated excitation voltage to the load cell
circuit and convert the mv/V output signal into another form of signal
that is more useful to the user. The signal generated by the strain gage
bridge is low strength signal and may not work with other components
of the system, such as PLC, data acquisition modules (DAQ),
computers, or microprocessors. Some application requires a local
signal readout, also known as load cell indicator.
Thus, sensor signal conditioner functions include excitation voltage,
noise filtering or attenuation, signal amplification, and output signal
conversion. Furthermore, the change in the amplifier voltage output is
calibrated to be linearly proportional to the Newtonian force applied
to the flexure, which can be calculated via the load cell circuit voltage
equation.
An important concept regarding load cells is sensitivity and accuracy.
Sensor accuracy can be defined as the smallest amount of force that
can be applied to the sensor body required to cause a linear and
repeatable variation in the voltage output. The higher the load cell
accuracy, the better, as it can consistently capture very sensible force
variations. In applications like high precision factory automation,
surgical robotics, aerospace, load cell linearity is paramount in order
to accurately feed the PLC or DAQ control system with the accurate
measurement. Some of our Universal Pancake Load Cells presents
Nonlinearity of ±0.1% (of Rated Output) and Nonrepeatability of
±0.05% RO.
 CONCLUSION
In conclusion, force measuring transducers play a pivotal role in
various industries and applications where precise force measurement
is essential. Through the conversion of mechanical force into an
electrical signal, these transducers provide valuable data for analysis,
monitoring, and control purposes. Their versatility allows them to be
employed in diverse settings, ranging from industrial manufacturing
processes to medical devices and research laboratories.

The significance of force measuring transducers lies in their ability to

accurately capture and quantify forces acting upon them, enabling
engineers, scientists, and technicians to make informed decisions,
optimize processes, and ensure product quality and safety. Moreover,
advancements in technology continue to enhance the performance,
reliability, and range of applications for these transducers, driving
innovation across multiple fields. As industries evolve and demand for
precision measurement grows, force measuring transducers will
remain indispensable tools for achieving efficiency, consistency, and
excellence in various endeavors. Whether in automotive engineering,
aerospace applications, biomechanics research, or countless other
fields, these transducers serve as critical components in the quest for
progress and excellence.