What is the difference between a force transducer and a load cell?

Force transducers and load cells are based on the same measuring principle – the strain gauge – and convert mechanical forces into electrical signals. The term load cell is predominantly used in weighing and process engineering, while force transducers cover the broader spectrum of force and torque measurement technology: from test benches in the aerospace industry to materials testing. interfaceforce® eK distributes both types in measuring ranges from 0,5 Newtons to 30 Meganewtons.

What types of force transducers does interfaceforce® eK offer?

The portfolio includes low-profile force transducers, S-shaped force transducers, miniature force transducers, measuring bolts, force rings, bending beam load cells, cylindrical high-load sensors, and multi-component transducers for up to 6 degrees of freedom (6DoF). All standard models are strain gauge based and supplied with a calibration certificate. Custom designs are developed according to customer specifications.

Which torque transducers are suitable for rotating applications?

For rotating shafts, torque measuring shafts (e.g., T2, T4, T6, T8, T11, T22, T25) are available, which operate without contact and without slip rings. The measuring ranges extend up to 10 kN·m. For static or reactive applications – such as in test benches or for measuring bolt preload – reaction torque transducers are used. Both variants provide strain gauge-based signals and are compatible with the measuring amplifiers from interfaceforce® eK.

How does the XSENSOR pressure distribution system work and what is it used for?

XSENSOR systems measure surface pressure distribution using ultra-flexible sensor mats in various geometries and resolutions. These imaging systems deliver precise, reproducible results and are used in automotive and medical technology, biomechanics, and point-of-sale applications – for example, for seat pressure analysis, tire contact patch measurement, mattress diagnostics, and wiper testing. The XSENSOR laboratory is accredited according to ISO/IEC 17025 (A2LA).

What measurement accuracy do the force transducers from interfaceforce® eK achieve?

The low-profile force transducers of the Interface series (e.g., 1200, 1201, 3200) typically achieve a total static error band of ≤ 0,02% of the nominal value (full-scale output). The Gold Standard® and Platinum Standard® reference force transducers are suitable for calibration tasks according to ISO 376 Class 0,5. All sensors are supplied with a calibration certificate; A2LA-accredited certificates according to ISO/IEC 17025 are available upon request.

Does interfaceforce® eK also perform calibrations of third-party sensors?

Yes. The calibration laboratory of interfaceforce® eK is ISO/IEC 17025 accredited (A2LA and DAkkS mutually recognized within the framework of the ILAC MRA) and calibrates force measuring devices regardless of the manufacturer. Supported standards: ISO 376, DKD-R 3-3, ASTM E74, VDI/VDE 2624, and custom calibration procedures. Force measuring ranges: 0,5 N to 250 kN (tension and compression). An RMA number will be issued in advance for submissions; the delivery address for calibrations and repairs is c/o SETFLEX, Oppelner Str. 23, 41199 Mönchengladbach, Germany.

How does a calibration process work and how long does it take?

The process begins with an inquiry via contact form or email; interfaceforce® eK promptly issues an RMA number. Upon receipt of the device, calibration is performed in an ISO 17025-accredited laboratory using static tensile and/or compressive force measurements with traceable transfer standards (DAkkS, NIST, or PTB). Calibrations according to ISO 376 or DKD-R 3-3 include multiple load stages in various mounting positions. Turnaround times are short – precise details are available upon request. The completed calibration certificate is internationally recognized.

Which force transducers are suitable for use in ATEX or explosion-hazardous areas?

For hazardous areas (ATEX/IECEx), interfaceforce® eK offers force transducers from the 3400 series as well as hermetically sealed sensor variants made of stainless steel. These models are designed for harsh and potentially explosive environments and deliver reliable measurement results even under continuous operation. For specific hazardous area requirements (Zone 1, Zone 2, etc.), we recommend individual consultation, as suitability depends on the respective device category and the medium being used.

From what quantity are special solutions and customer-specific force transducers available?

Custom designs are available even for single units. interfaceforce® eK develops customer-specific force transducers, torque transducers, and multi-component sensors based on over 25 years of experience and in-house strain gauge manufacturing. Rapid engineering and rapid prototyping enable solutions to be implemented in short lead times – from concept to series production. Application areas range from niche markets with small production runs to OEM integrations in high-volume series.

What distinguishes interfaceforce® eK from other providers in force measurement technology?

interfaceforce® eK has been the exclusive distributor in Germany for Interface Inc. (founded in 1968, Scottsdale, USA) since 1999 – one of the world's leading manufacturers of precision strain gauge-based force transducers. The service portfolio combines American manufacturing quality with local support: an ISO 17025-accredited calibration laboratory in Germany (A2LA/DAkkS, ILAC MRA), manufacturer-independent calibrations and repairs, custom manufacturing starting from a single unit, and exclusive distribution of XSENSOR pressure distribution systems. Measuring ranges from 0,5 Newtons to 30 Meganewtons cover virtually every industrial force measurement application.

What output signal do the force transducers provide, and what measuring amplifier do I need?

Strain gauge-based force transducers deliver a bridge signal of typically 2 mV/V or 4 mV/V at rated load. Further processing requires a measuring amplifier that converts this signal into a usable format – e.g., 0–10 V, 4–20 mA, USB, IO-Link, or digital interfaces. interfaceforce® eK offers suitable measuring amplifiers as complete measurement chains: from simple digital displays (IFFDA93, IFFDA5) and 8-channel data acquisition systems (IFFBX8) to wireless telemetry systems (WTS). Sensors with a TEDS chip also enable automatic parameterization at the measuring amplifier.

What protection ratings (IP classes) are available for the force transducers?

Most standard models are designed for industrial use and achieve protection ratings of IP65 to IP67 (dustproof, protected against water jets and temporary immersion). Hermetically sealed versions made of stainless steel achieve IP68 and are suitable for underwater, cleaning, and outdoor applications under harsh conditions. Certified versions are available for use in potentially explosive atmospheres (ATEX/IECEx). The exact IP rating can be found in each product data sheet; interfaceforce® eK is available upon request to advise on application-specific selection.

How often should a force transducer be recalibrated?

There are no legally mandated intervals; however, ISO 9001, IATF 16949, and industry-standard quality assurance systems recommend annual verification. In practice, the interval depends on the intensity of use, environmental conditions, and the required measurement uncertainty. In safety-critical applications or after mechanical overload events, immediate recalibration is recommended. The interfaceforce laboratory performs manufacturer-independent recalibrations with short turnaround times – even for sensors from other manufacturers.

What is TEDS and what advantages does it offer?

TEDS (Transducer Electronic Data Sheet, IEEE 1451.4) is an electronic data storage device integrated into the sensor or connector that automatically transmits calibration data and sensor characteristics to the measuring amplifier. This eliminates manual input and parameterization errors when replacing sensors – the measurement setup is ready for operation via plug-and-play. The IFFDA93 handheld device and other measuring amplifiers from interfaceforce® eK support the TEDS standard and enable quick, error-free commissioning, even with frequent sensor replacements.

What are parasitic forces and how do they affect measurement?

Parasitic forces are unwanted shear forces, bending moments, or torsional loads that act on the sensor simultaneously with the actual measuring force and can distort the result. Even an angular deviation of 5° in the load application causes a systematic error. To minimize parasitic influences, interfaceforce® eK recommends using rod ends, pressure load buttons, and mounting plates – all available as accessories. The interfaceforce® eK team provides support for sensor selection and installation advice upon request.

What are the delivery times and can I order small quantities?

Standard models from Interface Inc. that are in stock are available for immediate delivery. Custom designs and customer-specific receivers are manufactured upon receipt of order; thanks to rapid prototyping, initial samples are often available within a few weeks. There is no minimum order quantity – orders are possible starting from a single unit. Inquiries and orders can be made via email (info@interfaceforce.de), telephone (+49 8022 271667), or the contact form on the website.

Interface solutions for common challenges in metal processing

The metal industry is an integral part of the global economy and encompasses the Subsidies, production and processing of ferrous metals such as steel and iron as well as non-ferrous metals and special alloys such as Aluminium, copper, titanium and high-strength nickel. From massive steel beams in Infrastructure area down to microscopically small components in the electronics industry – the quality of every metal product depends on the precise control of forces.

In the MetalworkingParticularly in production and further processing, highly accurate force, torque, and weighing solutions are essential to overcome the inherent resistance of metals during forming. The transformation of raw ore into a finished component requires enormous energy – whether through high-pressure stamping, thermal forming, or high-speed machining.Cutting.

Without precise measuring technology, it is impossible to reliably maintain the boundary between successful shaping and material failure. Force sensors provide the necessary feedback loop to ensure that hydraulic presses to apply precisely the required tonnage for shaping, that drive shafts provide the necessary torque for rolling processes, and that alloying elements are weighed to the gram to ensure consistent material properties.

Overcoming challenges in metal production and processing

Metal production takes place under extreme conditions, requiring hardware that can withstand high temperatures, vibrations, and enormous physical stresses. Interface is ideally positioned to meet these requirements. Metalworking to meet the needs of our customers with a wide range of load cells and measuring instruments.

Processes such as Stamping, forging and Rollers They generate forces of up to several hundred tons and require sensors with high capacity and overload protection. In the Melting metal processing and the Hot rolling The sensors are exposed to high ambient temperatures, which requires special temperature compensation.

At the automated cutting and Shaping Undetected tool breakage can lead to scrap batches and costly machine damage. It is therefore crucial to find reliable solutions that prevent damage and identify maintenance needs early.

Interface sensors are frequently used in cutting and Grinding processes Used in applications where metal dust and shavings are generated, which can compromise the integrity of conventional electronic components. For this type of metal processing, the use of ATEX-approved equipment and equipment with a higher protection class (IP rating) is recommended.

Here are some of our products that are used to tackle the challenges in metal processing and production:

High-capacity LowProfile™ load cells are designed for massive pressure forces in hydraulic presses and forging hammers.
Stainless steel and sealed sensors are designed for use with corrosive liquids and high-pressure rinsing systems in metal processing plants.
Rotary torque sensors are used to monitor the efficiency and rotational force of motors in rolling mills, extruders and heavy-duty mixers.
Multi-axis sensors These load cells are indispensable for the simultaneous measurement of forces and moments during complex machining and multi-point forming processes. As industrial automation requires an increasing number of data points, these advanced load cells are valuable tools for optimizing processing and production.
Wireless Telemetry Systems (WTS) enable real-time data acquisition from moving machines or high-temperature areas without the risk of cable failures.
Weigh-Check™ load cells are specifically designed for large container and silo scales where material expansion and contraction occur.

Application examples from metal processing

Roboforming cutting

Roboforming is a relatively new term in manufacturing, where robotic systems shape various materials. In sheet metal roboforming – also known as robot-assisted incremental sheet forming (RISF) – a robot uses a forming tool to gradually shape a sheet of metal into the desired form. A force measurement system can monitor and control the force applied to the roboforming tool. Interfaces 6A40 6-axis load cell measures forces and torques (Fx, Fʏ, Fz, Mx, Mʏ, Mz), while the BXB-HD44 Data Acquisition System It logs, displays, and graphically represents these measurements and sends scaled analog output signals for these axes to the robot's control system. Read more here.

Hydraulic metal presses

Hydraulic presses are used at Metal forming processes such as stamping, punching, and bending are widely used. Checking the press for the required pressing force and compliance with component specifications are crucial. For metal cutting presses, Interface recommends installing a 3-axis force load cell below the plate on which metal parts are cut or punched. In conjunction with the BXB-HD44 Data Acquisition System The force measurement results of various metal cutting operations are displayed, graphically represented, and recorded on the customer's PC. The system also features an analog output that can be connected to the machine's PLC in case of overload. This is used in high-volume metal stamping. LowProfile™ load cell Integrated into the press, the sensor monitors the force applied with each stroke. It ensures that the tool engages fully and the metal is formed correctly without tearing or wrinkling. If the force deviates from the set parameters, the system triggers an immediate stop to prevent the production of defective parts.

Monitoring of milling tool forces and wear

Multi-axis sensors Interface's products offer valuable measurement capabilities for the development and monitoring of CNC cutting tools. By measuring the forces acting in three directions during a cut, engineers can pinpoint the exact moment a tool begins to dull or chatter. The sensor data enables predictive maintenance, ensuring tools are updated or replaced as needed and preserving the surface quality of the metal part. Learn more in our Application Note on Laser Machine Cutting Force.

Ladle and silo weighing in foundries

Precise mixing ratios of the components are crucial in the production of special metal alloys. We recommend a A4200 WeighCheck load cell and 1280 programmable weight display and control unit weighing system, in which the load cells are mounted under silos containing alloying elements such as chromium or nickel. These sensors provide continuous inventory data and enable automatic dosing by weight, which is significantly more accurate than volumetric measurement in high-temperature environments. Further information can be found in our Application Note on silo monitoring and weighing.

Torque analysis in rolling mills

To produce a uniform sheet of metal, the drive motors of the rollers must maintain a constant torque. Rotary torque sensors These sensors are installed on the drive shafts and provide real-time data on the resistance of the metal being processed. This information helps operators adjust the rolling speed and pressure to ensure that the final product maintains the specified thickness throughout the entire production run.

Why use an interface for metal processing?

Interface is the proven partner for metal manufacturers and OEMs of plants and machinery. We offer force measurement solutions that require structural rigidity and fatigue-resistant durability for millions of cycles in the most demanding industrial environments.

Our application engineers specialize in optimally adapting sensors to the specific thermal and physical requirements of metal production – ensuring your operation runs with maximum efficiency, safety and product consistency.