System integration design in MEMS - A case study of micromachined load cell

One of the critical issues in large scale commercial exploitation of MEMS technology is its system integration. In MEMS, a system design approach requires integration of varied and disparate subsystems with one of a kind interface. The physical scales as well as the magnitude of signals of various subsystems vary widely. Known and proven integration techniques often lead to considerable loss in advantages the tiny MEMS sensors have to offer. Therefore, it becomes imperative to think of the entire system at the outset, at least in terms of the concept design. Such design entails various aspects of the system ranging from selection of material, transduction mechanism, structural configuration, interface electronics, and packaging. One way of handling this problem is the system-in-package approach that uses optimized technology for each function using the concurrent hybrid engineering approach. The main strength of this design approach is the fast time to prototype development. In the present work, we pursue this approach for a MEMS load cell to complete the process of system integration for high capacity load sensing. The system includes; a micromachined sensing gauge, interface electronics and a packaging module representing a system-in-package ready for end characterization. The various subsystems are presented in a modular stacked form using hybrid technologies. The micromachined sensing subsystem works on principles of piezo-resistive sensing and is fabricated using CMOS compatible processes. The structural configuration of the sensing layer is designed to reduce the offset, temperature drift, and residual stress effects of the piezo-resistive sensor. ANSYS simulations are carried out to study the effect of substrate coupling on sensor structure and its sensitivity. The load cell system has built-in electronics for signal conditioning, processing, and communication, taking into consideration the issues associated with resolution of minimum detectable signal. The packaged system represents a compact and low cost solution for high capacity load sensing in the category of compressive type load sensor.

Evaluation of the accuracy of an impact load cell using lumped parameter modeling and analysis

The objective of the current study is to evaluate the fidelity of load cell reading during impact testing in a drop-weight impactor using lumped parameter modeling. For the most common configuration of a moving impactor-load cell system in which dynamic load is transferred from the impactor head to the load cell, a quantitative assessment is made of the possible discrepancy that can result in load cell response. A 3-DOF (degrees-of-freedom) LPM (lumped parameter model) is considered to represent a given impact testing set-up. In this model, a test specimen in the form of a steel hat section similar to front rails of cars is represented by a nonlinear spring while the load cell is assumed to behave in a linear manner due to its high stiffness. Assuming a given load-displacement response obtained in an actual test as the true behavior of the specimen, the numerical solution of the governing differential equations following an implicit time integration scheme is shown to yield an excellent reproduction of the mechanical behavior of the specimen thereby confirming the accuracy of the numerical approach. The spring representing the load cell, however,predicts a response that qualitatively matches the assumed load-displacement response of the test specimen with a perceptibly lower magnitude of load.

A load cell for grain-propelled ballistic rocket thrust measurement

A 1000-kgf resistive strain-gauge load cell has been developed for quality testing of rocket propellant grain. A 7075-T6 aluminum alloy has been used for the elastic column, in which 8 uniaxial, 120-Ω strain gauges have been bonded and connected to form a full Wheatstone bridge to detect the strain. The chosen geometry makes the transducer insensitive to moments and, also, to the temperature. Experimental tests using a universal testing machine to imposed compression force to the load cell have demonstrated that its behavior is linear, with sensitivity of 2.90 μV/kgf ± 0.34%, and negligible hysteresis. The designed force transducer response to a dynamic test has been comparable to that of a commercial load cell. © 2005 IEEE.

Discrete element analysis for the assessment of the accuracy of load cell-based dynamic weighing systems in grape harvesters under different ground conditions

Dynamic weighing systems based on load cells are commonly used to estimate crop yields in the field. There is lack of data, however, regarding the accuracy of such weighing systems mounted on harvesting machinery, especially on that used to collect high value crops such as fruits and vegetables. Certainly, dynamic weighing systems mounted on the bins of grape harvesters are affected by the displacement of the load inside the bin when moving over terrain of changing topography. In this work, the load that would be registered in a grape harvester bin by a dynamic weighing system based on the use of a load cell was inferred by using the discrete element method (DEM). DEM is a numerical technique capable of accurately describing the behaviour of granular materials under dynamic situations and it has been proven to provide successful predictions in many different scenarios. In this work, different DEM models of a grape harvester bin were developed contemplating different influencing factors. Results obtained from these models were used to infer the output given by the load cell of a real bin. The mass detected by the load cell when the bin was inclined depended strongly on the distribution of the load within the bin, but was underestimated in all scenarios. The distribution of the load was found to be dependent on the inclination of the bin caused by the topography of the terrain, but also by the history of inclination (inclination rate, presence of static periods, etc.) since the effect of the inertia of the particles (i.e., representing the grapes) was not negligible. Some recommendations are given to try to improve the accuracy of crop load measurement in the field.

25.0 mph 26 degree crabbed moving barrier impact tests into a 26 degree load cell barrier face. Test #1: NHTSA deformable barrier face. Test #2: EEVC deformable barrier face. Test report.

Mode of access: Internet.

Load displacement in grape harvesters: Discrete Element Analysis.

Dynamic weighing of the hopper in grape harvesters is affected by a number of factors. One of them is the displacement of the load inside the hopper as a consequence of the terrain topography. In this work, the weight obtained by a load cell in a grape harvester has been analysed and quantified using the discrete element method (DEM). Different models have been developed considering different scenarios for the terrain.

Die load and stresses in press forging

Several axi-symmetric EN3B steel components differing in shape and size were forged on a 100 ton joint knuckle press. A load cell fitted under the lower die inserts recorded the total deformation forces. Job parameters were measured off the billets and the forged parts. Slug temperatures were varied and two lubricants - aqueous colloidal graphite and oil - were used. An industrial study was also conducted to check the results of the laboratory experiments. Loads were measured (with calibrated extensometers attached to the press frames) when adequately heated mild steel slugs were being forged in finishing dies. Geometric parameters relating to the jobs and the dies were obtained from works drawings. All the variables considered in the laboratory study could not, however, be investigated without disrupting production. In spite of this obvious limitation, the study confirmed that parting area is the most significant geometric factor influencing the forging load. Multiple regression analyses of the laboratory and industrial results showed that die loads increase significantly with the weights and parting areas of press forged components, and with the width to thickness ratios of the flashes formed, but diminish with increasing slug temperatures and higher billet diameter to height ratios. The analyses also showed that more complicated parts require greater loads to forge them. Die stresses, due to applied axial loads, were investigated by the photoelastic method. The three dimensional frozen stress technique was employed. Model dies were machined from cast araldite cylinders, and the slug material was simulated with plasticene. Test samples were cut from the centres of the dies after the stress freezing. Examination of the samples, and subsequent calculations, showed that the highest stresses were developed in die outer corners. This observation partly explains why corner cracking occurs frequently in industrial forging dies. Investigation of die contact during the forging operation revealed the development of very high stresses.

Direct measurement as a tool for assessing the accuracy of inverse dynamics

The understanding of the loads generated within the prosthetic leg can aid engineers in the design of components and clinicians in the process of rehabilitation. Traditional methods to assess these loads have relied on inverse dynamics. This indirect method estimates the applied load using video recordings and force-plates located at a distance from the region of interest, such as the base of the residuum. The well-known limitations of this method are related to the accuracy of this recursive model and the experimental conditions required (Frossard et al., 2003). Recent developments in sensors (Frossard et al., 2003) and prosthetic fixation (Brånemark et al., 2000) permit the direct measurement of the loads applied on the residuum of transfemoral amputees. In principle, direct measurement should be an appropriate tool for assessing the accuracy of inverse dynamics. The purpose of this paper is to determine the validity of this assumption. The comparative variable used in this study is the velocity of the relative body center of mass (VCOM(t)). The relativity is used to align the static (w.r.t. position) force plate measurement with the dynamic load cell measurement.

Functional and structural of the erector spinae muscle during isometric lumbar extension

Study Design Cross-sectional study. Objectives To compare erector spinae (ES) muscle fatigue between chronic non-specific lower back pain (CNLBP) sufferers and healthy subjects from a biomechanical perspective during fatiguing isometric lumbar extensions. Background Paraspinal muscle maximal contraction and fatigue are used as a functional predictor for disabilities. The simplest method to determine muscle fatigue is by evaluating the evolution during specific contractions, such as isometric contractions. There are no studies that evaluate the evolution of the ES muscle during fatiguing isometric lumbar extensions and analyse functional and architectural variables. Methods In a pre-calibrated system, participants performed a maximal isometric extension of the lumbar spine for 5 and 30 seconds. Functional variables (torque and muscle activation) and architecture (pennation angle and muscle thickness) were measured using a load cell, surface electromyography and ultrasound, respectively. The results were normalised and a reliability study of the ultrasound measurement was made. Results: The ultrasound measurements were highly reliable, with Cronbach’s alpha values ranging from 0.951 0.981. All measured variables shown significant differences before and after fatiguing isometric lumbar extension. Conclusion During a lumbar isometric extension test, architecture and functional variables of the ES muscle could be analised using ultrasound, surface EMG and load cell. In adition, during an endurance test, ES muscle suffers an acute effect on architectural and functional variables.

Evaluation framework to assess orthopaedic procedures

Introduction & aims The demand for evidence of efficacy of treatments in general and orthopaedic surgical procedures in particular is ever increasing in Australia and worldwide. The aim of this study is to share the key elements of an evaluation framework recently implemented in Australia to determine the efficacy of bone-anchored prostheses. Method The proposed evaluation framework to determine the benefit and harms of bone-anchored prostheses for individuals with limb loss was extracted from a systematic review of the literature including seminal studies focusing on clinical benefits and safety of procedures involving screw-type implant (e.g., OPRA) and press-fit fixations (e.g., EEFT, ILP, OPL). [1-64] Results The literature review highlighted that a standard and replicable evaluation framework should focus on: • The clinical benefits with a systematic recording of health-related quality of life (e.g., SF-26, Q-TFA), mobility predictor (e.g., AMPRO), ambulation abilities (e.g., TUG, 6MWT), walking abilities (e.g., characteristic spatio-temporal) and actual activity level at baseline and follow-up post Stage 2 surgery, • The potential harms with systematic recording of residuum care, infection, implant stability, implant integrity, injuries (e.g., falls) after Stage 1 surgery. There was a general consensus around the instruments to monitor most of the benefits and harms. The benefits could be assessed using a wide spectrum of complementary assessments ranging from subjective patient self-reporting to objective measurements of physical activity. However, this latter was assessed using a broad range of measurements (e.g., pedometer, load cell, energy consumption). More importantly, the lack of consistent grading of infections was sufficiently noticeable to impede cross-fixation comparisons. Clearly, a more universal grading system is needed. Conclusions Investigators are encouraged to implement an evaluation framework featuring the domains and instruments proposed above using a single database to facilitate robust prospective studies about potential benefits and harms of their procedure. This work is also a milestone in the development of national and international clinical outcome registries.

A study on bullock carts. Part 2. Experimental study of forces in a bullock cart

A strain gauge load cell with separate bridges for measurement of the pull and the bending moment in the plane containing the net neck load and pull was developed and fixed in the longitudinal member of an experimental cart. A cart fitted first with pneumatic wheels and then with steel-rimmed wooden wheels was tested on three terrains—tar road, mud road and grassy terrain. Pull vs time and moment vs time records were obtained in each test and analysed. It is found that the bullocks pull the cart rather discontinuously at the low velocities at which these carts normally operate. On the tar road and the grassy terrain, the mean static coefficient of friction is significantly higher for the cart with steelrimmed wooden wheels. The dynamic frictional resistance of the terrain for the cart with steel-rimmed wooden wheels is lower than for the cart with pneumatic wheels so long as the wheels do not dig or sink into the terrain. The fluctuation in the neck load is lower in the cart fitted with pneumatic wheels. Also, the ground-induced low-amplitude high-frequency vibratory load content in the neck load is lower in the cart with pneumatic wheels.

Fiber Bragg Grating Sensor Package for Submicron Level Displacement Measurements

In this article, the design and development of a Fiber Bragg Grating (FBG) based displacement sensor package for submicron level displacement measurements are presented. A linear shift of 12.12 nm in Bragg wavelength of the FBG sensor is obtained for a displacement of 6 mm with a calibration factor of 0.495 mu m/pm. Field trials have also been conducted by comparing the FBG displacement sensor package against a conventional dial gauge, on a five block masonry prism specimen loaded using three-point bending technique. The responses from both the sensors are in good agreement, up to the failure of the masonry prism. Furthermore, from the real-time displacement data recorded using FBG, it is possible to detect the time at which early creaks generated inside the body of the specimen which then prorogate to the surface to develop visible surface cracks; the respective load from the load cell can be obtained from the inflection (stress release point) in the displacement curve. Thus the developed FBG displacement sensor package can be used to detect failures in structures much earlier and to provide an adequate time to exercise necessary action, thereby avoiding the possible disaster.

Avaliação da degradação de elásticos ortodônticos intraorais de látex

Avaliou-se a taxa de degradação de elásticos ortodônticos de látex de diferentes fabricantes e diâmetros em diversos intervalos de tempo. Grupos de 15 elásticos de força média dos fabricantes AmericanOrthodontics (Sheboygan, Wis, EUA), Tp (La Porte, IN, EUA), Morelli (Sorocaba, SP, Brasil) e Uniden (Sorocaba, SP, Brasil); de diâmetros 3/16, 1/4 e 5/16 foram analisados nos intervalos de 0,1,3,6,12 e 24 horas, totalizando-se 1080 espécimes. Os elásticos foram estirados individualmente à distância de 30mm, respeitando-se o intervalo de um minuto entre cada estiramento. Os materiais foram acondicionados imersos em água deionizada à 37C. Realizou-se leitura das forças na máquina de ensaios Emic DL 500 (Emic Co, Sao Paulo, Brasil) à velocidade de 30 mm/min, com uma célula de 2Kg (Emic Co, Sao Paulo, Brasil). A leitura de cada elástico consumiu aproximadamente um minuto. Teste Kruskal-wallis com correções por Dunns aferiu significância estatística dos resultados. Foram observadas diferenças entre os grupos analisados, exceto às marcas Morelli e Tp. Foram significativas as inferências das variáveis tempo e marca comercial. Em 0 hora, a relação entre as forças geradas foi Morelli>AO>Uniden>Tp para elásticos 3/16 (p=0,0016) e 1/4 (p=0,0016) e, de Morelli>AO>Tp>Uniden para elásticos 5/16 (p=0,0087). Após 24 horas, as porcentagens de degradação dos elásticos foram AO>Morelli>Uniden>Tp no diâmetro 3/16; AO>Tp>Morelli>Uniden no diâmetro 1/4 e Tp>AO>Uniden>Morelli para elásticos de diâmetro 5/16. O comportamento no intervalo de 0-24 horas demonstrou uma queda acentuada no período de 0-3 horas, um ligeiro aumento em 3-6 horas, seguido de uma queda progressiva no intervalo de 6-24 horas.

Influência de diferentes métodos de condicionamento superficial em pinos pré-fabricados resinosos fibro-reforçados em vidro e quartzo na resistência adesiva a compósito de polimerização dual: teste de push-out

O objetivo deste estudo foi realizar uma avaliação tridimensional da rugosidade superficial em 3 tipos de pinos de fibra - DT LightPost, FRC Postec Plus e Transluma Post - submetidos a diferentes tratamentos de superfície e avaliar os efeitos dos pré-tratamentos na resistência adesiva a um compósito de presa dual Biscore. Os tratamentos de superfície foram: imersão em ácido hidrofluorídrico, jateamento com óxido de alumínio a 50m, imersão em peróxido de hidrogênio, jateamento com óxido de alumínio a 50m seguido de imersão em ácido hidrofluorídrico e jateamento com óxido de alumínio a 50m seguido de imersão em peróxido de hidrogênio. No experimento 1, 75 pinos foram divididos em 3 grupos (n = 25), de acordo com seu fabricante e subdivididos em cinco subgrupos. A rugosidade superficial foi medida usando um rugosímetro tridimensional e analisada com o software de análise 3D. Os valores de rugosidade foram obtidos antes e após diferentes tratamentos de superfície na área dos mesmos corpos-de-prova. Para o experimento 2, foram utilizados os mesmos corpos-de-prova, os mesmos grupos e subgrupos do experimento 1, tendo sido adicionado o subgrupo de controle (n=90) e a resistência adesiva a um compósito presa dual Biscore foi mensurada através de um teste push-out. A resistência adesiva foi medida em uma máquina universal de ensaios, com uma célula de carga tipo SLBL-5kN em uma velocidade de 0,5 mm / min. Os resultados do experimento 1 foram analisados através de um teste estatístico t-Student. Jateamento e jateamento seguido de imersão em ácido hidrofluorídrico produziram um aumento estatisticamente significante na rugosidade, contudo somente o tratamento por jateamento proporcionou um aumento significativo nos valores de rugosidade. Os resultados do experimento 2 foram obtidos através de um um teste t-unilateral de hipótese com variância desconhecida. Concluiu-se que o jateamento com óxido de alumínio a 50μm em uma distância de 30 mm a 2,5 bar de pressão por 5 segundos foi suficiente para modificar a topografia dos pinos de fibra de vidro e quartzo e que o jateamento com partículas de 50 μ alumina a distância de 30 mm a 2,5 bar de pressão por 5 segundos foi o único tratamento de superfície que aumentou a resistência adesiva do compósito Biscore aos pinos DT Light Post e Transluma Post. Os pinos FRC Postec Plus não demostraram um aumento estatisticamente significante na resistência adesiva em nenhum grupo.