1. Ph.D. Colloquium
Effects of Design Parameters on Performance of
Dual Octal Load Cells
By
Mr. Vijay A. Kamble
USN : 2GI15PMJ14
Under the Guidance of
Prof.(Dr.) Jayant K. Kittur
Prof. (Dr.) Vasudev D. Shinde
Research center
Kls Gogte Institute of Technology,
Belgaum
Visvesvaraya Technological University
Belagavi-590018
2. 2
Outline of the presentation
• Introduction
• Literature survey
• Problem Statement and Objectives
• Retrospective study of load cells
• Introduction of Dual octal ring load cell
• DOE for Dual octal ring load cell
• Effect of geometric parameter on response variables
• Grey relational analysis of Dual octal ring load cell
• Manufacturing and testing of Dual octal ring load cell
• Conclusion
• References
• Publications
3. 3
Introduction
Force is that produces resistance or obstruction to any moving
body, or changes the motion of a body, or tends to produce these effects
• Previously levers and rollers were used for multiplying force
generated by the muscle.
• Sir Isaac Newton, did pioneer work for force measurement and
formulated laws
• Force,
where g is the local acceleration due to gravity , ρa and ρm are
densities of air and material of the mass respectively.
• Force measurement is required in applications like material testing
instruments, weighing machines, force measurement in various
manufacturing processes, thrust measurement in Aeronautics,
calibration of hardness and strength testing machines
4. 4
Sensor associated with force indicating instrument
Dial Gauged Load cell (Commonly called, Proving Ring)
5. 5
Strain gauge load cell
• strain gauges mounted on elastic element
connected in Wheatstone bridge circuit.
• converts force or weight into an electrical signal.
strain gauges
6. 6
Load cell types
a) Compression cylinder (50 kN to 50 MN) b) Compression cylinder (hollow) (10 kN to 50 MN)
c) Toroid ring (1 kN to 5 MN) d) Ring (1 kN to 1 MN)
e) S-beam (200 N to 50 kN) f) double-ended shear beam (20 kN to 2 MN)
g) double-bending beam (500 N to 50 kN) h) Shear beam (1 kN to 500 kN)
i) double-bending beam (100 N to 10 kN) j) Tension cylinder (50 kN to 50 MN)
7. Problem Statement and Objectives
“Effects of Design Parameters on Performance of
Dual Octal Load Cells”
Objectives :
• Investigation of the effect of variability of design
parameters of load cell on the variability of design relevant
response quantities
• Design of experiment for carrying simulation studies.
• Geometric optimization of critical parameters of load cell
using GRA
• Validation of the results by using experimental work
8. Author Research area Focus on
Kuhnel M. , Hilbrunner F., Buchner H. ,
Jager G .,Manske E., Frohlich T. (2014)
double bending beam
force transducers
Traceable measurement of
mechanical parameters
according to EN ISO 376
Stefanescu D.M., Stefanescu A., (2006) Force Transducers Criteria for Choosing the
Elastic Elements
Kumar, H., Sharma, C., Kumar, A., &
Arora, P. K. (2015)
force measurement Retrospective
investigations
Bulent Aydemir , Erdinc Kaluc , Sinan
Fank (2006)
force transducers
manufactured from 17-
4PH stainless steel
Influence of heat treatment
on hysteresis error
Gauri Ranadive, Anindya Deb (2012) impact load cell Evaluation of the accuracy
using lumped parameter
modeling and analysis
Robinson, Gordon M. (1995) load cell geometry Genetic algorithm
optimisation by finite
element analysis
Literature review (Load cell)
9. Author Research area Focus on
Surasith Piyasi (2002) Hollow Clevis-pin Type
Load Cells
Detail Design
Sudhir Kumar, Nabi Hasan, Harish
Kumar and Anil Kumar (2011)
force transducer Finite element analysis
Harb, A. M. (2013) dynamic weighing systems Enhancing the performance
using Kalman filter
Samuel Tileston Whittemore (2014) Application Specific Force
Sensor for Snowpack
Assessment
Development and Testing
John Van Tuyl (2014) force sensing insole Development to quantify
impact loading to the foot in
various postures
Rakesh Kolhapure ⇑, Vasudev
Shinde, Vijay Kamble(2017)
strain gauge force transducer Geometrical optimization
using GRA method
Randall M. Schoonover (1979) Load Cell Mass Comparator Precision
Literature review (Load cell)
10. Author Research area Focus on
Kamlesh H. Thakkar, Vipul.
M.Prajapati, Bipin D. Patel (2013)
Strain Gauge Based Load
Cell
Performance Evaluation to
Improve Weighing
Accuracy
A. Abu-Sinna, Yon-Kyu Park , Dae-Im
Kang, Min-Seok Kim (2009)
load cell–deadweight
force machine interaction
The influence of loading
frame stiffness
Jean-Marc Drouet and Yvan
Champoux(2014)
Strain Gauge Transducer
for Dynamic Load
Measurement in Cycling
Designing using numerical
simulation
JacekPiskorowski,, Tomasz Barcinski
(2008)
load cell response Dynamic compensation
Robert M. Williams (2014) Beam Load Cell Evaluation of Base
Reaction and Force
Collision Detection on
Industrial Robots
G.M. Robinson(1997) load cell hysteresis Finite element modelling
Er. Dharmendra Kumar Dubey Dr. R. L.
Yadav Manoj Kumar(2015)
Force Transducers Calibration
Literature review (Load cell)
11. Author Research area Focus on
Ted Kopczynski,(2011) Weighing System’s Accuracy Five Factors That Can Affect
GardarPáll Gíslason (2011) Load cell optimization
Chung Ket Thein (2013) load cell Structural sizing and shape
optimization
A Karaus, H Paul Hottinger
Baldwin Messtechnik GmbH,
Darmstadt, Germany(1962)
Load cells with small nominal
load based on strain gauges
thin-film techniques
Robert Zwijze(2000) High Capacity Silicon Load
Cells
Micro-Machining
Brent J. Maranzano , Bruno C.
Hancock (2016)
dynamic load cells Quantitative analysis of impact
measurements
Er Dharmendra Kumar Dubey,
Dr. R. L. Yadav (2016)
Force Transducers Retrospective Study for
Comprehensive Design
Literature review (Load cell)
12. Author Research area Focus on
Aravind Russel, Jugal Karda,
Piyush Jain,Shalmali Kale
Pallavi Khaire(2016)
‘S’ Type Load Cell Simulation and Experimental
Study for Selection of Gauge
Area Cross-Section
Meng Chun-Ling,Zheng Wei-
Zhi, Lin Mei-Hong(2002)
double-shear beam load cell Finite element analysis
Prof. Kamlesh H. Thakkar,
Prof. Vipul M.Prajapati, Prof.
Bipin D.Patel (2013)
Strain Gauge Based Load Cell Performance Evaluation to
Improve Weighing Accuracy
Rakesh Kolhapure, Vasudev
Shinde, Vijay Kamble (2015)
Strain Gauge Transducer for
Weighing Application
Optimization of using GRA
Method
Rakesh Kolhapure , Vasudev
Shinde, VijayKamble (2016)
Load Cell Optimization using Grey
Relational Analysis Method
VaibhavVarne, VasudeShinde,
Vijay Kamble(2016)
Rectangular Beam Force
Transducer
Effect of Geometrical
Parameters on Sensitivity and
Volume
Literature review (Load cell)
13. Author Research area Focus on
VaibhavVarne, VasudeShinde,
Vijay Kamble (2016)
Pancake Type Load Cell Parametric Optimization using
Response Surface
Methodology
Rakesh Kolhapure , Vasudev
Shinde, VijayKamble (2017)
force transducer Geometrical optimization using
GRA method
Shreyas S. Pandit , Vijay A.
Kamble (2018)
Multi-stage Strain gauge based
load cell
Review
Literature review (Load cell)
14. Author Research area Focus on
Mikael J. Hvorslev (1972) Proving Rings And Frames For
Soil Testing Equipment
Details
Madhuban Prasad ,NabiHasan
, Anil Kumar , Harish Kumar
(2011)
square ring shaped force sensor Design studies
R. A. Mitchell (1968) n-Degree Elliptical Elastic
Rings of Non Uniform Cross
Section
Analysis
Sudhir Kumar, Wakkar Ali,
Anil Kumar, Harish Kumar
(2011)
Ring Shaped Force Transducer Axial Deflection Studies
Shailendra V. Dhanal(2013) octagonal ring for a three
component milling tool
dynamometer
Finite element analysis
Sudhir Kumar and H Kumar
(2014)
Ring Shaped Force
Transducers
Development and Testing
Literature review (Ring type)
15. Author Research area Focus on
Sudhir Kumar, Nabi Hasan,
Harish Kumar & Anil Kumar
(2011)
force transducer Finite element analysis
A.P. Onwualu (2002) extended octagonal ring
dynamometer
measurement of forces on a
simple tillage tool
Humberto Rodríguez- Fuentes,
Martin Cadena-Zapata, Jesús
Alonso Esparza- Renteria,
Juan Antonio Vidales-
Contreras, Ma. del Carmen
Ojeda-Zacarías and Alejandro
Isabel Luna-Maldonado (2014)
Circular Ring Type Monolithic
Load Cell
Design, Manufacturing And
Calibration Addressed To
Drawbar Pull Testing Of The
Farm Tractor
Harish Kumar, Chitra Sharma
and Anil Kumar (2011)
precision force transducers Design and development
Harish Kumar, Mohit Kaushik,
Pardeepc and Pawan Kumar
Arora (2015)
elliptical shaped force
transducers
Investigations on metrological
characterization for precision
force measurement
Literature review (Ring type)
16. Author Research area Focus on
Harish Kumar(2015) Design And Metrological
Characterization Of Force
Transducers
Finite Element Computational
And Experimental
Investigations
Harish Kumar Chitra Sharma
Anil Kumar(2011)
Ring Shaped Force
Transducers
Design Studies
Essam Soliman(2015) octal rings as mechanical force
transducers
Performance analysis
Harish Kumar & Chitra
Sharma (2012)
force transducers Performance evaluation
A. Abuhasel and Essam
Soliman(2016)
Octal Rings As Mechanical
Force Transducers
Regression Analysis
Vijay A. Kamble, Vasudev D.
Shinde, Jayant K. Kittur
(2019)
Ring Shaped Load Cells Shape Optimization for
Enhancing Sensitivity at
Lower Deflection using FEM
Literature review (Ring type)
17. Author Research area Focus on
Qiao kang Liang, Dan Zhang,
Yaonan Wang, Yunjian
Ge2013)
Novel Six-Component F/T
Sensor based on CPM for
Passive Compliant Assembly
Design and Analysis
A.R. Tavakolpour-Saleh, M.R.
Sadeghzadeh (2014)
three-component force/moment
sensor for underwater
hydrodynamic tests
Design and development
J.W Jooa, K.S Naa, D.I Kangb
(2002)
six-component load cell Design and evaluation
Fu Shao (2015) Three-Component Force
Sensor for Meso-Milling
Applications
Design
Gab-Soon Kim(2007) Six-Axis Force/Moment
Sensor with Rectangular Taper
Beams for an Intelligent Robot
Development
Literature review (Multi axis)
18. Author Research area Focus on
M. Mencattelli, Donati, A
(2014)
Customized Load Cell Three-Dimensional Force-
Moment Measurements in
Orthodontics
Yun Lu, , Weijia Li,, Wenzhuo
Tian, and Kai Zhou (2014)
Six-DOF Force Method on Measurement for
Heavy Load Equipment
Wei Zhang, Kim Boon Lua,
Van Tien Truong, Kumar A.
Senthil, Tee Tai Lim,
KhoonSeng Yeo, and Guangya
Zhou (2016)
Novel T- shaped Multi-Axis
Piezoresistive Force/Moment
Sensor
Design and Characterization
HilmanSyaeful Alam, Demi
Soetraprawata and Bahrudin
(2015
Six-Axis Force/Torque Sensor The Structural Design Using
Virtual prototyping Technique
Vinay Ganti(2011) 4-Dof Force/Torque Sensor For
Intelligent Gripper
Analysis
Literature review (Multi axis)
19. Author Research area Focus on
Amin Valizadeh, Alireza
Akbarzadeh, Mohammad
HoseinTashakori Heravi (2015)
Six-Axis Force/Torque Sensor Effect of Structural Design
Parameters Using Full
Factorial Design
Nicolas Sommer (2011) Multi-Axis Force/Moment
Sensor for a mobile quadruped
platform
Design and Integration
S. Boukhenous (2011) Three-Directional Force
Sensor”,
Low cost
Chul-Goo Kang(2005) 6-Axis Force-torque Sensor Performance Improvement via
Novel Electronics and Cross-
shaped Double-hole Structure
Literature review (Multi axis)
20. Author Research area Focus on
Chang Y.S., Lin T.C., (2013) G-shaped load cell for two
range loading
Optimization
Osman S.M., Hasan E. H., El-
Hakeem H.M., Rashad R. M.,
Kouta F. (2014)
Multi-Capacity Load Cell Concept
Kluger J. M., Sapsis T. P.,
Slocum A.H., (2016)
load cell by means of nonlinear
cantilever beams
high-resolution and large force-
range
Seif. M. Osman ,Ebtisam H.
Hasan, H. M. El-Hakeem,
R.M.Rashad d F. Kouta (2013)
multi-capacity load cell Conceptual design
Literature review (Multi capacity)
21. Author Research area Focus on
Dhananjay Ghanshyam Pardhi
and S D Khamankar (2014)
spline shaft Stress analysis using finite
element method and its
experimental verification by
photo elasticity
Minvydas Ragulskisa,, Miguel
A.F. Sanjuanb (2008)
Photoelasticity Chaotic pattern of unsmoothed
isochromatics around the
regions of concentrated stresses
Prajna P, Patil N Konark,
Meshramkar Roseline, Nadiger
Ramesh K. Shetty (2013)
Teeth and Surrounding
Structure
Fast and Economical
Photoelastic Model Making
Pichet Pinit (2009) two-dimensional stress field in
digital photoelasticity
Development of Window-based
program for analysis and
visualization
Dipti Kanta Das, Ashok Kumar
Sahoo, Ratnakar Das, B. C.
Routara ( 2014 )
hard turning using coated
carbide insert
Investigations using Grey
Based Taguchi and regression
methodology
Literature review (General)
22. Author Research area Focus on
Prof. H. V. Shete, Prof. R. A.
Pasale, Prof. E. N. Eitawade
(2012)
Internal Combustion Engine
Piston
Photoelastic Stress Analysis &
Finite Element Analysis
Dr. P Ravinder Reddy, Mr. K B
Jagadeeshgouda Mr. Suprit
Malagi (2015)
Curved Structure Analysis of Stress Distribution
Using Photoelastic and Finite
Element Method
Uddan wadiker, R. (2011) crane hook Stress analysis and validation
by photo-elasticity
M. Durairaja, D. Sudharsunb,,
N. Swamynathanb (2014)
Wire EDM with Stainless Steel Analysis of Process Parameters
using Single Objective Taguchi
Method and Multi Objective
Grey Relational Grade
Raghu N. Kacker, Eric S.
Lagergren, & James J. Filliben
(1991)
Classical Designs of
Experiments
Taguchi Vs Orthogonal Arrays
Robinson, G. M. (1995) load cell geometry Genetic algorithm optimisation
by FEA
Literature review (General)
23. •Comparison of strain induced in different load cell spring elements
results that circular ring load cell spring element is most sensitive
•. But less deflection is required to get equivalent strain in octagonal ring
than the circular ring.
•So octagonal ring spring element should be preferred than circular ring
Study of ring load cells
24. 24
Retrospective study of load cells
Investigation of Influence of design parameters
(different geometrical parameters of elastic elements, of
different materials, with different simulation parameters like
different loads) on the performance measures (maximum
stress, sensitivity, and volume) of various load cells is done.
Following types of load cells are considered for study.
• S beam load cell
• Double ended shear beam load cell
• Rectangular beam load cell
• Pan cake type load cell
• G shape load cell
Above load cells are optimized using Toguchi and grey
relational analysis techniques.
25. 25
S type load cell
Double ended shear beam load cell strain distribution
Rectangular beam type load cell strain distribution
Pan cake load cell strain distribution
Retrospective study of load cells
26. 26
Structural Analysis (FEA)
S type load cell strain distribution
Double ended shear beam load cell strain distribution
Rectangular beam type load cell strain distribution
Pan cake load cell strain distribution
27. 27
Work flow process for study
Work flow process
1. Design of Experiment (DOE)
2. Structural Analysis (FEA)
3. Multi-Objective Optimization (Grey
Relational Analysis)
4. Validation using Photoelasticity (ESA)
28. 28
Sr.
No.
Strain gauge
load cell types
Material Young’s
modulus
N/mm2
Geometrical
parameters
Enhancem
ent in
sensitivity
Reductio
n in
volume
1 Double ended
shear beam
EN 24
Steel
2.1x105 Length,
Height,
Thickness
69.28% 3.12%
2 S beam EN 24
Steel
2.1x105 Thickness,
Length,
Height
55.08% 1.06%
3 Rectangular
beam
EN 24
Steel
2.1x105 cavity radius,
height &
length
60% 2.2%.
4 Pan cake type EN 24
Steel
2.1x105 Rim
thickness,
web height
and web
43% 7%
Outcome of retrospective study
29. 29
Photo elastic analysis
‘S’ type model
Double Ended Shear Beam’ type load cell
Rectangular Beam’ type load cell
Pan cake type load cell
30. 30
Ansys and Photo elasticity results
Comparison between Ansys and Photoelasticity results
Sr.
No.
Type of load cell p (N/mm2) a (N/mm2)
1 S 115.47 122.3
2
Double Ended
Shear Beam
176.40 185.30
3 Rectangular Beam 29.06 31.11
4 Pancake 239.12 249.08
31. 31
Study of G shape load cell
Parameter Before optimization Optimized % Improvement
Mass 0.2553 0.25191 1.33
Sensitivity 1.948 2.6438 35.72
32. 32
Literature outcome
• The literature cited above provides basic
information regarding different types and
applications of load cells,
• It gives details about new ways in designing load
cell.
• Some of them present’s information on DOE and
other optimization techniques with help of FEA
softwares.
• Literature also put a light on experimental
techniques used for verification of performance of
load cell.
33. 33
Literature Gap
• Researchers have carried out most of the work on standard
load cells, ring load cells, Multi axis load cells but for
multicapacity load cells very limited work has been
reported.
• The effect of geometric parameters on the performance
characteristics of multicapacity load cells has not been
explored
• Multi-Objective geometric optimization of Multicapacity
load cell is another thrust area which has been given less
attention in past studies.
34. 34
Need of the Dual octal ring load cell
These forces may vary over a wide range and it may be necessary
to have accurate measurements at both ends of the range.
In order to measure 300 N force, a 5,00 N capacity load cell
might be used.
In order to measure 20 N force using a 5,00 N capacity load cell , the
output of the transducer must be highly amplified. In view of the high
amplification, the system is subject to error due to electrical noise both
from the amplifier and from other nearby electrical equipment such as
motors, relays, switches,- brushes, etc.
A low capacity load cell of 50 N capacity for measuring a 20 N
load, is not susceptible to electrical noise of this type since its output
need not be highly amplified.
35. 35
Need of the Dual octal ring load cell
In the calibration process of UTM of capacity of 1000
KN according to UTM standard 1828 It has to be tested
against each 20% load like in the step of 200 KN
More number of load cells are required to cover
different load ranges, these increases handling efforts, in
addition to increase the cost of purchasing load cells.
This work concerns with introduction of dual octal ring
Load Cell for wide-range loading.
Load Load cell capacity
200 KN 200 KN
400 KN 500 KN
600 KN 750 KN
800 KN 1000 KN
1000 KN 1000 KN
36. 36
Development of Dual octal ring load cell
Fig. 1: Dual octal ring load cell 2D, 3D model along with Wheatstone bridge circuit
37. Experimental runs, L9 OA
Volume, strain, deflection
S/N ratio of 1-9 expt.
(Effect of processing
conditions on response
variables)
S/N ratio
Normalization 1-9 &
Deviation sequence 1-9
Grey Relational
Coefficient,1 -9
Single Grey
Relational Grade
Single processing
condition
Comparability
sequences
Response
37
Dual octal ring load cell
Geometrical parameters
Experimental
validation
Research
approach
38. 38
DOE for Dual octal ring load cell
Sr. no. Parameters Level 1 Level 2 Level 3
1 Height of top octagon (HU) 90 100 110
2 Thickness of top octagon (TU) 4 6 8
3 Height of bottom octagon (HL) 90 100 110
4 Thickness of bottom octagon (TL) 4 6 8
Sr. no. HU TU HL TL
1 90 4 90 4
2 90 6 100 6
3 90 8 110 8
4 100 4 100 8
5 100 6 110 4
6 100 8 90 6
7 110 4 110 6
8 110 6 100 8
9 110 8 90 4
Level of input parameters
(DOF)R=P×(L-1)
Where
(DOF)R:Degree of freedom of Expt.
P:No of parameters
L:No of levels
(DOF)R=4×(3-1)=8
“DOF of the OA should be greater than or equal to the
total DOF required for the experiment”
Here, DOF of OA=DOF of Expt.
Therefore L9 (32) OA is selected
Selection of orthogonal array (OA)
Taguchi L9 Array
39. g. 1: Dual octal ring load cell 2D, 3D model al
Fig. 1: Dual octal ring load cell 2D, 3D model along with
Structural analysis of Dual octal ring load cell
40. Constraints
• Load cell is fixed to rigid support.
• Uniformly distributed load is acting on top surface of load cell.
• At the location of strain gauges values of strains are measured.
• Applied load 0 to 2940 for light load condition
2940 to 5000N for heavy load condition.
• Maximum strain induced is less than 1500 µ strain.
•The 0.3 mm gap is maintained in the limbs.
Material Young’s Modulus Poisson's
ratio
Density
EN 24 2.1 X 105 N/mm2
0.33 7840 X 105 Kg/mm3
41. 41
Structural analysis of octal ring load cell
Experiment
number
Volume
mm3
Deflection
mm
εt1
µ strain
εb1
µ strain
εt2
µ strain
εb2
µ strain
1 36730 0.375 875.190 737.750 1366.000 1247.000
2 49110 0.016 408.460 386.480 682.000 646.000
3 62310 0.088 231.790 249.200 396.150 415.240
4 52940 0.361 981.620 217.900 1123.000 376.000
5 49300 0.349 455.450 909.080 761.440 1533.000
6 55120 0.011 265.830 346.620 1117.000 589.050
7 53470 0.511 108.000 406.640 1336.000 697.630
8 58670 0.192 516.537 196.840 611.100 345.360
9 56570 0.254 294.740 820.790 497.770 1384.000
strain under light load in bottom ring (εb1)
strain under heavy load in top ring (εt2)
strain under light load in top ring (εt1)
strain under heavy load in bottom ring (εb2)
42. n = -10 log10 [mean of sum of squares of measured data]
S/N Ratio: Lower is better
( volume, strain under light load in bottom ring (εb1) and
strain under heavy load in top ring (εt2) )
n = -10 log10 [mean of sum squares of reciprocal of measured data]
S/N Ratio: Larger is better
(deflection, strain under light load in top ring (εt1) and strain under
heavy load in bottom ring (εb2),)
Effect of geometric parameter on response variables
Higher S/N ratio means to closer to optimal parameters
43. S/N ratio for volume
476
.
94
52940
)
log(
10
S/N 2
Smaller is the better
Expt.
No.
Volume
S/N
ratio
1 36730 -91.300
2 49110 -93.823
3 62310 -95.891
4 52940 -94.476
5 49300 -93.857
6 55120 -94.826
7 53470 -94.562
8 58670 -95.368
9 56570 -95.052
21/7/2018 43
Effect of parameters on volume
Optimum combination for
volume
A1B1C1D1
44. S/N ratio for Deflection
856
.
8
361
.
0
/
1
)
log(
10
S/N 2
Larger is the better
Expt.
No.
Deflection S/N
1
0.375 -8.518
2
0.016 -36.053
3
0.088 -21.125
4
0.361 -8.856
5
0.349 -9.148
6
0.011 -39.114
7
0.511 -5.836
8
0.192 -14.339
9
0.254 -11.906
21/7/2018 44
Effect of parameters on Deflection
Optimum combination for
deflection
A3B1C3
D- Least affecting
45. S/N ratio for strain under light load in top ring (εt1)
839
.
59
620
.
981
/
1
)
log(
10
S/N 2
Larger is the better
Expt.
No. εt1 S/N
1 875.190 -58.842
2 408.460 -52.223
3 231.790 -47.302
4 981.620 -59.839
5 455.450 -53.169
6 265.830 -48.492
7 1080.000 -60.668
8 516.537 -54.262
9 294.740 -49.389
21/7/2018 45
Optimum combination for
εt1
A3B1
C & D - Least affecting
46. S/N ratio for strain under light load in bottom ring (εb1)
7651
.
46
900
.
217
)
log(
10
S/N 2
Smaller is the better
Expt.
No. εb1 S/N
1
737.750
-
57.3582
2
386.480 -51.742
3 249.200 -47.931
4
217.900 -46.765
5 909.080 -59.172
6
346.620 -50.797
7
406.640 -52.184
8
196.840 -45.882
9
820.790 -58.284
21/7/2018 46
Optimum combination for
εb1
C1D3
A & B- Least affecting
47. S/N ratio for strain under heavy load in top ring (εt2)
008
.
61
000
.
1123
)
log(
10
S/N 2
Smaller is the better
Expt.
No. εt2 S/N
1
1366.000 -62.709
2
682.000 -56.676
3 396.150 -51.957
4
1123.000 -61.008
5 761.440 -57.633
6
1117.000 -60.961
7
1336.000 -62.516
8
611.100 -55.722
9
497.770 -53.941
21/7/2018 47
Optimum combination for
εt2
B3C3
A & D - Least affecting
48. S/N ratio for strain under heavy load in bottom ring (εb2)
504
.
51
000
.
376
/
1
)
log(
10
S/N 2
Larger is the better
Expt.
No. εb2 S/N
1 1247.000 -61.917
2 646.000 -56.205
3 415.240 -52.366
4 376.000 -51.504
5 1533.000 -63.711
6 589.050 -55.403
7 697.630 -56.873
8 345.360 -50.765
9 1384.000 -62.823
21/7/2018 48
Optimum combination for
εb2
C3D1
A & B- Least affecting
49. 49
HU - top octagon height, TU - top octagon thickness, HL- bottom octagon height, TL -bottom octagon thickness
Fig.3. Mean of S/N Ratio plots for volume, deflection and maximum strain values
(A1B1C1D1)
result
min.volume.
(A3B1C3)
result
Max. deflection
(A3B1) result
Max. straining
in top ring under
light load.
(C1D3) result
Max. straining
in bottom ring
urder light load
(B3C3) result
max. straining
in top ring under
heavy load
(C3D1) result
Max. straining
in bottom ring
under
heavy load
59. 59
ANOVA for grey relational grade
Source Adj SS Adj MS % contribution
HU 0.002270 0.001135 7.41
TU 0.017998 0.008999 58.77
HL 0.003970 0.001985 12.96
TL 0.006383 0.003191 20.85
Total 0.030621 100.00
top octagon thickness (TU) followed by bottom octagon thickness (TL)
are most significant control factor
60. 60
Predicted and Validation values of optimal parameters
Sr.
No.
Process Parameters
Initial
Setting
Predicted
Value
FEA
Validation
1
Optimal parameters A3B1C2D2 A3B1C3D1 A3B1C3D
1
2 HU 110 110
3 TU 4 4
4 HL 100 110
5 TL 6 4
6 Grey Relational Grade 0.636 0.699 0.674
“Improvement of 5.97 %”
61. 61
Manufacturing of dual octal ring load cell
Using wire EDM because of its high
precision and ability to make small gap of 0.3
mm gap
Using 20 mm thick sheet of EN 24 steel.
This EDM uses 0.25 mm diameter brass wire
and creates spark of 0.025 mm and can cut to
an accuracy of 0.025 mm.
Four strain gauges are mounted in each ring
and Wheatstone bridge circuit is used to get
electrical output voltage
63. 63
Testing of dual octal ring load cell
• Load cell is tested under 5 kN Dead Weight Force Calibration
Machine at FIE Research Institute, Ichalkaranji.
• Loaded in the step of 500N up to 5000N in the compression
mode
• The electrical output from the top ring and bottom ring of the
dual ring load cell is recorded
64. 64
Electrical output of the dual octal ring load cell
• Output (millivolts) curves of upper ring and lower ring(left)
• Overall electrical output of loadcell(right).
65. 65
Uncertainty Calculation
• Uncertainty Calculation as per IS 4169-2014/ISO 376-2011.
• Calibrated from 10% - 100% of the rated capacity A high resolution
digital indicator is used to take the observations.
• Uncertainty of measurement of load cell involves uncertainty due to
factors including relative zero offset, relative repeatability, relative
resolution and relative interpolation.
• The relative repeatability of the force transducers is found up to 0.0224
% and is within the permissible limits as specified the standard
discussed.
• Uncertainty of force measurement of force calibration machine into
account is up to 0.038 %, which is well within limits as permitted by
the standard IS 4169-2014/ISO 376-2011.
66. The effect of design parameters of dual octal ring
load cell on its performance measures is investigated.
The conclusions based on multi-objective
optimization of dual octal ring load cell using Taguchi
with GRA and experimental performance evaluation
is summarized as follows:
• The newly developed Dual capacity load cell gives
low stiffness for light load causing high sensitivity,
while high stiffness for heavy load preventing over-
straining.
• Grey regression analysis optimization technique
indicated decrease in mass by 12% with 27% increase
in deflection.
Conclusions
67. • The performance evaluation test showed increase in
sensitivity by 15.88 % for light loads (up to 2940 N)
as compared to heavy load condition (2940 N to 5000
N), which is very essential to achieve high precision
measurements.
• The Polynomial regression equation is obtained using
experimental observations of load cell. The equation
obtained is y = 9E-10x3 - 1E-05x2 + 0.1392x -
10.576, Where x is force in Newton, y is electrical
output in millivolt.
• Based on ANOVA for Taguchi DOE method and
Grade values, top octagon thickness (TU) followed
by bottom octagon thickness (TL) are most
significant control factor for all performances
Conclusions
68. • At optimum level of GRG, Initial GRG is 0.762 and
after Confirmation experiment, it is obtained as 0.911,
means there is “Improvement of 16.36 %” is
observed which confirms the theoretical values.
• The uncertainty of the load cell is found to be ± 0.038
% which includes the relative deviations due to the
factors as per standard procedures.
• The load cell confirms to class 1 as per IS 4169-
2014/ISO 376-2011, respectively and is suitable for
use as force transfer standard.
• The experimental results will provide significant
guidance for designing of force sensor.
Conclusions
69. 69
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Papers published
•Vijay A. Kamble, Jayant K. Kittur ,Vasudev D. Shinde, “Geometrical Optimization of Dual Octal Ring
Force sensor for Wide Range Loading using GRA”, Materials Today: Proceedings, 2021 - Elsevier ,
https://doi.org/10.1016/j.matpr.2021.03.745
•Vijay A. Kamble, Jayant K. Kittur , Vasudev D. Shinde, “Finite element analysis of two stage force
transducer”, Journal of Mechatronics, Machine Design and Manufacturing ,Vol. 2 Issue 3, Page 21-25 ,2020
•Vijay A. Kamble, Vasudev D. Shinde, Jayant K. Kittur , “Shape Optimization of Ring Shaped Load Cells for
Enhancing Sensitivity at Lower Deflection using FEM”, Journal of Research in Mechanical Engineering and
Applied Mechanics, Vol. 4 ,Issue 2, Page 28-36, 2019
•Vijay A. Kamble, Vasudev D. Shinde, Jayant K. Kittur , “Review on optimization of load cells”, Journal
of,Advancements in Material Engineering, (e-ISSN: 2582-0036), Vol.5, Issue, 2020
•Vijay A. Kamble, Vasudev D. Shinde, Jayant K. Kittur , “Critical Assessment of Load Cells “Journal of
Advancement in Machines (e ISSN: 2582-2233), Vol. 5, Issue 3, 2020
•Vijay A. Kamble, Vasudev D. Shinde, Jayant K. Kittur , “Overview of Load Cells”, Journal of Mechanical
and Mechanics Engineering (e-ISSN: 2581-3722),Vol. 5 , Issue 3, 2020.
•Shreyas S. Pandit , Vijay A. Kamble ,“Finite element analysis for stress analysis and Non linear contact
analysis of Multi range load cell in Ansys software”, International journal of Engg. And
Technology,eISSN:2395-0056,p-ISSN2395-0072,vol. 05,issue 06,June 2018
•Shreyas S. Pandit , Vijay A. Kamble, “Review of Multi-stage Strain gauge based load cell”- National
conference on excellence in design manufacturing and automation Textile and engineering Institute
Ichalkarnaji, 26-27 April 2018
83. 83
Papers published
•Rakesh Kolhapure , Vasudev Shinde, VijayKamble “Geometrical optimization of strain gauge force
transducer using GRA method” - Measurement 101 (2017) 111–117
http://dx.doi.org/10.1016/j.measurement. 2017.01.030 0263-2241/_ 2017 Elsevier Ltd.
•VaibhavVarne, VasudevShinde, Vijay Kamble ,“Parametric Optimization of Pancake Type Load Cell Using
Response Surface Methodology” - International Journal of Current Engineering and Technology, issue 6, 2016
•Rakesh Kolhapure , Vasudev Shinde, VijayKamble ,“Optimization of Load Cell by Grey Relational Analysis
Method” - International Journal of Engineering Technology, Management and Applied Sciences, February
2016, Volume 4, Issue 2, ISSN 2349-4476.
•VaibhavVarne, VasudevShinde, Vijay Kamble “Effect of Geometrical Parameters on Sensitivity and Volume
of Rectangular Beam Force Transducer” - Journal of Recent Trends in Mechanics Volume 1 Issue 1, Page 1-
14, 2016
•D.M. Kalai, V.A.Kamble, A.M.Rathod, B. K. Khot “Parametric Optimization of Rectangular Beam Type
Load Cell Using Taguchi Method” - International Journal of Computer Engineering In Research Trends,
Volume 3, Issue 11, November-2016, pp. 596-601
•Rakesh Kolhapure, Vasudev Shinde , Vijay Kamble “Optimization of Strain Gauge Transducer for Weighing
Application Using GRA Method”, Asian Journal of Engineering and Applied Technology, Vol. 4 No. 2, 2015
pp 1-7
•Paper presented in Conference : “Geometrical Optimization of Dual Octal Ring Force sensor for Wide
Range Loading using GRA”, 3rd International e-Conference on Frontiers in Mechanical Engineering and
nanotechnology [ICFMET-2020] held on November 27-28, 2020.
