Table of Contents

COMPARISON OF INTERFACE PRESSURE MEASUREMENT OPTIONS ................................................................................. 3 SENSING PRESSURE ................................................................................................................................................................... 3 INTERFACE PRESSURE SENSING TECHNOLOGIES ............................................................................................................................... 3 Load Cell .......................................................................................................................................................................... 4 Pressure Indicating Film .................................................................................................................................................. 5 Tactile Pressure Sensor ................................................................................................................................................... 6 Tactile Force Sensor ........................................................................................................................................................ 8 COMPARISON OF MEASUREMENTS FROM DIFFERENT PRESSURE SENSING TECHNOLOGIES ....................................................................... 9 Load Cell .......................................................................................................................................................................... 9 Pressure Indicating Film ................................................................................................................................................ 10 Tactile Pressure Sensor ................................................................................................................................................. 11 Data from Three Technologies ...................................................................................................................................... 13 PRESSURE SENSING APPLICATIONS ............................................................................................................................................. 13 Fuel Cell Stack and Battery Plates ................................................................................................................................. 13 Tire Tread ...................................................................................................................................................................... 14 Chemical Mechanical Polishing (CMP) .......................................................................................................................... 15 Body Measurement in a Seat ........................................................................................................................................ 16 Nip or Roller Measurement ........................................................................................................................................... 17 CONCLUSION ......................................................................................................................................................................... 18

Comparison of Interface Pressure Measurement Options

COMPARISON OF INTERFACE PRESSURE MEASUREMENT OPTIONS

SENSING PRESSURE
An increasingly competitive global marketplace means that design engineers must efficiently deliver a high quality product. Countless emerging technologies impact the design process and engineers must practice due diligence to ensure analysis tools meet their applications requirements. This paper focuses specifically on technology for interface force and pressure measurement between two surfaces and includes a review of technology composition and data output. This paper will also examine capabilities driven by form factor, precision and environment that influence selection criteria of interface force and pressure sensors. Pressure is measured in a variety of applications, ranging from medical research to product development. Some key problems that engineers are trying to resolve are: Identifying failure mode of a product and/or design Hot Spot Understanding force distribution between two load bearing surfaces Verifying proper sealing or snap fit in product design Calibrating manufacturing equipment (nips, surface processes, or spray patterns) Verifying alignment of pressure rollers Evaluating effects of different manufacturing processes on product quality Benchmarking competitive product

The more data available in these applications, the better a researcher can assess the situation and identify a resolution.

INTERFACE PRESSURE SENSING TECHNOLOGIES

Pressure is the measurement of force over an area. The formula is commonly written as: P =F/A When two objects are held in contact, they exert force on each other. Therefore, the average interface pressure is the total force divided by the interface area. When this interface pressure is not uniformly distributed, localized interface pressure measurement is necessary to find concentrations of peak pressure. Even between relatively flat surfaces, one finds the interface pressure distribution is often non-uniform with localized areas of peak pressure. Interface pressure measurement sensing technologies can identify the location and magnitude of these peak pressures, or visualize pressure gradients across the interface. When trying to measure interface pressure, measurement devices should minimally impact the contact pressure profile of the items being measured. Three technologies to consider when trying to measure force or interface pressures are: 1. Load cells 2. Pressure indicating film 3. Tactile Pressure Mapping systems While there is some overlap with the information each sensing technology provides, they each present a unique value in the problem-solving process. The sensors ability to match the interface with the surfaces applying the load becomes critical as the shape of the target becomes increasingly abnormal.
Comparison of Interface Pressure Measurement Options 3

Load Cell
The force or pressure sensor that most researchers and engineers are familiar with is a load cell. They can use a variety of technologies to sense loads. Strain gauges, piezoelectric elements, and variable capacitance are among the methods in high use. Depending on the force applied and the mechanics of the application, multiple form factors of load cells are utilized. Compression, S- or Z- beam, and shear beam load cells all rely on strain gauges measuring the mechanical deformation of a beam to quantify the force of the load applied. One of the most reliable load cells is a compression canister (Figure 1), which utilizes a full bridge of strain gauges that are bonded to load-bearing structures.
Figure 1: Inside View of Load Cell

Strain Gauges

Bearing Structure When force is applied to the load cell, the bearings deform and a mechanical stress is placed on the strain gauges changing the resistance of the output signal. After calibration, the output voltage correlates to the force applied to the load. Because of the durability of the bearing structure, the reliability and accuracy of the device remain resilient through very high forces applied to the load cell. The strain gauges can measure forces that put the bearings in tension, in addition to compression. The form factor of the load cell yields a bulky device. When used in tight quarters, this bulkiness means that the load cell can be difficult to position in the manner desired for collecting relevant data. Furthermore, the load cell can only output the total force applied to the bearing and cannot show distribution of pressures on a surface. In some instances, researchers can use multiple load cells to measure forces over multiple regions of a contact interface.

Comparison of Interface Pressure Measurement Options

Figure 2: Pressure Measurement using Multiple Load Cells

LC

LC

LC

LC

In Figure 2, an interface or contact area is shown broken into four quadrants with a unique load cell measuring each area. This configuration provides more detail on the force distribution across the surface, giving the average pressure for each zone. The more load cells used, the finer the granularity of pressure distribution that can be measured. As more load cells are added to the array, the data collection apparatus can become very expensive and cumbersome to use. Furthermore, the size of the load cells themselves limits the density of measurement points. If localized pressure distribution is different between load cell locations, the pressure spike will be missed and the gradient will be averaged by the neighboring load cells. In addition, as load cells are typically embedded into the structure, the introduction of many load cells could affect the structural integrity of the device; thereby, altering or skewing the results. In most instances where force applied to an area is inconsistent, the load cell can show the total force but cannot identify localized spikes in pressure. Load cells are commonly used with testing equipment like an Instron system. A mechanical load is applied to an object (either compression or tension), and the load cell can accurately measure the forces experienced over a broad range.

Pressure Indicating Film

Pressure indicating film is used to measure interface pressures between two surfaces. Under a layer of polyester, a color developing material is layered next to tiny microcapsules, which are designed to break under different pressures. When pressure is applied to the film, the microcapsules rupture, distributing ink where pressure is applied. As more force is applied to a location, more microcapsules are broken, increasing the intensity of color on the film. The result is an image of the force applied across the sensing area. Typically, high sensitivity film for low-pressure measurements utilize two sheets of polyester to keep the color developing material and microcapsules separate until the measurement is taken. High-pressure films usually have all components on one sheet.
Figure 3: Components of Pressure Indicating Film

Comparison of Interface Pressure Measurement Options

This consumable film brings some unique features to applications. Its flexibility and thinness allow the film to be used in a broad range of applications to capture images of pressure profiles. The film can be cut in unique shapes to fit into applications with obstructions. Because there are no attached electronics, the film can be fed through rollers to obtain the pressure distribution with no concern of crushing wires or expensive electronics. An optional scanner and software solution provides the ability to run a digital analysis of a scanned sheet. The nature of the film will only provide the peak pressure between interfaces during a measurement. This has obvious limitations when trying to measure dynamic applications. Static measurements can also be affected, as there is often a spike force on the film as the two interfaces are initially brought together. An example is the measurement of pressure distribution between an engine block and its head. As each fastener is tightened to secure the two halves together, the fastener can relax the stress on a neighbor. When measuring this distribution dynamically, one will only observe the peak pressure during the tightening process. As the resting pressure between the interfaces is not measureable, designers can overestimate the actual final pressure when using pressure indicating film.

Tactile Pressure Sensor

A common type of tactile pressure sensor consists of a unique piezoresistive material sandwiched between two pieces of flexible polyester, with printed silver conductors on each half. The result is an extremely thin 0.004 (0.1 mm) sensor, which can be manipulated to fit in a broad range of applications with minimal disturbance to the behavior of the system being tested.
Figure 4: Construction of a Tactile Pressure Sensor

The silver traces provide a conductive track for the scanning electronics to transmit a signal through the piezoresistive ink. As pressure is applied to the sensing area, the resistance of the ink changes and the scanning electronics collects the analog data. The analog data is converted to a digital signal, which is then transmitted to a PC.
Figure 5: Components in a Tactile Pressure Mapping System

Tactile Array Pressure Sensor

Data Capture & Visualization Software

Data Acquisition Electronics

Comparison of Interface Pressure Measurement Options

Figure 5 shows the three components that make up a tactile pressure mapping system: the sensor, the scanning electronics and the software. When no force is applied to the sensor, the resistance of the ink is on the order of MegaOhms (M). As more force is applied, the output resistance drops to as low as 10 k. The output, expressed as conductance (1/R), is linearized to correlate with the load applied, and converted to digital counts or raw values on a scale of 0-255. The typical linearity error is <3%. When applying a known force to an area of the sensor face, the output can be converted to engineering units, such as psi or kPa.
Figure 6: Correlation of Resistance to Digital Output

To map the distribution of pressure over the target area, the tactile pressure sensor and scanning electronic must identify the position of all the forces applied. To do this, the sensor has a vertical and horizontal array of piezoresistive traces. Each sensing element found at the intersection of each row and column is called a sensel. The number of sensels in the array defines the spatial resolution of the sensor. The concept is similar to the matrix of load cells providing the average pressure over an area of the surface measured. However, the nature of the tactile pressure sensor has a much higher density of sensing elements, providing a better spatial resolution of the pressure distribution. Figure 7 illustrates the sensing system and a simplified electrical schematic of the 8-bit electronics that scan each sensel. The sensels are read in the presence of multiple contacts while simultaneously limiting the possible current flow through the device. Each sensel is represented by a variable resistor whose value is highest when no force is applied. The entire sensing area can be scanned at speeds as high as 20 kHz or a selected area can be scanned even faster.
Figure 7: Electric Schematic of Sensor

Comparison of Interface Pressure Measurement Options

The software that accompanies the tactile pressure sensor provides multiple tools for analysis. A real time window shows the activity in the sensor area, which allows the user to see the impact of adjustments made. In dynamic applications, a movie of the pressure distribution can be recorded for frame-by-frame analysis. The software can generate various types of graphs showing force, pressure, contact area, and other parameters versus time or position on the sensor. The software can also identify the center of force for the contact region. The tactile pressure sensor requires more work to calibrate properly as the end user must calibrate for the specific application. The stiffness or compliance of the interface material has an effect on the pressure distribution and on localized peak pressures. Therefore, the sensor should be calibrated against materials very similar to those in the application. Additionally, if the pressure sensitive elements are under a constant load for a prolonged duration of time, the ink will continue to compress, changing the resistance, creating a drift in the pressure measurement. The output increase is between 0%-3% per log time, which can be compensated for with proper calibration. Over time, sections of the sensor, which have been exposed to higher forces, can start to plastically deform and exhibit different sensitivity. A periodic equilibration will correct the inconsistency. A device called an equilibrator applies a uniform pressure across the sensor face. While this uniform pressure is applied, the software can create scale factors to normalize the output of each individual sensel. High pressure, complex contours and high temperatures will all have an impact on the overall lifespan of a tactile pressure sensor. The same scanning electronics can be used with a replacement sensor once a sensor has reached the end of its lifecycle.

Tactile Force Sensor

For basic applications, a tactile force sensor can be used. The construction of the force sensor is similar to a pressure sensor but instead of a matrix of sensing traces, the ink uniformly covers an area to measure the total force applied to that space as shown in Figure 8. This sensor cannot map the pressure distribution but the resistance change correlates to the force over the entire area. Since only one voltage is being measured for the entire sensing area, the data acquisition electronics are much simpler and compact. Furthermore, the output can easily be connected to custom electronics to integrate force data with other measurements. The sensing area is available in a variety of shapes. The thinness and flexibility of the force sensor allows it to be mounted in a broad range of hard-to-fit applications.
Figure 8: Tactile Force Sensor

The tactile force sensor enjoys many of the benefits as the tactile pressure sensors as they utilize the same technology. Therefore, similar considerations must be taken when using the force sensor. Application specific calibration, drift, and lifespan are all factors still to consider with this sensor. However, since there is one sensing area, equilibration is not necessary to ensure consistent data collection.

Comparison of Interface Pressure Measurement Options

Like a load cell, a tactile force sensor will only provide information of the total force applied to the sensing area. As described earlier, form factor and performance are the differentiators between the tactile force sensor and the load cell. Available in a variety of form factors -- some of which can be cut to shape tactile pressure and force sensors can be applied to a broad range of applications. Due to their flexibility, forces can be measured against tires, door seals, body parts, rollers, and numerous other surfaces. These sensors can provide a wealth of information about the pressure and force between two contacting surfaces.

COMPARISON OF MEASUREMENTS FROM DIFFERENT PRESSURE SENSING TECHNOLOGIES

To analyze the capabilities and limitations of load cells, pressure sensing film, and tactile pressure sensors, an identical load was applied by an Instron machine to all sensing technologies. For the comparison, the load is applied via a 2 x 2 aluminum plate interface. 800 lbs (363 kg) of force was applied to the sensor and then increased to 1600 lbs (726 kg).

Load Cell
With the support of data collection software and an analog-to-digital interface, accurate force data can be measured on the force applied by the plate. Figure 9 shows the results of data collected at 5 Hz for a duration of 100 seconds. The resulting force vs. time profile demonstrates increasing force for 20 seconds, constant force for 10 seconds, and then a second increase in force.
Figure 9: Output from Load Cell

The load cell used for data collection can measure up to 22,480 lbs (10,200 kg). The small bumps along the curve are a result of the low analog-to-digital converter resolution. Aside from the resolution issue, the data shown is linear and very consistent. Even though the input card A/D resolution limits the precision of the data, the measurement is still very accurate across a wide range of forces High precision over a broad spectrum of forces is one of the strengths of this technology. To determine the average pressure applied, the user divides the reported force by the area of the plate applying the force, to determine the two plateaus to have 200 (1.38 MPa) and 400psi (2.76 MPa), respectively. For a controlled experiment, the adjustment calculation is straightforward; however, for unique shapes, where the contact area is not known, or non-flat surfaces, the pressure estimate is less accurate.
Comparison of Interface Pressure Measurement Options 9

Pressure Indicating Film

The pressure indicating film was only used to measure the 800 lbs load applied to the interface. To collect data, the Super Low Pressure (LLW) film was used, which is rated for 71-355 psi (0.5 to 2.5 MPa), but there are many other pressure ranges available. The resulting peak pressure is shown in Figure 10.
Figure 10: Photo of Super Low Pressure (LLW)

The resulting image from the pressure indicating film only indicate peak pressures, so there is no data reflecting the dynamic nature of the pressure applied. In this experiment only 800 lbs (363 kg) was applied to the film. If the Instron were to also apply a 1600 lbs (726 kg) load to the film, the higher measurement would have covered up the 800 lbs (363 kg) reading. This can be problematic if a measurement application applies a spike force on the film before the two interfaces reach a resting pressure. The film was scanned and the data reviewed in film analyzing software. The resulting evaluation, shown in Figure 10, provides key metrics such as overall load, loaded area, peak pressure, average pressure, and Prescale Effective Rate percentage. The Prescale Effective Rate percentage provides an assessment of the quality of the data collected and is an indication of the accuracy of the data in the report.
Figure 11: Film Analytics

Comparison of Interface Pressure Measurement Options

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With a Prescale Effective Rate percentage around 80%, the data provided is suspect. The reported load, 3901N (877 lbs), and average pressure, of 1.52 MPa (220 psi), represent approximately a 10% error from the load actually applied by the Instron. The simplicity of the pressure indicating film provides versatility to collect interface pressure in a variety of applications. However, this simplicity means that only peak pressures can be recorded, resulting in loss of information regarding the dynamic nature of the applied pressure.

Tactile Pressure Sensor

A variety of tactile pressure sensor form factors are available, providing options for sensing area, spatial resolution, and pressure range. Because of the density of sensing elements, a wealth of data is collected.
Figure 12: Pressure Mapping System Display

Figure 12 shows the image generated by the tactile pressure mapping system software. The first image is pixelated because this is the raw data collected from the sensor. Each pixel represents the data from an individual sensel in the sensor. The second image demonstrates the softwares ability to interpolate, average, and contour the data in the image; creating a clearer representation of the object being measured. The algorithms used for interpolation have no impact on the softwares data analysis, only the image produced. This maintains accurate data while providing clearer images for review. In addition to the color representing the pressure distribution, the image plots two icons on the screen: a white box that identifies the location of the peak pressure, and a grey-white diamond that identifies the center of force in the contact area.

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Figure 13: Screen Shot of Software

The software provides multiple ways to view and analyze the data. Just under 100 seconds of data was recorded as the Instron applied various forces. The graph at the bottom of Figure 13 shows a plot of the total force applied versus time. Collected sensor frames can be synchronized with video to enhance the evaluation of data collection. The graph in Figure 13 plots two data series: the pressure sensor data and the analog input from the load cell. The left vertical axis defines the force, and it correlates to the output of the tactile pressure sensor. The right axis defines the load cell reading. This load cell is connected to the system via an analog-to-digital converter. In the experiment, force from the Instron was applied to the tactile pressure sensor and load cell simultaneously. This is possible because of the tactile pressure sensors thinness. The tactile pressure sensor was placed directly on top of the load cell and was nonintrusive when taking a measurement. The software used the input from the load cell to calibrate the tactile pressure sensor, creating an accurate measurement. This is reflected in the overlap of the two curves in Figure 13. This configuration leverages the strengths of load cells and tactile pressure sensors to provide the user with a complete and accurate analysis. In this experiment, the tactile pressure sensor reports force data within 3% of the actual force being applied. In addition to identifying the center of force, the software can show the peak pressures of each of the sensels, track the trajectory of the center of force, view the data in a 3-D graph, and view the force value of each sensel. Data can be reviewed in Microsoft Excel or exported in ASCII format for in-depth analysis. Graph options can be adjusted to show object area, contact area, force, and pressure over time, frame, or position in line/histogram graphs.

Comparison of Interface Pressure Measurement Options

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Data from Three Technologies

When measuring interface pressure, load cells provide the most reliable data, but the size and number of load cells restrict the range of applications in which they can be used. In addition, total load is easily reported but getting fine granularity of pressure distribution can be limited due to the size of the load cell. Pressure indicating film can be manipulated to fit into a variety of applications, but the data has less accuracy and cannot report the range of forces applied in dynamic applications. Tactile pressure sensors can provide detailed dynamic measurements of interface pressure with minimal impact on system dynamics. The sensing elements need to be properly calibrated to provide accurate data, but the resulting measurements provide the most in depth analysis of interface system dynamics. Depending on the information needed and the physical constraints of the system being measured, load cells, pressure indicating film, and tactile pressure sensors each have advantages and constraints for providing accurate and meaningful data. Understanding how these strengths and limitations influence an application is critical.

PRESSURE SENSING APPLICATIONS

Measuring the forces between two surfaces is critical in solving many problems involving product design and quality, manufacturing processes, failure mode identification, and system behavior. This section reviews some common applications and shows the information that a tactile pressure mapping system can provide when trying to optimize a solution.

Fuel Cell Stack and Battery Plates

Uniform contact pressure over a large area of dissimilar materials is an important factor in the performance of both fuel cells and some battery assemblies. In fuel cells, adjacent thin plates are stacked up to separate flows of hydrogen or hydrocarbons and oxygen. These plates must be in good contact with each other for efficient performance. Seals at the edge of the stack prevent leakage of chemicals from one region to another and from the interior to the environment. In batteries, consistent contact over large plate surface areas supports low internal resistance. Designers try to optimize clamp assembly configuration to get a uniform pressure distribution between the clamps. The consistency of pressure between the two plates has a correlation to the electrical performance of the cell in operation. A tactile pressure sensor can be placed between the plates of two different clamping configurations (standard and reinforced) to compare pressures.
Figure 14: Tactile Pressure Data of Forces Between Standard Clamping and Reinforced Clamping

A) Standard Clamp

B) Reinforced Clamp

Comparison of Interface Pressure Measurement Options

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Figure 14 shows the pressure distribution on the fuel cell with the original clamp configuration and the reinforced configuration. While the reinforced clamping costs more to implement, designers can see it improve the distribution of pressure across the plate face. Using the tactile pressure measurement system software, an analysis can be run on a section of the plate face near the clamping. A box is drawn around the area of interest, and the graphs are generated. The traces in the graph in Figure 15 correlate to the color of the boxes in Figure 14.
Figure 15: Histogram of Two Clamping Solutions for a Fuel Cell

Figure 15 shows the average pressure applied to the plate as a function of the distance across the drawn box object. Each distance interval is one sensor column width (1 cm.) across the length of the sensor face. Here, the graph shows the standard solution (in red) has a peak pressure near the clamp, but the pressure drops off toward the middle of the plate. The reinforced clamping (in green) applies a higher pressure across the middle of the plate. Load cells can provide accurate measurement of the forces applied, but require multiple units and complex configurations to reflect the interface pressure distribution. In addition, it can be very difficult to mount the larger load cells without influencing the dynamics of the system. Pressure indicating film can also be used in this application, but often the high spike pressures captured on the film occur during the clamping process and the actual pressures in these areas are lower when the cell is in operation. This can provide misleading information of the actual interface pressures. The film must be replaced for each incremental measurement, making measuring adjustments time consuming. In addition, as the seals or gaskets relax over time, the interface pressure will change, which cannot be captured by a static measurement. Engineers use the tactile pressure system to optimize the clamping design for fuel cells. The dynamic measurement of the tactile pressure sensor allows researchers to obtain real-time feedback while adjusting clamps, which greatly simplifies optimization of parameters.

Tire Tread
Understanding tire behavior during motion is critical to designing a high performance tire. A ruggedized tactile pressure sensor, with electronics in metal enclosures, sits on a steel plate, and can measure the pressure distribution of a tire rolling across the sensor face.

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Figure 16: Tactile Pressure Surface Image of Tire Footprint

The point-of-contact data is analyzed in the tactile pressure measurement software to determine perimeter area, crosssectional pressure profile, measure footprint length and width, and other configurable parameters. Tire manufacturers use the data to: Evaluate and compare tire designs and tread patterns Assess different materials and rubber compound formulations Conduct quality control measurements Perform competitive benchmarking Assess the impact of vehicle suspension

Load cells are often used in conjunction with tactile pressure sensors to control the force applied to the tire within a load frame. Alone, the force data does not provide much information for tread analysis. In lieu of pressure indicating film, ink is sometimes applied to the tire tread in order to evaluate the footprint of a tire. Ink measurements have many of the problems of pressure indicating film: the analysis is difficult and often inaccurate, it is difficult to collect data from a moving tire and only spatial dimensions can be measured. For the most comprehensive feedback of tire functionality, the tire can be rolled over the tactile pressure sensor while collecting dynamic measurements.

Chemical Mechanical Polishing (CMP)

In semiconductors, Liquid Crystal Displays (LCDs), Printed Circuit Boards (PCBs), and other high-end electronics manufacturing, chemical machine polishing requires that an even polish be performed on parts to avoid adversely affecting subsequent manufacturing steps. Measuring this process with a load cell results in an overview of the total force applied to the surface, but does not identify the regions of the parts that experience excess force. The load cell output is shown in Figure 17.

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Figure 17: Load Cell Data Recorded during CMP Process

A thin tactile pressure sensor can be placed between a wafer and polishing head to measure pressures applied to the product during the process, as shown in Figure 18.
Figure 18 (right): Data Collected by Tactile Pressure Sensor on Wafer Surface During Polishing Process

Because the full process is recorded, different points in the process are scrutinized. Designers can then make adjustments or changes based on frame evaluation or by reviewing the peak pressures the tactile pressure sensor experiences. The same sensor is used in the commissioning process and then reused for scheduled reliability testing to identify worn parts or other issues affecting product quality. Designers can use the data from the tactile pressure sensor to improve yield and productivity for manufacturing.
Figure 19 (right): Software Display of Body Pressure on Seat Back and Cushion

Here, pressure indicating film can provide similar information about the peak pressures across the face of the wafer. However, capturing the impact of adjustments made to the polishing fixture is more cumbersome, as a new sheet of film must be cut, placed, and analyzed for each measurement. Here, a load cell can be used to calibrate the tension of the tool on the part, but it cannot evaluate the consistency of the process. Pressure indicating film can be used for evaluation, but tactile pressure sensors are often the sensor of choice because of their resistance to heat and dynamic measurement capabilities.

Body Measurement in a Seat

Measuring interface pressure between a persons body and a seat is very difficult because of the contours of the two objects and because these contours change as the subject sinks into the seat. The body measurement tactile pressure sensor has a unique construction that provides minimal disturbance, conforms to the targets being measured, and does not capture pressure artifacts from sheet tension (hammocking), only the forces applied to the loaded area.

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Very popular with automobile manufacturers and tier 1 suppliers, body tactile pressure sensors are used to record user experience while driving. The data is used in competitive benchmarking, foam shape and stiffness adjustments, ergonomic improvements, and identifying high-pressure spots. Physicians, clinicians, and medical equipment manufacturers also find the data from body tactile pressure sensors invaluable. Sometimes multiple load cells are placed in a seat, but this is typically used in presence sensing applications to identify the presence or absence of a seated person. Pressure indicating film does not capture this information well, as the film crinkles under the contours of the human form, resulting in nuisance streaks. The body measurement tactile pressure sensors unique construction conforms to complex, contoured and deformable support surfaces like seat cushions. Removing pressure artifacts from sheet tension provides the most accurate pressure data across the contours of the human form.

Nip or Roller Measurement

Any industry that manufactures products on rolls requires consistent pressure across the rollers to maintain product quality. These industries include steel, copper, film, paper, printing, packaging, and any materials that run through a converting line. Nip rollers and pinch rollers need to be calibrated to hold tension on the line and maintain uniform thickness across products. System failures can lead to product derailment or deformities along the material surface. The cost incurred because of down time and scrap material can be significant. Tactile pressure sensors are excellent tools for measuring nip profiles, force, and pressure variations along a roll axis. The system measures and displays pinch roll nip static forces in real-time. For many large machines, nip contact is adjusted by setting hydraulic pressure at contact bearings located on the ends of the rollers. In the absence of measurements, the relationship between hydraulic pressure and nip force is assumed linear, even though the machine linkage and system hysteresis do not have linear behavior. Tactile pressure sensors measure nip force and width at locations along the axis at various hydraulic pressures, providing real-time feedback to a PC. Crowning effectiveness, as well as differences in pressures and contact width along the length of the roll, can be documented.
Figure 20: Screen Shot of Nip Roller Measurement

To measure roller pressure, the tactile pressure sensor has columns along the length of the roller. The system can simultaneously provide total force, force applied to each column, nip width at each column, and force distribution. This data provides a process engineer or an operator with critical data for optimizing the settings on a machine. Worn parts can be identified early, avoiding unproductive and costly production runs. Because the tactile pressure sensor is paired with a PC, measurements are saved by the software and referenced later for quality reviews or comparison to other identical machines in other plants, globally.
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Load cells can be used in this application, but the resolution is only as good as the number of unique load cells used. This can be cumbersome to apply. In addition, the load cells cannot identify the nip width. When pressure-sensitive film is run through the rollers, it can only identify peak pressures. Rollers must be secured and reopened to see measurements between adjustments, which can be very costly during production downtime. The tactile pressure sensor has the ability to provide real-time feedback and remove guesswork from calibration of rollers, for quick and reliable maintenance.

CONCLUSION
When trying to evaluate the forces and interface pressures, multiple data collection options are available. Form factor, precision, and environment all influence the solutions to be considered. The data provided by a tactile pressure sensor provides a unique insight into a system or products performance, which is invaluable in system or process design. Leveraging a stronger understanding of pressure distribution yields positive results in a variety of applications in research, product development, manufacturing and quality control. Visit www.tekscan.com for more information on these technologies and products: Pressure Mapping Systems - http://www.tekscan.com/industrial-pressure-measurement Pressure Indicating Film - http://www.tekscan.com/pressure-indicating-film.html Force Sensors and Measurement Systems - http://www.tekscan.com/flexiforce.html

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