Understanding Force and Torque Measurement: Choosing the Right Sensor

Measuring force and torque is one of the important things that machines, equipment, and systems have to undertake. The two serve to manage an amount of pressure or turning force applied in a procedure. When they are not measured properly by a machine, there is a high possibility of it halting its operations or breaking down. That is why, rather hardly noticed by most people, it is important to select the proper sensor.

Why Force and Torque Sensors Matter

The pull or push of an object is called force, and the twist or turn on an object is called torque. There is a very broad range of applications where sensors to measure these quantities are essential, including automobile testing, robotic systems and even aerospace. They ensure that the systems are in operation safely, peacefully, and with a proper amount of control. You might make errors, lose time, or break something in case you utilize the kind of sensor of a different nature. That’s why the first step to better performance is knowing what kind of sensor to employ.

Types of Sensors and How They Work

There exist a lot of various kinds of sensors, including single-axis force sensors, torque sensors, and multi-axis sensors. All of them do a different task and are designed to measure force or torque in one or multiple directions. An example is the multi-axis sensors that are able to detect motion in several directions simultaneously. This is ideal for complex machines such as a motion simulator or robotic arm. Most sensors give the capability of reading the data in a short span and come with inbuilt accessories so that they may work easily. Most sensors are made of durable material instead of wearing out.

Force and Torque Sensor

Choosing the Right Sensor for Your Needs

What you want to measure and where you want to use it will determine the best sensor. A single-axis sensor can be all you need if your project simply needs to measure force in one direction. However, you might be required to have multi-axis force and torque sensors in case you are dealing with systems that have the potential for movements in different directions. It is also important to think of the size of the sensor required; its weight capacity and the level of accuracy it should have. An example can be security testing of automotive parts that may require very exact pressure readings, but that may not be the case for a smaller job.

Things to Keep in Mind Before Buying

• Find out if you need to measure simply torque, just force, or both. Also, find out if your system travels in one direction or many.
• Pick a sensor size that works with your machine or configuration.
• Test the capability of the sensor to control torque or force.
• Select sensors made up of hard and durable materials.
• Ensure that the sensor will provide readings that are both readable and fast.
• Make that the sensor works in your setting (temperature, dust, etc.).

Conclusion

Modern businesses cannot do without force and torque sensors. Make the right selection and you will save your time, avoid error and maybe be able to get better outcomes. Being a mere maker or high-tech employee, one would need to know what kind of sensor they need. MareX is your trusted partner in precise measurement. Get experienced advice and reliable sensor solutions from them.

How Multi-Axis Sensors Enable Precision in Industrial Automation

In the currently advanced and busy industrial lifestyles, machines have to be more efficient, quicker and accurate. The multi-axis sensor is one technology that is making this possible. These strong sensors can monitor forces or movements in more than one direction, which gives machines the information they need to work accurately. The multi-axis sensors assist factories to run more normally and at least safer because they have improved control and response. They may be applied to robotics, assembly lines, and packaging systems.

Understanding Multi-Axis Sensors in Simple Terms

A multi-axis sensor may measure force, pressure, or movement along two or more axes simultaneously as though your hand is being shoved forward and pulled at the same time. Similar to human beings, machines also use multi-axis sensors to detect their environment and make quick transitions. These are great for industrial jobs that need precise placement, including putting things in the appropriate place or tightening screws with the right amount of pressure.

Why Industrial Automation Depends on Precision

Consistency is important for automation. Even a small mistake might cause significant issues when a robot does the same thing a thousand times. A multi-axis force sensor helps cut down on these mistakes by giving the system real-time feedback. As machines change based on sensor data, they become more accurate and less likely to make mistakes. This cuts down on waste, saves time, and makes the product better. Things are not just about how fast you do things; it’s about doing it perfectly every time.

6 Axis Force Torque Sensor

Sensor Customisation Improves Task Performance

There are different kinds of occupations in a factory. Some machines need to be able to feel light pressure, while others need to be able to lift huge things. This is where customising sensors for torque and force comes in. Engineers may now make sensors that are just right for each use. A robot that puts together cellphones might utilise light-touch sensors, while one that moves automotive parts might need a heavy-duty version. Custom sensors make sure that each job is done with the proper amount of attention and strength.

Benefits of Multi-Axis Sensors at a Glance

• Send accurate real-time data in many directions.
• Make it easier to operate machines and repeat tasks.
• Keep an eye on load conditions to help cut down on wear and tear.
• Allow for specific settings for torque, pressure, and positioning. They play a very significant role in robotics, packaging, testing and automation systems.
• Enhance quality control in order to reduce errors and idle time.
• Quickly finding overload or imbalance makes operations safer.

The Role of Force Sensors in Smart Manufacturing

Smart factories of today use data to make better choices. A force sensor helps collect that information by monitoring how much pressure is being put on it at any given time. These sensors inform robotic arms how hard to hold on or how gently to touch. They let machines handle both heavy and fragile things with the same level of care. This combination of strength and sensitivity makes it easier to handle products and keeps everyone on the floor safer.

Looking Ahead to the Future of Automation

The requirement for specialised sensor manufacture will only grow as companies grow and need more accuracy. Companies are already using multi-axis force sensors to make automation smarter. The capacity to fine-tune machines with accurate input is changing the way products are made, tested, and shipped. These sensors are making factories more efficient and less wasteful with every upgrade, from small electronics to big construction.

Conclusion

Multi-axis sensors are transforming how machines work in factories. By providing them with stronger control, real-time feedback, and the possibility of quantifying force in a manner they find useful, they make it possible to make systems work more accurately and with fewer errors. These sensors enhance the automation to become smarter and safer since robots are capable of doing simple jobs as well as complex ones. Because of the continuous improvement of technology, there will always be an increasing demand for an accurate and flexible sensor solution. For the latest multi-axis sensor technology that is made to last, trust the professionals at MareX.

Advantages of Force Control Grinding System Automation

With the advancement of lean manufacturing, environmental protection policy requirements, and the needs of the factory’s own development, both manual operation and robots have shown certain limitations and cannot meet the growing demand.

Advantages of Force Control Grinding System Automation

First of all, the method based on manual operation mainly depends on the experience of the workers. People have vision, touch, their own thinking and judgment, and can flexibly handle workpieces of any shape and size difference, which is the great advantage of manual grinding. The more experienced technical workers there are, the higher the efficiency and the better the treatment effect.

However, its disadvantages are also obvious. Manual grinding can only rely on feeling and experience. It is impossible to know how much force you have used, nor can it guarantee the stable output of force, the uniformity of the workpiece surface and the consistency of the effect between workpieces; uncertain labor leads to fluctuations in productivity and output.

From a health perspective, the large amount of diffuse dust, noisy noise and high-frequency vibration of the grinder generated during the grinding process pose a great threat to the health of operators, resulting in a sharp reduction in the number of employees. Compared with manual grinding, the use of can achieve efficient and stable continuous operation according to the edited path, helping enterprises to effectively improve production efficiency, product yield and reduce production costs. In the case of complex and diverse workpiece materials, there are many processes involved in workpiece forming, including sheet metal, stamping, casting, injection molding, CNC, etc. Due to differences in material properties and forming methods, the workpiece will have dimensional tolerances, and there will only be differences in data size.

Since force-controlled grinding usually runs precisely according to a debugged path, the running path is fixed and the error is extremely small, when the surface size of the workpiece is slightly larger or the positioning position is slightly deviated, the grinding effect will fluctuate greatly, or even grinding may not be performed. Or due to excessive pressure and excessive grinding, the yield is low and mass production cannot be achieved.

As an independent control execution system, force control grinding is specially developed for polishing and grinding applications. It has more advantages in helping customers overcome the difficulties of automation upgrades, and helps customers reduce costs and improve efficiency in terms of personnel, equipment and processes:

Through flexible force control, the grinding automation of enterprises can be realized;

Make the surface effect of batch-produced workpieces more uniform and consistent; increase production and reduce subsequent grinding costs;

The programming and teaching of robots become very simple, which can greatly improve the debugging efficiency and reduce the requirements for operators;

Data can be stored and retrieved, so grinding and polishing can also be included in the digital production line system;

Reduce the load requirements of the robot for grinding and polishing, extend the life of the robot and grinder, and reduce equipment costs;

In order to make it easier and more cost-effective for customers to apply automated polishing and finishing solutions, the force-controlled grinding system is also being further developed.

The market prospects for collaborative robot end tools are huge!

The rapid development of the industrial robot industry has also promoted the growth of the collaborative robot end-tool market. According to industry analysis, the transaction volume of robot end-tools exceeded US$ 2.5 billion in 2018 and is expected to reach US$ 6.5 billion by 2025 , maintaining a compound growth rate of 14% . Due to the growth of the automation market, the use of end-tools, a key part of robot solutions, in the industry has begun to rise rapidly.

With the continuous breakthroughs in technologies such as artificial intelligence, the concept of intelligence has set off waves in the field of automation and brought new product inspiration. Automation products are beginning to become intelligent, achieving new levels that were previously unattainable through integrated sensors, artificial intelligence, and the Internet of Things.

Collaborative robot end-of-line tooling is a new direction for the industry. It can collect key data and communicate it to the robot to improve its accuracy and overall performance, further protecting the safety of the goods, especially some fragile objects. The smart gripper can control the appropriate force to ensure that it can be safely delivered to the operator.

In complex production lines, there are often some parts that are not sorted and sorted, and traditional grippers are powerless. Using collaborative robot end tools, it can adapt to the grasping of various objects without external cables, and the direction can be adjusted to adapt to different objects.

More and more companies are experiencing the benefits of collaborative robots in various automation scenarios. Advantages such as easy installation and debugging, small programming amount, and plug-and-play make collaborative robots suitable for more scenarios.

Under the trend of human-machine collaboration, collaborative robot end-of-line tools have achieved good growth. Last year, nearly 14,000 collaborative robots were installed worldwide, and the annual installation volume of collaborative robots increased by 23% from 2017 to 2018. If collaborative robot sales continue to grow, end-of-line tools will double in a few years, creating unprecedented EOAT market opportunities.

In principle, one robot can only perform one type of work. If you want to perform complex work, you need to constantly change the robot. When this exchange operation is done manually, it not only takes time, but it can also lead to human errors. If you use a collaborative robot end tool, the robot can automatically change the manipulator by itself. In addition, even if it is changed manually, the operation becomes very simple and quick.

Even on robots that do not require replacement of the gripper, tool, or end effector, etc., using a gripper quick changer can simplify maintenance or fine-tuning. In addition, for laboratory robots in R&D departments or schools, simply replacing the gripper allows the robot to be shared, making it convenient to carry out various experiments.

In some cases, manufacturers use collaborative robot end-of-line tools mainly because of repetitive and boring work and the lack of suitable workers. In addition, manufacturers want to find ways to improve efficiency, even if the run time is reduced by a few seconds, it can bring more product output. Buying more robots and grippers can create huge benefits.

In the manufacturing industry, intelligent and simplified automation methods for production tasks will become more and more popular. Manufacturers do not need to spend too much time and money to deploy and can apply faster. Terminal tools are part of the automation strategy. , which can greatly improve productivity.

With the breakthrough in the field of digitalization of traditional Chinese medicine, the deep integration of robotics, large models of traditional Chinese medicine and artificial intelligence algorithms is leading the construction of “technological, visual, data-based, intelligent and globalized” traditional Chinese medicine, and promoting traditional Chinese medicine to a higher level of intelligence. Relying on the traditional Chinese medicine research team and senior treatment institutions, the new generation of traditional Chinese medicine robots, after years of technical accumulation and multiple rounds of product iterations, can provide patients with more efficient, accurate, convenient and personalized traditional Chinese medicine medical services, intelligently identify the meridians and treatment pathways throughout the body, ensure the efficiency and accuracy of treatment, and even surpass traditional techniques in terms of pressure.

MareX massage robot is your best partner for health management. It uses a combination of professional-grade physiotherapy technology, intelligent sensing and bionics technology to deliver high-frequency electromagnetic energy to target tissues and perform selective heating physiotherapy for sub-healthy people. It uses a robotic arm to replace human hands for physiotherapy, with the characteristics of light labor, precise positioning, intelligent control of temperature and strength, and automatic planning of massage paths. It is a fusion of traditional physiotherapy and intelligent technology solutions. It uses big data, AI visual algorithms, and Internet of Things technologies to solve the sub-health problems of modern people and enhance human immunity and other core needs.

The robot’s high-definition camera and dialectical recognition function allow it to accurately lock acupuncture points, and its ergonomic design ensures that every contact is very comfortable. The display screen provides professional solutions, such as expelling cold and dampness, strengthening the waist, warming the back and expelling cold, relaxing the shoulders and neck, and shaping the waist, which can fully meet your health needs.

Selection of end-of-arm tools for collaborative robots suitable for their needs need to consider the following factors:

1. application needs: first of all, you need to clarify their application needs, such as the need for fine assembly, material handling, welding, etc., different application needs require different end-of-arm tools.

2. working environment: the working environment is also an important factor in the selection of end-of-arm tools. For example, if the working environment is narrower, you need to choose a smaller end tool; if the working environment exists higher temperature, humidity or corrosive gases, etc., you need to choose to adapt to these environments of the end of the tool.

3. Load capacity: the load capacity of the end tool is also an important factor in the selection. Need to choose the appropriate load capacity of the end-of-tool according to their own application needs, to avoid insufficient load capacity and lead to the robot can not complete the task.

4. control mode: end-of-tool control mode also needs to be considered. For example, some end-of-arm tools can be realized through manual control, while others need to be realized through software control.

5. Cost factor: Finally, the cost factor also needs to be considered. Different end tools have different prices, and you need to choose the right end tool according to your budget.

To summarize, choosing the end-of-arm tool for collaborative robots that suits your needs requires comprehensive consideration of application requirements, working environment, load capacity, control methods and cost factors

The use of six-axis force sensors to realize the force control of the collaborative robotic arm can be realized through the following steps:

1. installing the six-axis force sensor: first of all, it is necessary to install the six-axis force sensor at the end of the collaborative robotic arm, which is used to sense the external forces and moments.

2. Collecting sensor data: Through programming, the data collected by the six-axis force sensor is transmitted to the controller of the robotic arm for real-time monitoring of external forces and moments.

3. design force control algorithm: according to the application requirements, design the corresponding force control algorithm. For example, the force control algorithm based on PID control can be designed to adjust the trajectory and strength of the robotic arm in real time according to the data collected by the sensor, so that it can operate according to the preset strength and direction.

4. Realize force control: Embed the designed force control algorithm into the controller of the robotic arm to realize force control. In actual operation, the robotic arm will be adjusted in real time according to the data collected by the sensor to ensure the accuracy and safety of the operation.

In conclusion, the use of six-axis force sensors to realize the force control of a collaborative robotic arm requires multiple steps such as installing sensors, collecting data, designing force control algorithms and realizing force control. Through these steps, the force control of the robotic arm can be realized to improve the operation precision and safety of the collaborative robotic arm.

With the rapid development of industrial automation, the performance of six-axis force sensors, as core components in robotics technology, directly affects the robot’s operating accuracy, safety, and flexibility. This article aims to deeply explore the performance evaluation indicators and selection guidelines of six-axis force sensors for industrial robots, to help engineers and R&D personnel better understand and select sensors suitable for their application scenarios.

1. Overview of Six-Axis Force Sensor

A six-axis force sensor, also known as a six-dimensional force sensor, is a precision measuring device that can simultaneously measure the force and torque of an object in three directions. It is based on the interaction principle of force and torque in mechanics, and converts mechanical information into electrical signals for output through the tiny deformation of elastic elements (such as elastomers or elastic diaphragms). This sensor is widely used in robotics, aerospace, automobile manufacturing, biomechanics and other fields.

2. Performance Evaluation Indicators

1. Accuracy and sensitivity
Accuracy and sensitivity are important indicators for evaluating the performance of six-axis force sensors. Accuracy refers to the degree of deviation between the sensor’s measured value and the actual value, while sensitivity reflects the sensor’s ability to respond to small changes. For industrial robots, high-precision six-axis force sensors can ensure the accuracy and stability of robot operations.

2. Range and overload capacity
The range refers to the maximum load force (or torque) that the sensor can effectively measure. When selecting a sensor, make sure its range can meet the actual working requirements of the robot. In addition, overload capacity is also a factor that cannot be ignored. It refers to the ability of the sensor to maintain a certain measurement capability when exceeding its range. Good overload capacity can protect the sensor from accidental damage.

3. Linearity and hysteresis
Linearity describes the degree of linear relationship between sensor output and input, while hysteresis reflects the inconsistency of sensor output values ​​during loading and unloading. For industrial robots, six-axis force sensors with low linearity and low hysteresis can provide more accurate measurement results and reduce error accumulation.

4. Resolution and Noise
Resolution refers to the amount of small signal changes that a sensor can distinguish. A high-resolution sensor can capture more subtle mechanical changes and improve measurement accuracy. At the same time, the noise level is also an important factor affecting sensor performance. A low-noise sensor can provide a clearer signal output.

5. Environmental adaptability
The working environment of industrial robots is complex and changeable, so the six-axis force sensor needs to have good environmental adaptability. This includes temperature stability, waterproof and dustproof capabilities (such as IP rating) and electromagnetic compatibility. Good environmental adaptability can ensure that the sensor can maintain stable measurement performance under different working conditions.

3. Selection Guide

1. Clarify application scenario requirements
Before choosing a six-axis force sensor, you first need to clarify the specific requirements of the application scenario, including measurement accuracy, range, frequency response, etc. Select the appropriate sensor model and specifications according to the requirements.

2. Investigate sensor brands and manufacturers
There are many six-axis force sensor brands and manufacturers on the market, and their product quality and performance vary greatly. Therefore, when choosing, you need to examine the manufacturer’s technical strength, product quality, after-sales service and other factors, and choose a reputable and powerful brand.

3. Evaluate the cost-effectiveness
Under the premise of meeting application requirements, the cost-effectiveness between the price and performance of the sensor needs to be comprehensively considered. We should not blindly pursue high prices or high performance while ignoring actual needs and economic costs.

4. Field testing and verification
Before finalizing the sensor model, it is recommended to conduct field testing and verification. The sensor is tested for performance by simulating actual working scenarios to evaluate whether its performance in actual applications meets expectations.

IV. Conclusion

As an important component of industrial robots, the performance of six-axis force sensors directly affects the operation and safety of robots. Through the introduction of this article, we hope to help engineers and R&D personnel better understand and select six-axis force sensors suitable for their application scenarios. In the selection process, it is necessary to comprehensively consider multiple factors such as accuracy, range, linearity, hysteresis, resolution, noise, and environmental adaptability, and conduct a comprehensive evaluation based on actual needs and economic costs. Finally, a six-axis force sensor with high cost performance and stable performance is selected to provide strong guarantee for the precise operation and efficient operation of industrial robots.

Revolutionizing Precision: The Rise of Six-Axis Force Sensors

Six-axis force/torque sensors, capable of measuring forces (Fx, Fy, Fz) and torques (Mx, My, Mz) simultaneously, are redefining precision across industries. With sub-Newton accuracy and real-time data processing, these sensors enable machines to “feel” and adapt to dynamic environments—a critical capability for applications ranging from robotic surgery to aerospace assembly.

Industry Applications Driving Demand

1.Humanoid Robotics
Leading robotics firms, including Tesla (Optimus) and Ubtech (Walker X), now rely on six-axis sensors for tasks requiring human-like dexterity. Installed in wrists, ankles, and grippers, these sensors enable precise force feedback during object manipulation and adaptive walking on uneven terrain.

2.Automotive & Aerospace
In BMW’s smart factories, six-axis sensors reduced assembly defects by 43% through real-time torque monitoring during engine installations. Aerospace applications include SpaceX’s satellite docking systems and flight attitude control, where sensors achieve 5kHz dynamic response rates for split-second adjustments.

3.Medical Advancements
Surgical robots integrated with six-axis sensors, such as those developed by Haixi Medical, demonstrate 97% force feedback accuracy, enabling safer minimally invasive procedures. Rehabilitation devices also leverage this technology for personalized therapy regimens.

Market Outlook & Technological Trends

The global six-axis sensor market is projected to grow at a CAGR of 18.7% through 2030, driven by:
AI Integration: Machine learning algorithms analyze sensor data to optimize robotic motion planning and predictive maintenance9.
Miniaturization: MEMS-based designs like HBM’s K-SP5/8KG-JW2 now fit into micro-robots and IoT devices without sacrificing performance

Looking Ahead

As six-axis sensors evolve toward nanoscale resolution and cloud-connected ecosystems, their role in Industry 4.0 and human-robot collaboration will expand exponentially. With Kelishi and Huawei paving the way, China is poised to lead this transformative wave, reshaping industries from intelligent manufacturing to AI-driven healthcare.

For technical specifications or partnership inquiries, visit [Company Website：https://mare-x.com/] or contact [email protected]

Let’s explore six key applications of collaborative UR robots in automotive production: polishing, welding, painting, assembly, machine tending and material removal, and quality inspection.

1.Assembly
Collaborative UR robots play a vital role in automotive factories, including assembly plants. They handle repetitive tasks on production lines, such as installing door handles and windshield wipers, freeing workers to focus on higher-value tasks.
UR robots like the UR16e (16 kg/35.3 lbs payload capacity) manage larger/heavier components—wheels, hatches, and hoods—with precision.

2.Painting
Painting robots deliver unmatched consistency and 24/7 availability, surpassing human capabilities. They are widely adopted by automakers for:
Applying perfectly uniform coatings on large surfaces
Reducing paint waste by 15-20% vs. manual spraying
Eliminating health risks from toxic automotive paints
Minimizing human error with ±0.1mm repeatability

3.Welding
Collaborative UR robots excel in hazardous arc/TIG/MIG/laser/ultrasonic welding applications. The UR+ ecosystem provides turnkey solutions like:
Olympus UR Welding System: Cost-effective for small parts (e.g., brackets, exhaust components)
Automated Spot Welding: 200% faster than manual processes
Seam Tracking: AI-powered vision systems ensure weld path accuracy

4.Material Removal & Polishing
Critical for finishing processes, UR robots perform:
Grinding: Surface prep for composites
Deburring: Edge refinement on cast parts
Polishing: Mirror finishes on trim components
Drilling: Precision hole patterns in chassis
Equipped with force-torque sensors, they adapt to material variations while maintaining ISO 9001 quality standards.

5.Quality Inspection
UR robots automate vehicle QA through:
3D Vision Systems: Detect sub-0.1mm defects
Dimensional Metrology: Verify tolerances <±0.05mm
Surface Scanning: Identify paint flaws invisible to the human eye
Integrated UR+ toolkits reduce inspection time by 40% while improving defect detection rates.

6.Automotive Innovation
UR robots drive industry growth by:
Cutting production cycle times by 30%
Reducing workplace injuries by 72% (OSHA data)
Enabling flexible small-batch production via quick redeployment

With compact, fence-free designs, UR’s collaborative robots seamlessly integrate into existing workflows—from legacy factories to EV battery gigafactories.