Modern machines are increasingly automated and connected, yet their physical behaviour often remains only partially controlled.
Critical parameters like force, torque, load, motion, and structural deformation directly determine product quality and throughput. However, in many machines, these forces are still derived, filtered, or compensated post-process, rather than controlled directly at their source. Typical examples include motor current used as a proxy for torque, or hydraulic pressure used to estimate force, both of which introduce model uncertainty and delay.
| Challenge | Solution |
| Machines exhibit mechanical variability under real operating conditions, leading to instability and inconsistent performance. | HBK embeds force, strain, and dynamic measurement directly into the control loop to measure operating conditions in real time. This enables true feedback control instead of open-loop compensation. |
| Force and torque are inferred from indirect signals rather than direct physical measurements, leading to inaccuracies and delayed corrections. | HBK provides high-speed, low-latency measurement chains that deliver calibrated physical data directly into machine control loops. These measurement chains must be compatible with real-time industrial protocols (e.g., EtherCAT, PROFINET IRT) to ensure deterministic behaviour. |
| Increasing machine throughput often introduces vibration, instability, and loss of accuracy. | HBK combines high-dynamic piezo, MEMS, and inertial sensing with real-time processing to capture and control transient effects, enabling higher machine speed without compromising precision or quality. Sensor selection must match the application (e.g., piezo for dynamic response, strain gauges for static accuracy). |
| Limited space, mechanical constraints and load-path requirements make it difficult to integrate sensors into machines. | HBK adapts measurement solutions to specific machine constraints – including fully customised designs – allowing for scalable, seamless integration. This includes load-path compliant sensor integration to avoid measurement distortion. |
| Engineers compensate for mechanical uncertainty with increasingly complex PLC logic, tuning, and filtering. | HBK shifts control from software compensation to physics-based measurement and control, simplifying the control architecture, speeding up commissioning, and enabling more robust machine behaviour. However, integration requires clear definition of control loop ownership between PLC, drive, and measurement system. |
High-fidelity sensors are seamlessly integrated into the machine’s critical points to capture the full spectrum of its physical behaviour.
Sensors can be made plug-and-play for fast deployment, adapted to fit machine constraints, or completely custom-engineered for maximum accuracy and control performance.
Industrial amplifiers and smart sensors condition raw signals at the source, providing clean, data ready for control systems.
Actionable Intelligence.
Data is delivered seamlessly into the machine control architecture, enabling true closed-loop performance.
HBK Force Sensors and Force Transducers with strain gauge or piezo technology measure static and dynamic tensile and compressive loads up to 20 MN - with virtually no displacement.
Many force sensors are now available with IO - Link, 4-20 mA or 0 - 10 V output. Use output signal filter below to view IO - link or analogue amplifier options.
Rely on the highest precision and best performance from the worldwide market leader in torque measurement. Find the torque sensor, and interface module that you need to achieve precise results suitable for your application.
HBK weighing technology is synonymous with precision, safety, dependability, and quality. The brand stands for innovative capacity as well as flexible and cost-effective solutions that meet virtually any customer requirement. We are also committed to the promotion and advancement of hygiene in relevant industries.
Our load cells have set the standard for decades. Whether it is analog or digital load cells, single point load cells or bending beam load cells – it’s your choice! In addition, we offer the right weighing electronics and matching accessories for your application.
Strain gauges are the key asset for measuring fatigue and testing materials for better and safer products. Whether it is in structural durability testing, structural health monitoring, or the production of OEM transducers, HBK's optical and electrical strain gauges are the first choice.
Force control enables machines to apply and maintain precise loads during each cycle, directly impacting product quality and consistency. By measuring real force instead of estimating it, engineers can reduce variability, improve repeatability, and improve Cp/Cpk. This is particularly critical in applications such as press-fit, bonding, and material testing where force-displacement signatures define product acceptance.
Having a real-time machine control system allows machines to react instantly to physical variations, such as load changes, vibration, or material differences. Reaction time and loop stability are directly dependent on system latency and bandwidth. This prevents deviation during the process, ensuring stable operation, reduced scrap, and consistent output at high speed.
Closed-loop control uses direct feedback from sensors to continuously adjust machine behaviour. In advanced systems, this may include multi-variable control (e.g., force + position) or adaptive control strategies. This improves accuracy, reduces dependence on PLC compensation, and enables consistent performance across cycles and production conditions.
Machine repeatability is improved by controlling physical parameters at their source, including force, torque, and structural behaviour. High-accuracy measurement combined with real-time control reduces cycle-to-cycle variation and stabilises machine output. Mechanical design (stiffness, damping) remains a key contributing factor alongside measurement.
Dynamic load control captures and regulates fast-changing forces and transient effects that occur at high speed. This includes vibration modes, structural resonance, and impact phenomena. This allows engineers to increase throughput without compromising high-precision machines by introducing vibration-induced errors or instability.
Improving Cp/Cpk requires reducing process variability at its origin. By embedding high-fidelity measurement and force load, and torque control, machines achieve tighter tolerances, more consistent output, and measurable performance capability. However, full Cp/Cpk optimisation also depends on upstream process stability, material consistency, and tooling conditions.
This will bring together HBM, Brüel & Kjær, nCode, ReliaSoft, MicroStrain and Discom brands, helping you innovate faster for a cleaner, healthier, and more productive world.
