Embedded Files
Tension Link Load Cell (Aug 2026 – Present)
Tension Link Load Cell (Aug 2026 – Present)
Project Overview & Mechanical Architecture
Project Overview & Mechanical Architecture
Objective: Collaborated with an electrical engineer to develop an extremely durable, low-cost tension link load cell specifically designed to measure force during isometric physical training.
Sensor Geometry: The core structure is a flat, 1/8-inch thick aluminum dog-bone profile. Wide eyelets at each end accommodate standard carabiners, while the center narrows to a straight 10mm-wide section to isolate uniform strain for the directly epoxied strain gauges.
Dynamic Enclosure: Developed a support-free, 3D-printed housing that sandwiches the custom circuit board. The enclosure is engineered to remain mechanically constrained to the load cell without binding or interfering with the aluminum's axial stretch under heavy loads.
Engineering Analysis & Fabrication
Engineering Analysis & Fabrication
Material Selection: Specified 6063-T6 aluminum for the structural body due to its excellent availability, machinability, and highly predictable elastic properties under tensile loading.
Simulation & Validation: Conducted SolidWorks Finite Element Analysis (FEA) to map von Mises stress and verify the 10mm test section yields measurable strain while strictly avoiding plastic deformation under maximum load. These digital simulations were cross-verified using classical hand calculations.
Manufacturing Role: Led the complete mechanical design and physical manufacturing cycle, including in-house CNC machining of the aluminum load cell body and additive manufacturing for the protective electronics housing.
Load Cell Strain Test (5000 N)
Initial Dogbone Prototype with PCB
Page updated
Google Sites
Report abuse