Recent Blog Posts
Ted NachazelMay 18, 2026BlogElectric vehicle (EV) powertrain development depends on understanding how torque, force, and temperature interact across motors, gear reduction stages, driveline components, and the wheel. Unlike traditional ICE architectures, EVs introduce higher rotational speeds, bidirectional torque flow, concentrated thermal loads, and electrically noisy environments, all of which place new demands on instrumentation. Michigan Scientific supports EV programs by engineering measurement systems that perform reliably under real operating conditions. Rather than offering one-size-fits-all solutions, we design an instrumentation architecture that preserves component behavior while delivering high‑fidelity data wherever torque, force, or temperature must be understood. Why EV Powertrain Measurement Is Different While the fundamentals of torque and force measurement remain the same, EV powertrains introduce conditions that fundamentally change how instrumentation must be designed: Very high rotational speeds, often exceeding those seen in ICE applications High thermal density, particularly within motors and compact gearboxes Electromagnetic interference (EMI) from motors and inverters Heavier vehicles, resulting in increased force and torque on components Successful EV instrumentation must account for all of these factors simultaneously, without altering stiffness, balance, or load paths that would compromise test validity. A System‑Driven View of the EV Powertrain Rather than focusing on individual components, effective EV testing captures how the entire system behaves under real use. Michigan Scientific supports measurement across the full powertrain, including: Electric motor output torque and rotor temperature Gear reduction and gear tooth strain Bearing loads and thermal effects Driveshaft, axle, and downstream torque transmission Wheel forces and moments at the tire–road interface This system‑level approach allows engineers to correlate data across components, identify loss mechanisms, and validate both physical designs and simulation models. This system-level approach also provides the physical data needed to develop and validate digital twin models of EV powertrain behavior. Motor Torque and Temperature Measurement Electric motors operate at high speeds and high power density, making direct measurement critical for performance, efficiency, and durability analysis. Michigan Scientific instruments motor rotors to measure: Torque and strain under real electromagnetic loading Rotor, magnet, and lamination temperatures Thermal gradients that influence efficiency and bearing life Thermocouples are often embedded during manufacturing of the rotor and routed through the rotor shaft to slip rings or telemetry systems. Proper planning can mitigate EMI and other instrumentation issues during the testing phase. Both bench‑level motor testing and fully integrated on‑vehicle measurements are supported. Depending on speed, temperature, and test duration, data may be transmitted using high‑speed telemetry or instrumentation‑grade slip rings, selected to preserve signal integrity in electrically noisy environments. Managing EMI and Signal Integrity in EV Environments EV powertrains present some of the most challenging environments for strain‑based measurement. High electromagnetic fields can corrupt low‑level signals if instrumentation is not properly designed. Michigan Scientific addresses these challenges through: Careful strain gauge selection and placement Shielded wiring and optimized routing Signal conditioning placed close to the measurement source Proven grounding and EMI rejection techniques By mitigating noise at the source, measurement accuracy is preserved without relying on aggressive post‑processing corrections. Gear Reduction, Bearing, and Driveline Instrumentation EV gear trains experience unique loading profiles, including high transient torque and elevated operating temperatures. Michigan Scientific applies strain gauges directly to production gear and driveline components to measure: Gear torque and tooth strain Bearing strain and load distribution Thermal effects that influence alignment and durability Instrumentation is designed to preserve real‑world stiffness and boundary conditions, ensuring that measured behavior reflects actual operating conditions—not artifacts introduced by the test setup. Wheel Force Measurements and Power Delivery While torque is generated at the motor and transmitted through gear reduction and driveline components, power is ultimately delivered at the wheel–road interface. Measuring wheel torque provides the final mechanical output of the EV powertrain, capturing the cumulative effect of upstream losses under real operating conditions. Wheel Force Transducers (WFTs) enable direct measurement of wheel torque, forces, and moments at the tire–road interface. When correlated with motor and drivetrain measurements, wheel data allows engineers to close the loop on power delivery, validate efficiency and simulation models, and evaluate how control strategies translate into real‑world vehicle performance. From Physical Testing to Simulation Confidence As EV development relies increasingly on virtual tools, high‑quality physical data becomes essential. Digital twin models become more valuable when simulation outputs are validated against high-fidelity, real-world measurements. Direct measurements of torque, force, and temperature allow engineers to: Validate FEA and system‑level simulations Refine efficiency maps and thermal models Correlate bench testing with on‑road behavior Reduce uncertainty earlier in the development cycle Accurate, synchronized measurements across multiple components help ensure that simulations remain grounded in reality. Instrumentation Designed Around Your Challenge Packaging, speed, temperature, channel count, test duration, and environment all influence instrumentation strategy. Michigan Scientific works directly with engineering teams to design measurement systems that fit the application—whether instrumenting a single component on a test stand or deploying a fully integrated, multi‑channel system on a vehicle. Contact Michigan Scientific to discuss an instrumentation strategy for your EV powertrain test program.   [...] Read more...
Ted NachazelMay 18, 2026BlogAccurately measuring driver input is critical to understanding vehicle performance, driver behavior, and occupant response. Forces applied by the driver, and forces experienced by the driver, directly influence brake development, steering tuning, ride and handling, and ADAS validation. Michigan Scientific supports driver‑focused testing by measuring forces at the human–vehicle interface. The examples below highlight several ways these measurements are captured using standard and custom Michigan Scientific instrumentation equipment. Steering Wheel Torque and Angle Measurement Steering wheel torque and angle measurement quantifies driver steering effort and control. These signals are critical for steering system development, electric power steering calibration, and ADAS evaluation. The SW‑SR2 Steering Wheel Torque and Angle Transducer measures: Steering torque applied by the driver Steering wheel angle This data helps engineers evaluate steering feel, driver workload, and steering system response under real‑world conditions. Brake Pedal Force Measurement Brake pedal force measurement captures driver braking intent directly at the pedal. This data is essential for correlating braking effort with deceleration, brake system response, and vehicle stability. Michigan Scientific’s Brake Pedal Force Transducers (BPFT series) mount directly to production pedals while maintaining realistic pedal feel. These sensors are commonly used for: Brake system development Brake balance and tuning Driver behavior and repeatability studies Brake pedal force data is often synchronized with vehicle speed, wheel force, and longitudinal acceleration measurements. Custom Shift and Control Effort Measurement Many test programs require measurement of driver controls, such as shift knobs, levers, hand controls, or other operator interfaces. Michigan Scientific designs custom strain-gage-based transducers to measure shift effort and control forces while preserving ergonomics and normal operation. These measurements support: Michigan Scientific designs custom strain‑gage‑based transducers to measure shift effort and control forces while preserving ergonomics and normal operation. These measurements support: Shift effort and consistency analysis Control usability and ergonomics evaluation Driver workload assessment Development and validation of adaptive or accessibility-focused vehicle controls Custom solutions allow instrumentation to be tailored to the vehicle, control geometry, and test objectives, including specialized interfaces designed for drivers with limited mobility or alternative input methods. Seat Belt Load Measurement Seat belt load measurement captures restraint forces acting on the occupant during braking, cornering, and dynamic maneuvers. Seat belt transducers provide insight into: Load transfer during aggressive events Occupant interaction with restraint systems This data complements pedal and steering input measurements by showing how driver actions translate into physical loads on the occupant. Measuring Driver–Seat Interaction Using Multi‑Axis Load Cells Driver response to vehicle motion can also be measured at the seat interface. TR3D Multi‑Axis Load Cells can be integrated into seat structures to measure forces transmitted between the driver and the seat. Seat force measurements support analysis of: Occupant load distribution Driver reaction to braking, acceleration, and cornering Ride comfort and seating ergonomics When combined with steering, pedal, and restraint measurements, seat force data helps close the loop between driver input and occupant response. A System‑Level View of Driver Interaction Multiple driver input and occupant interaction measurements can be synchronized using Michigan Scientific’s 12-Channel Analog to CAN Module. The MUX signal conditioning and CAN‑based data acquisition solutions. The MUX delivers clean, digital, time‑aligned output from twelve channels over a single CAN 2.0 or CAN FD bus. Up to 4 modules can be stacked, enabling synchronized sampling of up to 48 channels. By stacking different MUX models within one mechanically unified assembly, the platform supports mixed‑sensor configurations—strain, temperature, displacement, acceleration, RTD, and encoder inputs—all consolidated onto a single CAN output. Michigan Scientific’s 12-Channel Analog to CAN Modules bring modern, digital, synchronized signal conditioning into a compact package designed for today’s demanding test environments. Whether you’re instrumenting a rotating shaft, outfitting a full vehicle, or building a multi-sensor thermal map, the MUX provides the speed, accuracy, and reliability to collect clean, actionable data. Prototype Analog to CAN Module- 4 stack assembly used in vehicle testing By measuring forces at the driver interface, engineers gain a more complete understanding of how human input influences vehicle behavior and how the vehicle physically interacts with the driver. [...] Read more...
webdevOctober 6, 2025BlogAccurate suspension component force measurement is essential for designing and validating vehicle suspension systems. Whether you’re correlating Road Load Data Acquisition (RLDA) with rig testing (i.e. MTS329) or optimizing chassis durability, understanding how forces travel through the suspension is critical. At Michigan Scientific, we specialize in instrumenting suspension components to deliver precise, reliable data in the most demanding environments. Why Component-Level Measurement Matters Total force and moment at the wheel can be captured using Wheel Force Transducers or virtual road estimation. But to understand how loads are distributed through the suspension and into the chassis, component-level measurements are required. That’s where suspension transducers come in. Michigan Scientific’s Approach Michigan Scientific has extensive experience in instrumenting suspension components to accurately measure forces in individual suspension components and chassis. Our transducers are engineered to minimize crosstalk and reduce sensitivity to boundary conditions and mounting effects. The specific component selected for instrumentation depends on both the component’s geometry and the suspension layout. Our experience allows us to identify which components will yield the most accurate and meaningful force measurements for each design. Michigan Scientific offers free consultations and quotes for this type of work. All complex components will go through FEA to determine the optimal strain gauge type and placement. This promotes high-quality strain gauge output and minimizes crosstalk. Every transducer is temperature compensated and coated with a durable, waterproof coating to ensure long-term reliability in demanding environment Common Suspension Components Tie Rod Force Transducer Tie rods are a commonly instrumented component to measure steering forces.  Michigan Scientific can instrument either the inner or outer tie rod.  We prefer inner tie rod transducers because they have more strain output and are generally more accurate. Ball Joint Transducers Most vehicles have several ball joints. Lower control arm ball joints often experience the highest load and are the most important instrument. Michigan Scientific can instrument ball joints to measure two- or three-dimensional forces. A reference line is machined across the end of the ball joint stud to indicate the measurement axes. Custom calibration fixtures are fabricated to match the specific ball joint geometry. As an additional service, Michigan Scientific can remove ball joints from control arms for instrumentation and reinstall them afterward. If the ball joint cannot be removed due to design constraints, strain gauging can be performed with the joint still installed in the control arm. To maintain transducer integrity, care must be taken during installation to avoid bottoming out the ball joint stud. Sway Bar Link Force Transducer The sway bar link is a commonly instrumented component. Michigan Scientific ensures that boundary conditions during calibration match boundary conditions in the vehicle.  Sway Bar Torsion Transducer Michigan Scientific can strain gauge and calibrate the sway bar to measure torque. Suspension Link Axial Force Transducer Michigan Scientific can strain gauge the suspension links to measure axial force.  Curved or complex geometry links require FEA to determine the ideal strain gauge location. Strut Transducers Measuring force in a strut is challenging due to the coil spring and damper being arranged in parallel and directly mounted to the chassis. There are several effective methods that allow for accurate measurement without altering suspension height or geometry. Each of the approaches captures the total load transmitted into the strut. Strut Bracket Transducer A semi-custom transducer that replaces the bottom bracket portion of the Macpherson strut and clamps onto the strut tube. This does not require modification to the knuckle.  This four-beam transducer is made from high strength stainless steel and makes a very accurate transducer. Double Shear Pins Strut Force An alternative approach that replaces the two bolts connecting the MacPherson strut to the knuckle with custom-engineered shear pins. These transducers are designed to measure load directly through the joint. While this method requires minor modifications to the knuckle and strut bracket, it offers excellent accuracy and preserves suspension geometry. Shear Pin Strut Force In cases of a strut with a lower through hole bushing, Michigan Scientific can replace the bolted joint at the bottom of the damper with a one- or two-axis Shear Pin Transducer to measure total force into the damper. Shear pins are semi-custom transducers that replace a bolted joint. This option requires some modification to the damper bushing and lower control arm. Crossbar Strut Force In cases of a strut with a lower bolting crossbar, Michigan Scientific press/machine out the lower bolting crossbar at the bottom of the damper. Then replace that crossbar with a one- or two-axis custom transducer to measure total force into the damper. A new crossbar would then be pressed into the bushing, and the strut can be installed as normal. This requires no modification to the lower control arm.  Fork/Clevis Strut Force Transducer In cases of a strut with a lower fork or clevis, Michigan Scientific can strain gauge the OEM fork/clevis with accurate results. If the geometry allows, this is the quickest and most cost-effective option and requires minimal modification. Michigan Scientific ensures the bolt clamping load is representative of OEM installation to ensure accurate results. Non-Recommended Method Attempts have been made to instrument MacPherson struts by installing strain gauges on the strut tube. This method does not yield accurate results due to the piston moving inside the damper and the fluid pressure inside the tube. Damper Transducers Damper Fork/Clevis Transducer In cases of a damper with a lower fork or clevis, Michigan Scientific can strain gauge the OEM fork/clevis with accurate results. If the geometry allows, this is the quickest and most cost-effective option and requires minimal modification. Michigan Scientific ensures the bolt clamping load is representative of OEM installation to ensure accurate results. Damper Rod Force Transducer Michigan Scientific can strain gauge damper rods to measure force specifically going through the damper rod. For this transducer, the damper shroud is removed or modified to allow for gauging. Some dampers allow for the wire to simply exit through the remaining shroud. Some dampers require the drilling of the end of the damper rod to allow the wire to exit through the end of the rod.  Damper Top Mount Force Transducer If the damper top mount geometry allows, we can modify and strain gauge the top of the damper mount or replace it with a custom transducer to measure force. This will measure the total force from the damper to the chassis. Rear Suspension Components Shackle Force Transducer Michigan Scientific can instrument the shackle to measure vertical force from the leaf spring into the chassis at one end of the leaf spring. We will run FEA on the shackle to determine the best strain gauge location. Maintaining representative boundary conditions is critical for this transducer. Coil Spring Force Transducer Measuring force in a coil spring provides valuable insight into how vertical loads are transmitted through the suspension system. Michigan Scientific can instrument coil springs to capture this data accurately, even under dynamic conditions. In addition to force, coil springs can be calibrated to measure displacement, which is useful for correlating spring compression with ride height and suspension travel. Contact us for a free consultation to discuss suspension instrumentation. Michigan Scientific engineers will work with you to identify the most effective instrumentation strategy based on your specific suspension layout and testing goals. Authored by Vice President Andrew Cook [...] Read more...
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Ted NachazelAugust 10, 2023NewsCustom Multi-Axis Load Cells: Solutions for Your Measurement Needs When a project requires a custom force and moment measurement solution, Michigan Scientific will work with our customers to define their requirements and propose solutions based on the number of measurement axes, load capacity, size limitations, accuracy, and load cell quantity needed. Michigan Scientific employs some of the world’s most experienced and creative engineers and physicists in the design of Multi-Axis Load Cells. With our extensive expertise and innovative approach, we are confident we can deliver a solution that will work for your application. Standard Multi-Axis Load Cells and Adaptation Michigan Scientific has been designing and manufacturing Multi-Axis Load Cells for over 30 years. We currently manufacture 17 different standard Six Axis Load Cell models and 14 standard Three-Axis Load Cell models. Many of these standard Multi-Axis Load Cells are kept in stock for quick delivery times. Meeting Unique Requirements with Custom Solutions For some applications, a standard solution is not the best choice or even possible, so a custom load cell should be considered. Michigan Scientific designs load cells compatible with clean, medical industry standards to highly corrosive industrial environments, with IP67 protection being attainable for many applications. Michigan Scientific will design and manufacture custom load cells for any quantity and has provided both standard and custom load cells for many industries including automotive, heavy equipment, agricultural, aircraft, industrial, energy generation, and ship development. Six Axis Calibration Capabilities Michigan Scientific has one of the world’s largest Six-Axis Load Cell calibration stands, capable of calibrating load cells up to 667 kN force and 203 kN ∙ m moment. If higher calibration loads are required, larger calibration fixturing can be built. Our calibrations are accredited to ISO/IEC 17025:2017 and traceable to the National Institute of Standards and Technology (NIST). Working with Michigan Scientific Michigan Scientific provides free consultations to determine a system price and a basic design proposal.  After receipt of the PO or contract from a customer, the proposed design will be modified through direct consultation with the customer until a final design is approved.  To set up a load cell consultation, please fill out the Contact Us page. [...] Read more...
Ted NachazelApril 11, 2022Michigan Scientific has extensive experience in applying strain gauges to a wide variety of components and equipment. The gauged part maintains its strength and physical integrity and can be used to collect accurate data on the forces it experiences during product development, component testing, and structural analysis. Our team has successfully instrumented small and large-scale components in even the most complex environments across industries and applications.  Michigan Scientific provides onsite strain gauge services and can instrument both component and structural applications for measurement and analysis at the customer’s location.   Michigan Scientific has strain gauged and collected data on:  Structural beams for deflection and stress testing Circuit boards for monitoring stress Thermal chamber door panel, monitored for deformation during manufacturing Industrial 16 inch diameter drive shaft of a large cement plant ball mill for measuring torque, acceleration, and rotational velocity Applications requiring deep bore gauging up to six inches in depth with a minimum diameter of 0.5 inches Gearbox components Solid axles via deep-bore gauging Michigan Scientific also supports clients with data acquisition during testing and provides data processing, analysis, and reporting services. Data recording can be performed during the manufacturing process or in-service use to support a wide range of test and development activities.    Visit the Custom Force and Torque Transducers page for Michigan Scientific instrumentation solutions for research and development across industries.  Find out more about strain gauges; how they work and what they measure.  Reach out to a Michigan Scientific representative to start your project today. [...] Read more...
Ted NachazelMarch 15, 2022NewsWheel Force Transducers (WFTs) are used to measure vehicle reaction forces during durability and vehicle dynamics testing. MSC WFTs are known for their durability, accuracy, simple installation, and ease of use. Installed on cars, SUVs, all sizes of trucks, ATVs, agriculture equipment and construction machinery, MSC has a wide range of WFT capacities to fit almost any wheeled vehicle. Wheel Force Transducer Michigan Scientific Corporation WFTs output three forces, three moments, two accelerations, wheel speed, and wheel position signals to provide complete spindle load data with extreme accuracy. All WFTs include both CAN and Analog signal outputs. Every system combines a high strength, lightweight transducer with weatherproofed protective coatings to function in a variety of driving conditions. Product engineers determine appropriate WFT rental models for any application providing availability, pricing, and customized adapter options. Rental systems can be shipped immediately if Michigan Scientific has already manufactured the hub and rim adapter. CAD models of the WFT adapter layout guidelines and design review are provided at no additional charge. Rental periods can be as short as two weeks, for customers who only need short term use.  System Components Michigan Scientific WFT rental systems include the WFT and the built in amplifier in either the Slip Ring or Telemetry system. The Stator Angle Corrector adjusts the real-time rotational angle signal from the wheel. The adjusted rotational angle signal is used in the coordinate transformation to prevent any error while the wheels are steered during dynamic testing. The WFT User Interface Electronics (CT2) provides high level CAN, Ethernet, and analog outputs. The CT2 accepts either analog or digital signals from the WFT. In addition, CT2 can also accept built in WFT accelerometer signals. All the signals together can be transmitted to the data acquisition system or computer through the digital outputs. The CAN signal cable is included, as well as the cabling for analog signal outputs. All the required cabling and fasteners are included to ensure easy setup. Adapters can be made available as needed. All systems are shopped in rugged packaging or shipping containers. Support Comprehensive support is available through phone, email, or on-site instruction. Michigan Scientific will provide on-site training and support at no charge if the facility is within 50 miles of Michigan Scientific. If the distance is greater, a travel fee would be charged.   [...] Read more...