We pride ourselves on providing innovative and highly customised force measurement solutions for various industries. One recent project highlights our customisation expertise in aerospace, where we developed specialised custom load pins to measure forces on components within a jet engine nacelle. This case study delves into the unique challenges, the tailored solutions we provided, and an overview of our broader customisation services. 
Addressing these challenges required a close collaboration between our design team and the client, involving detailed discussions, customised engineering, and iterative approval processes. The resulting solution included: Custom-Designed Load Pins: Each load pin was engineered to replicate the client’s existing components, such as bolts or mounting pins, with required modifications for accuracy and fit. Enhanced Durability and Safety Features: To ensure measurement reliability, we added features like specific threading, precise orientation markers, and high-temperature compensation. Rigorous Testing and Backup Plan: To guarantee accuracy and reliability, we manufactured spare units, which were essential to avoid delays due to unforeseen issues during testing. Despite the challenges posed by the COVID-19 pandemic, our team delivered these custom-designed devices on time and within budget. The client’s testing was successful, and they praised the reliability and performance of our load pins.
Client challenge: measuring forces on a jet engine nacelle
An aerospace client required precise measurements of forces acting on about 20 different bolts and mountings within a jet engine nacelle. The testing environment and stringent requirements of aerospace engineering made this an intricate project, with the following challenges: Multiple Component Sizes: The load pins needed to replace bolts and mounting pins of varying sizes. Threading and Locking Mechanisms: Several pins required threads or locking nuts to ensure secure installation. Preload Sensitivity: Over-tightening risked preloading the pins, potentially skewing measurements. Orientation: Correct orientation of load pins was essential for accurate force measurement. Varied Capacities: The pins needed to handle loads ranging from 2kN to 33kN. Multi-Axis Measurement: Some components required force measurement in two axes. High-Temperature Tolerance: Components had to be temperature-compensated up to 300˚C. High Accuracy: Measurement accuracy needed to be within 1% or better.Our solution: customised load pins for precise force measurement
Addressing these challenges required a close collaboration between our design team and the client, involving detailed discussions, customised engineering, and iterative approval processes. The resulting solution included: Custom-Designed Load Pins: Each load pin was engineered to replicate the client’s existing components, such as bolts or mounting pins, with required modifications for accuracy and fit. Enhanced Durability and Safety Features: To ensure measurement reliability, we added features like specific threading, precise orientation markers, and high-temperature compensation. Rigorous Testing and Backup Plan: To guarantee accuracy and reliability, we manufactured spare units, which were essential to avoid delays due to unforeseen issues during testing. Despite the challenges posed by the COVID-19 pandemic, our team delivered these custom-designed devices on time and within budget. The client’s testing was successful, and they praised the reliability and performance of our load pins. Customisation services and broader applications
Beyond aerospace, our customisation service addresses force measurement needs in various sectors where standard devices may not suffice. Common applications for our load pins include: Luggage Carousels: Wireless load pins for predictive maintenance, monitoring load and identifying potential issues. Stage Lifting Equipment: Load pins replace pully pins to monitor safe weight limits. Wind Turbines: Load monitoring on blades, gearboxes, and towers to enhance operational safety and efficiency. Winch and Tow Systems: Real-time tension measurement to prevent overloading. Structural Monitoring: Force measurement in buildings, bridges, and other structures for structural health assessment.Conclusion
Our customisation service provides tailored solutions that are precise, reliable, and engineered to meet the most demanding requirements. Whether in aerospace, energy, transportation, or construction, our commitment to understanding unique needs and delivering quality products ensures that we are a trusted partner in force measurement solutions.Custom load pins & customised solutions - find out more
- Learn more about our Custom Wired and Wireless Load Pins.
- Please get in touch if you'd like to discuss a customised solution.
- Read our article "Force measurement keeps UAVs flying high".
