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Strain Gauges*

     If a strip of conductive metal is stretched, it will become skinnier and longer, both changes resulting in an increase of electrical resistance end-to-end. Conversely, if a strip of conductive metal is placed under compressive force (without buckling), it will broaden and shorten. If these stresses are kept within the elastic limit of the metal strip (so that the strip does not permanently deform), the strip can be used as a measuring element for physical force, the amount of applied force inferred from measuring its resistance.

Such a device is called a strain gauge. Strain gauges are frequently used in mechanical engineering research and development to measure the stresses generated by machinery. Aircraft component testing is one area of application, tiny strain-gauge strips glued to structural members, linkages, and any other critical component of an airframe to measure stress. Most strain gauges are smaller than a postage stamp, and they look something like this:
Picture
Typical strain gauge resistances range from 30 Ω to 3 kΩ (unstressed). This resistance may change only a fraction of a percent for the full force range of the gauge, given the limitations imposed by the elastic limits of the gauge material and of the test specimen. Forces great enough to induce greater resistance changes would permanently deform the test specimen and/or the gauge conductors themselves, thus ruining the gauge as a measurement device. Thus, in order to use the strain gauge as a practical instrument, we must measure extremely small changes in resistance with high accuracy. Such demanding precision calls for a bridge measurement circuit (refer below): 
Picture
A. strain gauge bridge circuit indicates measured strain by the degree of imbalance, and uses a precision voltmeter in the center of the bridge to provide an accurate measurement of that imbalance. An example of how a pair of strain gauges may be bonded to a test specimen to cancel each other out in an effort to "balance" the circuit is illustrated here: 
Picture
With no force applied to the test specimen, both strain gauges have equal resistance and the bridge circuit is balanced. However, when a downward force is applied to the free end of the specimen, it will bend downward, stretching gauge #1 and compressing gauge #2 at the same time:
Picture
In applications where such complementary pairs of strain gauges can be bonded to the test specimen, it may be advantageous to make all four elements of the bridge “active” for even greater sensitivity. This is called a full-bridge circuit:
Picture
Both half-bridge and full-bridge configurations grant greater sensitivity over the quarter-bridge circuit, but often it is not possible to bond complementary pairs of strain gauges to the test specimen. Thus, the quarter-bridge circuit is frequently used in strain measurement systems.

When possible, the full-bridge configuration is the best to use. This is true not only because it is more sensitive than the others, but because it is linear while the others are not. Quarter-bridge and half-bridge circuits provide an output (imbalance) signal that is only approximately proportional to applied strain gauge force. Linearity, or proportionality, of these bridge circuits is best when the amount of resistance change due to applied force is very small compared to the nominal resistance of the gauge(s). With a full-bridge, however, the output voltage is directly proportional to applied force, with no approximation (provided that the change in resistance caused by the applied force is equal for all four strain gauges!).

* = Reprinted with permission from open source Design Science License from Kuphaldt, T.R., Lessons in Electric Circuits. Vol. I-DC., 5th ed. 18 Oct 2006.  http://www.allaboutcircuits.com/assets/pdf/direct-current.pdf. 

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