A three-axis load cell algorithm development and real-time implementation

This thesis describes the development, testing, and real-time implementation of an algorithm to compute the tool forces applied to a three-axis load cell. The algorithm was implemented on a Zenithn portable computer along with an analog-to-digital converter. The load cell system is capable of monitoring low frequency (under 5 hz), low level (under 10 Ib_f) tool forces on a real-time basis.

The load cell system was tested for accuracy under static conditions and functionality under dynamic conditions. The system exhibited a two standard deviation confidence level (95 % ) within the range from 0.58% to -6.58% error. The mean percent error was observed to be -3.0%. Functionality was demonstrated through use of the load cell system to turn a piece of aluminum stock on a milling machine.