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<p>Conventional tensile testing systems rely on load cells as their primary force-sensing component. In contrast, this study presents a prototype platform that estimates tensile force using only the electromechanical behavior of a DC motor. A calibration procedure with a transient force gauge enabled the development of a force prediction model based on linear regression. Experimental validation on low-strength materials (PLA and soft plastics) showed a mean absolute percentage error of less than 5 %. Time-domain responses confirmed close agreement between predicted and measured forces, while approximate engineering strain derived from actuator displacement due to noisy extensometer signals in the limited experimental setup was used to generate stress-strain curves. The approximate engineering strain derived from actuator displacement was used to generate representative stress-strain curves for qualitative verification. Despite nonlinear effects such as friction and thermal slip, the prototype provides a practical proof-of-concept platform for educational and early-stage research applications.</p>

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Design and validation of a prototype load-cell-free tensile testing device based on DC motor electrical characteristics

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Nihat Çabuk

摘要

Conventional tensile testing systems rely on load cells as their primary force-sensing component. In contrast, this study presents a prototype platform that estimates tensile force using only the electromechanical behavior of a DC motor. A calibration procedure with a transient force gauge enabled the development of a force prediction model based on linear regression. Experimental validation on low-strength materials (PLA and soft plastics) showed a mean absolute percentage error of less than 5 %. Time-domain responses confirmed close agreement between predicted and measured forces, while approximate engineering strain derived from actuator displacement due to noisy extensometer signals in the limited experimental setup was used to generate stress-strain curves. The approximate engineering strain derived from actuator displacement was used to generate representative stress-strain curves for qualitative verification. Despite nonlinear effects such as friction and thermal slip, the prototype provides a practical proof-of-concept platform for educational and early-stage research applications.