Like so many other manufacturing technologies, counterbalance systems make life easier for the end customer. Matched with the right application, they can be a game-changer for user experience and safety.
A counterbalancing mechanism makes it possible to open heavy lids, covers, surfaces and equipment with little to no effort on the user’s part. This is how Grandma can open the lid of her grill without help. From single users to entire industries, counterbalance systems offer benefits that are worth considering for numerous motion control needs.
Before we get into specifics, let's start with basics: What is counterbalancing?
What Is Counterbalancing?
If you look at many products with heavy lids, you’ll find a counterbalance hinge -- at least, if that lid is easy to open. (“Find” is a deceptive word, because often these are hidden or concealed hinges.)
That lid could weigh 80 lbs., but you only feel 2 lbs. of force when you try to open it. You’re lifting “only” 2 lbs. because an engineer expertly designed the lid with a counterbalance.
If the designer wants to, he can create a lid that opens with 3 lbs., 10 lbs., or 15 lbs. of applied force -- basically any number he wants (though that number is sometimes determined by price point). That’s one of the most exciting things about a counterbalancing system -- it can be designed to operate in numerous ways depending on your application.
How Does a Counterbalance Work?
You might ask, “How does a counterbalance work?” We could go into a deep dive of the specifics of this technology, but a simple explanation is best for most purchasers.
We define a counterbalance as a weight or force that offsets or mitigates another weight or force.
In essence, a counterbalancing system incorporates various types of springs to take the effort out of lifting and supporting a lid, countertop, cover, or electromechanical equipment. It’s not just the spring itself -- it’s how an engineer applies geometry and other design techniques to support the lid.
The system counteracts the weight of the lid and balances it in a way that achieves the desired result.
What Makes Counterbalance Hinges Different?
There are numerous advantages that come with great counterbalance system design. These include:
- Safety. Counterbalancing keeps lids from slamming on Grandma’s fingers, or a fridge door from inviting a lawsuit.
- Ease of use. It’s much easier to lift counterbalanced lids.
- Minimized stress on the product. A door that slams closed 40 times a day is going to dent or crack sooner.
- Ergonomics. Science doesn’t lie -- mechanisms with counterbalancing technology improves health.
Customizing Your Counterbalance Hinge
These systems are surprisingly customizable. They can be designed for specific life cycles -- you can specify that you want your product to last 5,000 cycles, 250,000 cycles, or whatever else you want!
Lids can be made to stay open, to coast open, pop up, etc. You can combine multiple types of hinges, springs, and so on. It all depends on your preference.
The best way to determine the right counterbalance design for your product is to speak to a knowledgeable design team. With the right feedback, you can determine what you can do with the budget you prefer (and your sales/marketing team’s guidelines).
Which Industries Use Counterbalancing?
Counterbalance systems are common in a wide variety of applications, including:
- Grills (Kamado Joe calls it an air lift hinge)
- Medical centrifuges
- Silicon vapor deposition chambers (for making silicon wafer boards)
- Scientific equipment
- Industrial toolboxes
- Deli and restaurant food display cases
- Medical slide preparation devices
- Tanning beds
- Backs of cargo trailers -- panels on fold-down decking (these combine spring hinges with counterbalances)
Really, any product or equipment that requires a certain type of motion control is fair game for counterbalancing technology. Again, this is where collaboration with a counterbalance technology expert early in the design phase can get you the perfect result, tailored to your industry and product needs.
Some projects that use motion control concepts get quite complicated. If you have a question about product design using counterbalancing or motion control in general, comment below. We’ll forward your question to our experienced engineering team. (We love a good challenge!)