Kistler 9109AA Owner's manual

Instruction

Manual

MicroDyn

Mehrkomponenten-

Dynamometer bis

500 N

Typ 9109AA

9109AA_002-827e-06.18

MicroDyn

Multicomponent

Dynamometer

up to 500 N

Type 9109AA1

Instruction

Manual

MicroDyn

Mehrkomponenten-

Dynamometer bis

500 N

Typ 9109AA

9109AA_002-827e-06.18

MicroDyn

Multicomponent

Dynamometer

up to 500 N

Type 9109AA1

Foreword

9109AA_002-827d-06.18 Page 1

Foreword

Thank you for choosing a Kistler quality product charac-

terized by technical innovation, precision and long life.

Information in this document is subject to change without

notice. Kistler reserves the right to change or improve its

products and make changes in the content without

obligation to notify any person or organization of such

changes or improvements.

protected by various intellectual property rights. For more

details visit www.kistler.com. The Kistler Group includes

Kistler Holding AG and all its subsidiaries in Europe,

Asia, the Americas and Australia.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

[email protected]

www.kistler.com

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 2 9109AA_002-827d-06.18

Contents

1.Introduction .................................................................................................................................. 4

2.Important information ................................................................................................................. 5

2.1For your safety .................................................................................................................... 5

2.2Hints for handling this device .............................................................................................. 6

2.3Tips on using the instruction manual .................................................................................. 7

2.4What happens when there are changes? .............................................................................. 7

3.General device description ........................................................................................................ 8

3.1What is a Multicomponent Dynamometer used for? ........................................................... 8

3.2Functional principle ............................................................................................................. 9

3.3Dynamometer construction ............................................................................................... 10

4.Mounting, installation and initial startup ................................................................................ 11

4.1Important information ........................................................................................................ 11

4.2Mounting the Dynamometer .............................................................................................. 12

4.3Basic connection and cabling of the measuring system ................................................... 15

4.4Dynamometer positioning ................................................................................................. 15

4.5Measuring system for 3- or 4-component measurement (Fx, Fy, Fz / Mz) .......................... 16

5.Operation .................................................................................................................................... 19

5.1Range selection ................................................................................................................ 19

5.2Measuring small changes in force .................................................................................... 19

5.3Useful frequency range ..................................................................................................... 21

5.4Piezoelectric force measurement ...................................................................................... 23

5.5Tips for better measuring results ...................................................................................... 26

5.6Measurement signal polarity ............................................................................................. 26

6.Maintenance ............................................................................................................................... 27

6.1Re-calibrating the device ................................................................................................... 27

6.2Maintenance work ............................................................................................................. 28

7.Fault elimination ........................................................................................................................ 29

7.1Troubleshooting ................................................................................................................ 29

7.2What to do if the Dynamometer is faulty ........................................................................... 30

8.Technical data............................................................................................................................ 31

8.1MicroDyn Type 9109AA .................................................................................................... 31

8.2Dimensions ....................................................................................................................... 32

9.Accessories ............................................................................................................................... 33

9.1Included accessories ......................................................................................................... 33

9.2Optional accessories ......................................................................................................... 33

10.Ordering code ............................................................................................................................ 35

11.Appendix .................................................................................................................................... 36

11.1Glossary ............................................................................................................................ 36

11.2Measurement Uncertainty ................................................................................................. 39

Introduction

9109AA_002-827d-06.18 Page 3

11.3Linearity ............................................................................................................................. 40

11.4Frequency Range .............................................................................................................. 42

11.5Temperature effect ............................................................................................................. 43

Total number of pages: 44

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 4 9109AA_002-827d-06.18

1. Introduction

Please take the time to thoroughly read this instruction

manual. It will help you with the installation, maintenance,

and use of this product.

To the extent permitted by law Kistler does not accept

any liability if this instruction manual is not followed or

products other than those listed under Accessories are

used.

Kistler offers a wide range of products for use in

measuring technology:

 Piezoelectric sensors for measuring force, torque,

strain, pressure, acceleration, shock, vibration and

acoustic-emission

 Strain gage sensor systems for measuring force and

torque

 Piezoresistive pressure sensors and transmitters

 Signal conditioners, indicators and calibrators

 Electronic control and monitoring systems as well as

software for specific measurement applications

 Data transmission modules (telemetry)

Kistler also develops and produces measuring solutions

for the application fields engines, vehicles,

manufacturing, plastics and biomechanics sectors.

Our product and application brochures will provide you

with an overview of our product range. Detailed data

sheets are available for almost all products.

If you need additional help beyond what can be found

either on-line or in this manual, please contact Kistler's

extensive support organization.

Important information

9109AA_002-827d-06.18 Page 5

2. Important information

It is essential to follow the instructions below for your own

personal safety when working and to ensure long-lasting,

trouble-free operation of the device.

2.1 For your safety

 This device has been thoroughly tested and was

perfectly safe when it left the factory. To keep it in this

condition and ensure risk-free operation, the user

must observe the information and warnings contained

in this Instruction Manual.

 The dynamometer must only be installed, operated

and repaired by persons who are familiar with the

device and who are suitably qualified for their

particular work.

 If you believe that the device can no longer be

operated without risk, it must be taken out of operation

and secured to prevent accidental operation.

You should believe that the device can no longer be

operated without risk,

 if there are visible signs of damage on the device,

 if the device is no longer working,

 after prolonged storage under adverse conditions,

 if mishandled during transportation.

When measuring the cutting force, fasten the

dynamometer to the machine tool as specified! Details

can be found in the 4.2 "Mounting the dynamometer"

chapter.

Fasten all the parts mounted on the cover plate of the

dynamometer in accordance with the forces that are

expected!

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 6 9109AA_002-827d-06.18

2.2 Hints for handling this device

 You must only work with the dynamometer in

specified environmental and operating conditions

 Insulation resistance is crucial for piezoelectric

measurements; it must be about 100 T (but at least

10 T)

 To obtain this value, all the plug connections must be

kept scrupulously clean and dry

 The insulation resistance can be measured with a

Type 5493 insulation tester

 Protect the device signal output against contamination

and do not touch it with your fingers. Put on the

supplied cover if the connection is not assigned

 The connecting cable (connecting cable from the

dynamometer to the charge amplifier input) has high

insulation. Only specified connecting cables must be

used

 The connecting cable should not be removed from the

dynamometer

 When the dynamometer is not being used, keep it in

the supplied packing case to protect it

 During long-term measurements, make sure that the

dynamometer temperature stays as constant as

possible

Important information

9109AA_002-827d-06.18 Page 7

2.3 Tips on using the instruction manual

We always recommend that you read the entire

Instruction Manual. But if you are in a hurry and are

already familiar with Kistler dynamometers, you only have

to read the particular information you need.

We have tried to design this manual to make it easy for

you to directly access the information you are looking for.

Keep this Instruction Manual in a safe place, where it will

always be close at hand.

Should you lose the manual, contact your Kistler

customer service department to obtain an immediate

replacement.

All the information and instructions in this manual may be

changed at any time without prior notic

e.

2.4 What happens when there are changes?

Modifications to the device usually result in changes to

the Instruction Manual. Ask your Kistler customer service

department about the update options for your

documentation.

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 8 9109AA_002-827d-06.18

3. General device description

3.1 What is a Multicomponent Dynamometer used for?

The multicomponent dynamometer is used for dynamic

and quasistatic measurement of the 3 orthogonal

components of any force acting on the cover plate (Fx, Fy

and Fz).

The dynamometer is extremely rigid and therefore has a

high natural frequency. The high resolution allows the

smallest dynamic changes of large forces to be

measured.

The dynamometer measures the active force, irrespective

of its application point. Both the average force value and

the dynamic increase in force can be measured. The

useful frequency range mainly depends on the natural

frequency of the entire measurement setup.

Fig. 1: MicroDyn Type 9109AA

The most important areas of application for the multicom-

ponent dynamometer are

:

 General 3-component force measurement of small

forces

 Force measurement in confined spaces

 Cutting force measurement with small forces, such as:

 precision machining

 micromachining

 ultra-high precision machining of brittle, hard

materials

General device description

9109AA_002-827d-06.18 Page 9

3.2 Functional principle

The force to be measured is applied via a cover plate and

distributed to four, 3-component force sensors arranged

between the cover plate and the two base plates.

Each force sensor contains three quartz crystal plate

pairs, of which one is sensitive to pressure in the

z direction and the other two are sensitive to shear in the

x and y directions. The arrangement of pressure- and

shear-sensitive plate pairs for the dynamometer’s spatial

direction (x, y and z) depends on the mounting direction

of the respective sensor in the dynamometer.

Measurement takes place practically without deflection.

Fig. 2: Force sensor setup in the multicomponent

dynamometer: quartz crystal plate pairs for the 3

measuring directions

Positive or negative charges are produced at the

connections, depending on the direction of the force.

Negative charges produce positive voltages at the charge

amplifier output, and vice versa.

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 10 9109AA_002-827d-06.18

3.3 Dynamometer construction

The dynamometer consists of four 3-component force

sensors, mounted under high preload between four base

plates and one cover plate.

This preload is the requirement for friction force trans-

mission

Fig. 3: Basic dynamometer construction

The four force sensors are installed ground-isolated for

dry condition. This largely eliminates ground loop

problems.

The dynamometer is rustproof and protected against the

ingress of splash water and cooling agent. Together with

the connecting cable (Type 1677A5, Type 1677AQ02,

Type 1679A5), the dynamometer meets the requirements

of degree of protection IP67.

As a result of the specific sensor location and signal

connection, the dynamometer is largely insensitive to

temperature shifts.

1 Base plates

2 Cover plate

3 Connector

Mounting, installation and initial startup

9109AA_002-827d-06.18 Page 11

4. Mounting, installation and initial startup

4.1 Important information

The Type 9109AA multicomponent dynamometer is a

precision instrument, with inherent accuracy that will only

remain useful and intact if the device is carefully handled.

It is therefore important to observe the following

instructions:

 Do not drop the dynamometer and do not subject it to

sharp blows! The maximum force of this type of shock

could exceed the device measuring range and cause

lasting deformation

 Do not use a hammer to position the workpieces, as

striking the workpieces will also cause deformation

The chapters that follow contain information about

dynamometer installation.

MicroDyn Multicomponent Dynamometer up to 500 N, Type 9109AA1

Page 12 9109AA_002-827d-06.18

4.2 Mounting the Dynamometer

To mount the dynamometer properly, please note the

following:

 The dynamometer must only be installed by persons

who are familiar with the device and who are suitably

qualified for this work

 The connecting cable is first connected to the

dynamometer. Both sides of the connector (the

dynamometer and the cable) are cleaned with Type

1003 cleaning and insulating spray. The enclosed O-

ring is used for sealing. The bearing surfaces for the

O-ring must be clean. The O-ring is inserted and the

cable flange screwed to the dynamometer with two

screws, and tightened until seated

 Tightening torque (MA): 4.5 N·m



Before mounting the dynamometer on a machine tool

or a testing device, check that the mounting surface is

flat. Uneven bearing surfaces cause inner distortion,

which additionally exposes the individual force

sensors to high shear loads and can increase

crosstalk

Abb. 4:

Cable mounting with O-ring seal

3

4

1 Dynamometer

2 O-ring seal

3 M4x10 screw

4 Cable (high insulation)

1 2

Mounting, installation and initial startup

9109AA_002-827d-06.18 Page 13

The bottom surface of the dynamometer is ground, i.e.

precision machined. The device must therefore only be

installed on mounting surfaces that are ground or

machined to the same standard. The specific alignment

of the force sensors requires the quality of the mounting

surface to be meticulously monitored. Thoroughly clean

the bearing surfaces before assembly.

 Make sure that the dynamometer is resting completely

flat. Even the tiniest air gap can produce unwanted

elasticity and lead to a reduction in the resonance

frequency of the measuring arrangement. Please

therefore pay attention to the oscillation aspects of the

assemblies as well

 If possible, the connecting cable should always stay

connected to the dynamometer

 Install the connecting cable so that it can neither

shear off nor be pulled out when working

 The long sides of the base plates are used to align the

dynamometer on a magnetic plate or a machine table.

The dynamometer can be mounted in two different ways.

a. With 8 M4x25 screws

For this type of mounting, 8 M4 threaded bores

(minimum thread length: 12 mm) are required on the

assembly table. The tightening torque is always 4.3

N·m, the strength class 12.9.

The tightening torque for the cover plate screws is

3.0 N·m for M4 and 2.0 N·m for M3 screws.

.

Fig. 4: Dynamometer mounted on a machine base plate

MicroDyn Mehrkomponenten-Dynamometer bis 500 N, Type 9109AA

Page 14 9109AA_002-827d-06.18

a. On a magnetic plate

If a magnetic plate is used, there is no need to

subsequently provide the assembly table with

mounting bores

Fig. 5: Dynamometer with steel base plate mounted on a

magnetic table

Beware!

With this type of mounting, the process forces must not

be greater than the magnetic forces. It is essential to

stop the dynamometer slipping in order to prevent

damage to the measuring instrument.

Mounting, installation and initial startup

9109AA_002-827d-06.18 Page 15

4.3 Basic connection and cabling of the measuring system

Charge amplifiers convert the electric charges output by

the dynamometer (picocoulomb = pC) into proportional

voltages that can be displayed, recorded or processed

with the usual instruments.

Please note the following information when cabling

the measuring system

 The connecting cables from the dynamometer to the

charge amplifier must have good insulation and be

low triboelectricity. Only the specified connecting

cables must be used.

 Conventional cables can be used for the connection

between the charge amplifier and the indicators or

evaluation devices.

 All work on electrical connections must be carried out

carefully and tidily. Only remove the caps covering the

connections immediately before connecting a cable.

 Please refer to the two chapters below for the cabling

information for specific configurations.

4.4 Dynamometer positioning

 The dynamometer and the cables must be positioned

so that coolants can drain completely. This stops

aggressive bacteria forming in old coolant, which

could then damage the dynamometer and the cables.

Depressions and creases should therefore be avoided

 Install the connecting cable so that it can neither

shear off nor be pulled out when working

MicroDyn Mehrkomponenten-Dynamometer bis 500 N, Type 9109AA

Page 16 9109AA_002-827d-06.18

4.5 Measuring system for 3- or 4-component measurement (F

x

, F

y

,

F

z

/ M

z

)

The diagram below shows the elements required to

connect a dynamometer to a multichannel charge

amplifier (e.g., Type 5080Axx8x004). Because two

sensor elements in the dynamometer are oriented for

pressure and two for shear in the orthogonal spatial

directions x and y, these sensors have different

sensitivities. For this reason, an 8-channel measuring

chain is required for a 3- or 4-component measurement in

order to amplify the individual sensors with different

sensitivities.

MicroDyn 8-channel connecting cable 8-channel charge amplifier

Type 9109AA Type 1677A5 Type 5080Axx8x004

Degree of protection: EN60529

Fig. 6: Measuring system for 3- or 4-component

measurement Fx, Fy, Fz, Mz

Fig 7: Charge amplifier output assignment for 3- or 4-

component measurement

Output ±10 V

Ch1 F

x’1

Ch2 F

x’2+4

Ch3 F

x’3

Ch4 F

y’1+3

Ch5 F

y’2

Ch6 F

y’4

Ch7 F

z’1+2+3+4

Ch8 NC

Mounting, installation and initial startup

9109AA_002-827d-06.18 Page 17

Input signals Pin

no.

Pin no. Output signals

Masse

1 1

Masse

Fx‘1

2 2

Fx‘1

Fx‘2+4

3 3

Fx‘2+4

Fx‘3

4 4

Fx‘3

Fy‘1+3

5 5

Fy‘1+3

Fy‘2

6 6

Fy‘2

Fy‘4

7 7

Fy‘4

Fz‘1+2+3+4

8 8

Fz‘1+2+3+4

NC

9 9

NC

Fig. 8: Cable diagram for connecting cable Type 1677A5

For a 3-component force measurement with a

dynamometer consisting of four 3-component sensors,

the output signals (each of Fx, Fy and Fz) of the four

sensors are summed. However, the sum of the four

sensors always shows the correct value irrespective of

the force application point. Because the individual

sensors have different sensitivities in the orthogonal

spatial directions x and y, summing must take place after

the charge amplifier. The sum of the four sensors always

indicates the correct value, irrespective of the force

application point. The individual forces are calculated as

follows:

A 3-Component Dynamometer Measures

 the three components of all the resulting forces

acting on the dynamometer and their direction but

not their position in space

Depending on the location of the force application point,

the load is distributed over all four sensors. However,

alternatively, an individual sensor can receive the main

part of the force. If the force is applied far outside the

dynamometer then, according to the law of the lever, an

individual sensor can experience a multiple of the force to

be measured. For applications of this kind, the load on an

individual sensor must be accurately calculated.

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Kistler 9109AA Owner's manual

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