Kistler 9240AA3 Owner's manual

Category
Measuring, testing & control
Type
Owner's manual

This manual is also suitable for

Instruction
manual
9240A_002-763e-08.19
Quartz transverse
measuring pin
Type 9240A...
Type 9241C...
Instruction
manual
9240A_002-763e-08.19
Quartz transverse
measuring pin
Type 9240A...
Type 9241C...
Page 1
9240A_002-763e-08.19
The information in this manual is subject to change at any
time without prior notice. Kistler reserves the right to im-
prove and modify the product to reflect technical progress
without having to inform persons and organizations of
these changes.
© 2011 ... 2019 Kistler Group. Kistler Group products are
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
info@kistler.com
www.kistler.com
Foreword
Foreword
Foreword
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 2
Content
1. Introduction .................................................................................................................................4
2. Important instructions ................................................................................................................5
2.1 For your safety ....................................................................................................................5
2.2 Unpacking ...........................................................................................................................5
2.3 Instructions on handling the device ....................................................................................6
2.4 Tips for using the Instruction manual ..................................................................................6
3. General device description ........................................................................................................7
3.1 What is extension? .............................................................................................................7
3.1.1 Longitudinal extension – transverse extension .....................................................7
3.2 What purpose does a strain sensor serve? .......................................................................8
3.3 Design and functional principle of strain sensor Types 9240A... and 9241C… ..................9
3.3.1 Design ...................................................................................................................9
3.3.2 Measuring principle ...............................................................................................9
3.4 Manufacturer's calibration of sensors ...............................................................................10
4. Installation and commissioning ..............................................................................................12
4.1 Important instructions .......................................................................................................12
4.2 Selecting the measuring point ..........................................................................................12
4.3 Structure materials ...........................................................................................................14
4.4 Consideration of thermal effects .......................................................................................14
4.5 Positioning the sensor ......................................................................................................14
4.5.1 Type 9240A…......................................................................................................14
4.5.2 Type 9241C… .....................................................................................................15
4.6 Installation ........................................................................................................................16
4.6.1 General installation instructions ..........................................................................16
4.6.2 Installation tool ....................................................................................................16
4.6.3 Installation instructions .......................................................................................17
4.6.4 Cable installation instructions ..............................................................................20
4.6.5 Cable concept .....................................................................................................21
4.7 Initial commissioning ........................................................................................................21
4.7.1 The simplest form of measurement – relative measurement ..............................22
4.7.2 The simplest form of measurement – extension .................................................22
4.7.3 Indirect force measurement.................................................................................24
5. Calibration ................................................................................................................................25
5.1 On-site calibration of a strain sensor ................................................................................25
5.1.1 Calibration of the operation point via a peak value comparison ..........................25
5.1.1.1 Test system requirements ....................................................................25
5.1.1.2 Installing the reference sensor .............................................................26
5.1.1.3 Procedure in the event of load application ...........................................26
5.1.1.4 Worksheet for the calibration process..................................................27
5.2 Kistler calibration service ..................................................................................................28
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9240A_002-763e-08.19
Total pages 48
6. Operation ...................................................................................................................................30
6.1 Quasistatic measurements ...............................................................................................30
6.2 Tips for good measurement values ..................................................................................30
7. Maintenance ..............................................................................................................................31
8. Eliminating malfunctions .........................................................................................................32
8.1 Troubleshooting and malfunction elimination ...................................................................32
8.2 Repairing the strain sensor ...............................................................................................32
8.3 Technical data ...................................................................................................................33
8.3.1 Strain sensor Type 9240A… ...............................................................................33
8.3.2 Strain sensor Type 9241C… ...............................................................................34
8.4 Dimensions of Type 9240A… ...........................................................................................34
8.5 Dimensions of Type 9241C… ...........................................................................................35
8.6 Connection variants ..........................................................................................................35
8.7 Ordering key .....................................................................................................................35
8.8 Optional accessories ........................................................................................................36
9. Appendix ....................................................................................................................................38
9.1 Glossary ...........................................................................................................................38
9.2 Measurement uncertainty .................................................................................................41
9.3 Linearity ............................................................................................................................42
9.4 Frequency range ..............................................................................................................44
9.5 Inuenceoftemperature ...................................................................................................45
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 4
1. Introduction
Thank you for choosing a Kistler quality product. Please
read this Instruction Manual carefully, so that you can
take optimum advantage of the versatile features of this
product.
Insofar as permitted under statute, Kistler refuses any
and all liability resulting from failure to observe this Instruc-
tion Manual or from the use of products other than
those listed under Accessories.
Kistler offers a wide range of measurement technology
products and complete solutions:
• Piezoelectric sensors for measuring pressure, power,
torque, extension, acceleration, shock, and vibration
• Strain gage sensor systems for measuring power and
torque
• Piezoresistive pressure sensors and transmitters with the
associated measuring amplifiers
• Associated measuring amplifiers (charge amplifiers,
piezoresistive amplifiers, etc.), indicators, and charge
calibrators
• Electronic control, monitoring, and evaluation units as
well as application-specific software for measurement
technology
• Data transmission modules (telemetry)
Kistler also designs complete measuring systems for spe-
cial-purpose
applications, e.g., in the automotive industry, in plastics
processing, and in the biomechanics sector.
Our General Catalog provides an overview of what we
offer. Detailed data sheets are available for practically
all of the products.
Should you have any specific questions after
reading these instructions, the global Kistler Customer Ser-
vice team is available to provide you with expert advice
on any application-specific problems.
Important instructions
Page 5
9240A_002-763e-08.19
2. Important instructions
Please observe the following instructions. Observing the
instructions is in the interest of your personal safety while
working and will ensure that the device continues to oper-
ate without any problems for a long period of time.
2.1 For your safety
• This device has been meticulously checked and left the
plant in an impeccable condition with respect to safety
considerations. To maintain this condition and ensure
hazard-free operation,
users must observe the instructions and warnings in this
Instruction Manual.
• The strain sensor may only be installed, operated,
and maintained by persons who are familiar with the
device and who are sufficiently qualified for their respec-
tive work.
• If it is to be assumed that hazard-free operation is no lon-
ger possible, then the device is to be put out of operation
and secured against being operated inadvertently.
It is to be assumed that hazard-free operation is no longer
possible:
If the device exhibits visible damage
If the device has been overloaded
If the device no longer functions
After prolonged storage under unfavorable conditions
After significant stress during transport
Attach the strain sensor in accordance with regulations.
For details on this, please refer to Chapter 4.
2.2 Unpacking
Check all of the device packaging for any transport dam-
age. Report any such damage to the transport company
and the responsible Kistler distributor.
Please check the included Accessories (see Chapter 1) be-
fore you start commissioning the device. If a part is miss-
ing, please contact the responsible Kistler distributor.
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 6
2.3 Instructions on handling the device
• Use the strain sensor only under the specified environ-
mental and operating conditions.
Protect the connector of the strain sensor from con-
tamination and never touch the connector with your
fingers (front of connector). Fit the cover supplied if
the connection is not occupied.
• Only use specified connecting cables.
• When not using the strain sensor, protect it by keeping it
in its original packaging.
2.4 Tips for using the Instruction manual
As a rule, we recommend that you read the entire Instruction
Manual. If, however, you are in a hurry and already have
experience with Kistler strain sensors, then you can limit your
reading to the information you currently require.
We have endeavored to structure these instructions in a
clear manner and thereby facilitate direct access
to the information you are looking for.
Please store this Instruction Manual in a safe place where it
always ready at hand.
If these instructions become lost, please contact your
Kistler
distributor and you will receive a replacement without
delay.
General device description
Page 7
9240A_002-763e-08.19
3. General device description
3.1 What is extension?
The physical measurand that is measured is the relative
extension ε and is defined as the elongation of a machine
part under load divided by the original length l0.
If the dimensions of the object increase, reference is made to
a positive extension (or elongation); otherwise, reference is
made to a negative extension (or compression).
The measurand of ε is dimensionless. The SI unit for relative
extension ε is [m/m].
Kistler uses με as the unit for relative extension
1 με = 1 microstrain = 10–6 m/m = μm/m
3.1.1 Longitudinal extension – transverse extension
Each component that is extended or compressed in terms
of length undergoes a transverse extension in the trans-
verse direction. The transverse extension is usually around
30 % of the linear extension in the opposite direction. If
the component is compressed longitudinally, for example,
it elongates in the transverse direction. It can be possible
to utilize this effect depending on the application, with
the transverse extension measured instead of the linear
extension.
Fig. 1: Every object that is extended or compressed in a
given direction undergoes the opposite extension
in the transverse direction.
=
=
m
m
l
l
l
ll µ
ε
00
01
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 8
3.2 What purpose does a strain sensor serve?
A strain sensor is primarily used to measure the extension
of a material within a structure. However, since the bearing
machine structure is subject to a more or less significant ex-
tension or compression in the case of all processes in which
forces are applied, a strain sensor can be used just as well
for indirectly measuring dynamic and quasistatic forces
(see Fig. 2). The sensitivity of the indirect force measure-
ment must be determined using on-site system calibration.
Force shunt
Sensitivity
Direct force measurement undirect force measurement
Force shunt measurement
Fp = process force
Fs = force on the sensor
Fn = force on the structure,
force shunt
Fig. 2: The indirect force measurement based on the
extension forms one extreme in the spectrum
above. Despite low sensitivity, the relationship
between force and extension is in most cases
linear enough to allow measurements to be taken
and monitoring to be performed in a sufficiently
accurate manner.
The most important application areas for strain sensor
Types 9240A... and 9241C… are:
Process monitoring of average forces
(press-fitting, crimping, bonding, punching, precision
blanking, deep drawing, embossing)
Process monitoring in presses that apply significant
forces
(press forging, body pressing, etc.)
Machine monitoring for machine tools
• Quality monitoring directly in the tool (punching, cold
massive forming, etc.) with compact Type 9240A
Range of the
indirect force
measurement
via the exten-
sion
General device description
Page 9
9240A_002-763e-08.19
Strain sensor Types 9240A... and 9241C… feature the
following excellent properties:
• Very good protection of the built-in sensor
• Long-term stability of the sensitivity level without
any signs of aging
• Durability when subjected to mechanical stress
• Miniaturized design
• High degree of flexibility in terms of positioning within
the machine part
3.3 Design and functional principle of strain sensor Types 9240A...
and 9241C…
3.3.1 Design
Fig. 3: Schematic cross-section of strain sensor Type
9240A... / 9241C…
Strain sensor Type 9240A... and Type 9241C… primarily
consist of the following elements, which play an important
role in the equipment's function:
• Machine structure with 8 or 10 mm mounting bore,
which is cylindrically elongated or compressed.
• Piezoelectric measuring element (blue), which generates
a charge proportional to the deformation of the machine
structure by means of compression.
• Preload design consisting of preload cone, preload nut,
and threaded sleeve. Screwing the preload nut onto
the threaded sleeve pushes the sensor element into the
preload cone, thereby generating the desired preload
toward the outside.
8/10 mm
mounting bore
Preload cone
Sensor Preload nut Threaded sleeve Cable
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 10
3.3.2 Measuring principle
The deformation of the mounting bore caused by the
extension of the surrounding material results in a vertical
force being applied to the sensor element, in a similar way
to a conventional load washer. The alignment of the mea-
suring element can be varied prior to the preload by means
of turning so that the sensor can be precisely adapted to the
actual force flux.
Alignment and preload are carried out with a specialized
installation tool (see 4.6 Installation).
Fig. 4: Typical characteristic curve of a strain sensor based
on conventional Kistler approach. This results in
negative sensor sensitivity S [pC/µε]
All Kistler force sensors are designed such that positive force
application generates a negative charge at the sensor out-
put. This corresponds to compressing the sensor and, there-
fore, compressing the surrounding material. By default, this
is converted into a positive output signal (voltage or current,
or digital value) by the connected charge amplifier, based on
the conventional Kistler approach. In the case of elongation,
the plus/minus signs change accordingly.
General device description
Page 11
9240A_002-763e-08.19
3.4 Manufacturer's calibration of sensors
The transverse measuring pins are calibrated at the plant
where they were manufactured. During this, the actual
sensitivity [pC/µε] and the maximum linearity deviation
are determined using the process of 'continuous calibra-
tion'. The calibration is logged on the calibration certificate
supplied.
Calibrated ranges:
Measuring range
Type 9240A... 0–200 µε
Type 9241C… 0–200 µε
Fig. 5: Example of calibration certificate supplied; Type
9240A… (left) and Type 9241C… (right)
The calibration process is carried out using a model com-
pression body, making it possible to determine the resulting
extension due to the force applied at any time.
In the case of direct extension measurement, the result of
the manufacturer's calibration can be used. If the sen-
sor sensitivity and the charge amplification are known, it
is possible to back-calculate the extension measured by
means of the voltage signal.
In all cases where an indirect force measurement is to be
performed using the strain sensors, on-site calibration must
be carried out (see Chapter 5.1).
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 12
4. Installation and commissioning
4.1 Important instructions
Strain sensor Type 9240A... and Type 9241C… are preci-
sion instruments; the features specified can only be fully
utilized if the sensors are used correctly and can only be
maintained if the sensors are handled with care. Please
observe the following instructions:
• Strain sensors may only be installed by persons who are
sufficiently qualified for this work.
• Do not allow strain sensors to fall and do not expose
them to severe impact. The peak force of this kind of
shock can cause lasting damage.
• Do not use a hammer to position the workpieces as
impact of this kind can also lead to damage.
You will find instructions for installing the strain sensor and
setting up the measuring chain in the chapters below.
If anything is unclear or difficulties arise when installing the
strain sensors, please contact the responsible plant distribu-
tor for advice. In cases where it is necessary to contact the
customer service team, the user must adequately docu-
ment the measurement issue through drawings, descrip-
tions, and calculations.
4.2 Selecting the measuring point
To enable a successful indirect force measurement, particu-
lar attention must be paid to selecting the measuring point.
Requirements for the measuring chain:
• The extension at the measuring point should be as pro-
portional as possible to the force being measured.
• A machine that does not allow exact position fixing
of the force application point must be equipped with
multiple strain sensors if the measurement always has
to correspond precisely to the working force irrespective
of the force application point (e.g., 2 or 4 sensors are
required for a 4-column press).
• On the one hand, the extensions at the measuring point
must be within the measuring range of the sensor. On
the other hand, however, it must be ensured that the
measuring range of the strain sensor is used as effective-
ly as possible to maintain the greatest possible interfer-
ence signal distance during operation.
Installation and commissioning
Page 13
9240A_002-763e-08.19
• The measuring point must not be exposed to high
thermal stress (thermal radiation and airflow). Ideally,
the material and ambient temperature at the measuring
point will be equal and consistent during the measuring
cycle.
• To keep the sensor dry, it must be ensured that the
mounting bore does not fill up with liquid.
There is very little chance of finding machine measuring
points with extensions caused by tensile and compression
loads alone. At virtually every measuring point, there is
an extension resulting from a combination of tensile or
compression load and bending stress. The proportion of
the extension caused by bending is often significantly
higher than that caused purely by tension or pressure. A
more precise examination of the link between extension
caused by bending and working force frequently indi-
cates nonlinear characteristics, the cause of which is to be
found in opening suspension effects of bearing and flange
surfaces or in separation plane sliding effects. In the case
of extension measurement during working force calibra-
tion, nonlinearities of this kind become apparent when the
correlation between the reference force and the extension
signal is measured.
The proportion of bending stress and elongation in the
measurement can be influenced by the position of the
sensor within the machine component.
Fig. 6: Simultaneously occurring extension and compres-
sion on a bent object. The proportion of these
two force effects in the measurement result may
vary according to the horizontal positioning of
the transverse measuring pin.
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 14
4.3 Structure materials
As a rule, it is possible to use the equipment in steel
structures without any problems. Extension measurements
in other materials such as cast iron, aluminum, or other
metals must be undertaken with caution; in such cases,
the sensor must be re-calibrated. Known problems include
reduced surface pressure and, consequently, reduced
preload, hysteresis effects, as well as material fatigue in the
contact area.
4.4 Consideration of thermal effects
The preload and, to a limited extent, the sensitivity of the
sensor change as a result of temperature changes in the
structure. The change to the preload has a direct influence
on the measuring range that can be used and is highly
dependent on the material of the surrounding structure.
4.5 Positioning the sensor
4.5.1 Type 9240A…
Fig. 7: Hole-mounting, Type 9240A
In contrast to other strain sensors, the measuring point can
be varied slightly in the direction of the borehole by means
of a transverse measuring pin, enabling a greater degree
of flexibility when selecting the measuring point. However,
the following points must be considered in the process:
Installation and commissioning
Page 15
9240A_002-763e-08.19
• The borehole must be clean and prepared with a toler-
ance of H8 over 8 mm
• A minimum installation depth of 8mm must be main-
tained
• In the event that the measuring pin is completely coun-
tersunk, the borehole must be sealed following installa-
tion with a Type 65000539 sealing plug
4.5.2 Type 9241C…
Fig. 8: Deep hole-mounting, Type 9240A
In contrast to other strain sensors, the measuring point can
be varied slightly in the direction of the borehole by means
of a transverse measuring pin, enabling a greater degree
of flexibility when selecting the measuring point. However,
the following points must be considered in the process:
• The borehole must be clean and prepared with a toler-
ance of H8 over 10 mm
• A minimum installation depth of 10mm must be main-
tained
• In the event that the measuring pin is completely coun-
tersunk, the borehole must be sealed following installa-
tion with a Type 3,112,024 sealing plug
Quartz transverse measuring pin Type 9240A..., Type 9241C...
9240A_002-763e-08.19
Page 16
4.6 Installation
4.6.1 General installation instructions
Correct installation is important for ensuring quality – par-
ticularly when it comes to reproducibility.
• Carefully clean the mounting bore to be used with a
de-greasing cleaning agent (such as ethanol, acetone,
carbon tetrachloride, or benzine).
• The sensor must be aligned with the direction of the
greatest anticipated extension.
• Special installation tool Type 1393B… must be
used for installing sensor Type 9241C… and special tool
Type 1300A161A must be used for installing sensor Type
9240A....
• Before installation, the insulation must be checked with
an insulation testing device (Type 5493).
Before performing the measurement or calibration, the ma-
chine must be exposed to the maximum working force at
least ten times using installed and preloaded strain sensors.
4.6.2 Installation tool
Fig. 9: Design of the installation tool
The installation tool consists of 2 parts:
A – Positioning and preloading tool
This is the external part
B – Orientation tool
This is the internal part
C – The notch on the orientation tool indicates
the alignment of the sensor during the installation
process
Installation and commissioning
Page 17
9240A_002-763e-08.19
4.6.3 Installation instructions
Step 1:
Guide the connector and sensor cable through the preload-
ing tool (A) as shown
Fig. 10: Inserting the cable into the installation tool
Step 2:
Carefully pull the sensor cable completely through the tool
element (A) until the sensor is at the front end.
Never pull the sensor cable forcefully or in a jolting manner
as this may damage it.
Fig. 11: Pulling the sensor cable completely through
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Kistler 9240AA3 Owner's manual

Category
Measuring, testing & control
Type
Owner's manual
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