Kistler 9255C Owner's manual

Brand: Kistler

Model: 9255C

Type: Owner's manual

Instruction

Manual

Quartz 3-Component

Dynamometer

Type 9255C

9255C_002-615e-02.15

Instruction

Manual

Quartz 3-Component

Dynamometer

Type 9255C

9255C_002-615e-02.15

Foreword

9255C_002-615e-02.15 Page 1

Foreword

Thank you for choosing a Kistler quality product character-

ized 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 obliga-

tion to notify any person or organization of such changes

or improvements.

expressly provided herein, no part of this manual may be

reproduced for any purpose without the express prior writ-

ten consent of Kistler Group.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

Fax +41 52 224 14 14

[email protected]

www.kistler.com

Content

Page 2 9255C_002-615e-02.15

Content

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

2. Important Information .................................................................................................................... 5

2.1 For Your Safety .................................................................................................................... 5

2.2 How to Treat the Instrument ................................................................................................ 6

2.3 Tips for Using the Instruction Manual .................................................................................. 7

2.4 What Happens After Modifications? .................................................................................... 7

2.5 Disposal Instructions for Electrical and Electronic Equipment ................................................ 7

3. General Description of the Instrument ........................................................................................... 8

3.1 What Does a Multicomponent Dynamometer Do? .............................................................. 8

3.2 Functional Principle .............................................................................................................. 9

3.3 Design of the Dynamometer .............................................................................................. 10

4. Assembly, Installation and Putting into Operation ...................................................................... 11

4.1 Important Remarks ............................................................................................................. 11

4.2 Assembling the Dynamometer ........................................................................................... 11

4.3 Positioning of the Dynamometer ........................................................................................ 12

4.4 Basic Circuitry and Cabling of the Measuring System ......................................................... 13

4.4.1 Force Measuring with 3 Components (F

, F

) ................................................................. 14

4.4.2 3-Component Force Measurement .................................................................................... 15

4.4.3 Force and Moment Measuring with 6 Components (F

, F

, M

) ......................... 16

5. Operation ..................................................................................................................................... 18

5.1 Range Selection .................................................................................................................. 18

5.2 Measuring Small Force Changes ......................................................................................... 18

5.3 Usable Frequency Range .................................................................................................... 20

5.4 Temperature Influences ...................................................................................................... 22

5.5 Polarity of the Measuring Signal ......................................................................................... 22

6. Maintenance ................................................................................................................................ 23

6.1 Recalibrating the Instrument .............................................................................................. 23

6.2 Maintenance Tasks ............................................................................................................. 24

7. Trouble Shooting ......................................................................................................................... 25

7.1 Tracing Faults and Remedying Them .................................................................................. 25

7.2 Defective Dynamometer .................................................................................................... 26

8. Technical Data ............................................................................................................................. 27

8.1 3-Component Dynamometer Type 9255C ......................................................................... 27

8.2 Accessories ......................................................................................................................... 29

Content

9255C_002-615e-02.15 Page 3

9. Annex ........................................................................................................................................... 30

9.1 Glossary .............................................................................................................................. 30

9.2 Measurement Uncertainty .................................................................................................. 34

9.3 Linearity .............................................................................................................................. 35

9.4 Frequency Range ................................................................................................................ 37

9.5 Influence of Temperature .................................................................................................... 38

Total Pages 39

Quartz 3-Component Dynamometer Type 9255C

Page 4 9255C_002-615e-02.15

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 prod-

ucts 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

moment

 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 ei-

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

tensive support organization.

Important Information

9255C_002-615e-02.15 Page 5

2. Important Information

2.1 For Your Safety

 This instrument has been tested thoroughly and it left

the works in a perfectly safe condition. To maintain

this condition and assure safe operation, the user must

observe the directives and warnings contained in these

instructions

 The dynamometer must be installed, operated and

maintained only by persons who are familiar with it

and adequately qualified for their particular tasks

 When it must be assumed that safe operation is no

longer possible, the instrument must be taken out of

operation and secured against unintentional use.

It must be assumed that safe operation is no longer

possible if:

 the instrument is visibly damaged,

 it no longer functions,

 it has been in lengthy storage under adverse con-

ditions,

 it has received rough treatment during transport

Important!

For measuring cutting forces, fix the dynamometer on the

machine tool according to the instructions. See section

4.2: Assembling the Dynamometer, for details.

Important!

Fix all parts mounted on the top plate of the dynamome-

ter according to the forces expected!

Quartz 3-Component Dynamometer Type 9255C

Page 6 9255C_002-615e-02.15

2.2 How to Treat the Instrument

The dynamometer may be used only under the specified

environmental and operating conditions

 The insulation resistance is crucially important with pi-

ezoelectric measurements. It must be around 10

(but at least 10

Ω)

 To obtain this resistance, all plug and socket connec-

tions must be kept meticulously clean and dry

 The insulation resistance can be measured with the

insulation tester Type 5493

 Protect the signal output against dirt and do not touch

it with your fingers. When the connection is not being

used, cover it with the cap provided

 The connecting cable from dynamometer to charge

amplifier is highly insulating. Use only the proper

cable

 Do not remove the connecting cable from the dyna-

mometer

 When the dynamometer is not in use, protect it by

keeping it in the packing case supplied

 When performing long-time measurements, make sure

that the temperature of the dynamometer remains as

constant as possible

Important Information

9255C_002-615e-02.15 Page 7

2.3 Tips for Using the Instruction Manual

We recommend reading the entire Instruction Manual as a

matter of principle. If you're in a hurry, however, and

you've already gathered experience with Kistler dynamo-

meters, you can confine your reading to the information

that you really need (see section 4).

We have endeavoured to arrange these instructions so that

you can find the information you need without difficulty.

Please keep this Instruction Manual in a safe place where

they can be consulted any time.

If the instructions get lost, just turn to your Kistler customer

service station and they will be replaced without delay.

All information and directives in these instructions may be

modified at any time without prior notification.

2.4 What Happens After Modifications?

Modifications to instruments result in alterations of the

operating instructions as a rule. In such cases, enquire at

your Kistler customer service station about the possibilities

of updating your documentation.

2.5 Disposal Instructions for Electrical and Electronic Equipment

Do not discard old electronic instruments in municipal

trash. For disposal at end of life, please return this prod-

uct to an authorized local electronic waste disposal ser-

vice or contact the nearest Kistler Instrument sales office

for return instructions.

Quartz 3-Component Dynamometer Type 9255C

Page 8 9255C_002-615e-02.15

3. General Description of the Instrument

3.1 What Does a Multicomponent Dynamometer Do?

The multicomponent dynamometer provides dynamic and

quasi-static measurement of the 3 orthogonal components

of a force (F

, F

) acting from any direction onto the top

plate.

With the aid of optional evaluation devices the 3 moments

, M

and M

can be measured as well (see section

4.4.3).

The dynamometer has high rigidity and hence high natural

frequency. The high resolution enables very small dynamic

changes to be measured in large forces.

The dynamometer measures the active cutting force

regardless of its application point. The usable frequency

range depends mainly on the resonance frequency of the en-

tire measuring rig.

Fig. 1: Dynamometer Type 9255C

Most important applications for the multicomponent dy-

namometer are:

 Cutting force measurements while milling and grinding

on larger machines and in machining centers

 Measurements on stamping machines

 Measurements on wind tunnel models

 Measurements of supporting forces at machinery

foundations

General Description of the Instrument

9255C_002-615e-02.15 Page 9

3.2 Functional Principle

The force to be measured is introduced via a top plate and

distributed between four piezoelectric 3-component force

sensors arranged between the base and top plates.

Each of the sensors has three pairs of quartz plates, one

sensitive to pressure in the z direction and the other two to

shear in the x and y directions respectively. The measure

ment is virtually without displacement.

In these four force sensors the force introduced is broken

down into three components.

Fig. 2: Function principle

For the force measurement in 3 components the individual

signals are led together in the connecting cable.

For force and moment measuring with 6 components, all 8

individual signals are led via the connecting cable straight

to the charge amplifiers.

Depending on the direction of the force, positive or nega-

tive charges occur at the connections. Negative charges

give positive voltages at the output of the charge amplifier,

and vice versa.

Quartz 3-Component Dynamometer Type 9255C

Page 10 9255C_002-615e-02.15

3.3 Design of the Dynamometer

The dynamometer consists of four 3-component force sensors

sandwiched under high preload between a baseplate and a

top plate. This preload is needed to transmit the friction

forces.

Fig. 3: Design of the dynamometer

The four force sensors are mounted ground-insulated.

Ground loop problems are largely eliminated in conse-

quence.

The dynamometer is rustproof and protected against

ingress of splashwater and coolant. Together with the

connecting cable Type 1687B5/1689B5 or 1677A5/1679A5

the dynamometer meets the requirements of protection

class IP67.

1 Force senso

2 Base plate

3 Top plate

4 Connector

5 Cap

Assembly, Installation and Putting into Operation

9255C_002-615e-02.15 Page 11

4. Assembly, Installation and Putting into Operation

4.1 Important Remarks

The multicomponent dynamometer Type 9255C is a preci-

sion instrument, but its inherent accuracy can be exploited

and retained only if it is treated with care. The following

rules should therefore be noted:

 Never drop the dynamometer or expose it to heavy

impacts! The maximum force of a shock of this kind

could exceed the measuring range of the instrument

and cause permanent deformations

 Never use a hammer to position the workpieces, as

such blows might also cause deformation!

On the following pages you will find directions for installing

the dynamometer and basic data for designing the measuring

facility.

4.2 Assembling the Dynamometer

The following directions must be observed if the dyna-

mometer is to be mounted properly:

 The dynamometer must be installed only by persons

who are familiar with it and sufficiently qualified for

this work

 First the connecting cable has to be mounted. Both

connector sides (dynamometer and cable) have to be

cleaned with Kistler cleansing and insulating spray

Type 1003. To seal the connector the O-Ring is used

(scope of delivery). The mounting surface for the

O-Ring must be clean. The O-Ring is placed properly

and the flange of the cable is mounted onto the

dynamometer by means of two screws (M4x10) and

tightened

Tightening moment = 4,5 N·m

 Before mounting the dynamometer on a machine tool

or testing device, make sure that the mounting surface

is flat. Uneven supporting surfaces will cause internal

stresses, which may expose the individual force sensors

to severe additional shear stressing and cause increased

crosstalk

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

fine-machined. The instrument should therefore be

mounted on ground or equivalently machined supporting

surfaces

 Clean the contact surfaces thoroughly before mounting

Quartz 3-Component Dynamometer Type 9255C

Page 12 9255C_002-615e-02.15

 To align the Dynamometer on the machine table one

of the side wall of the flange can be used

 Make sure that the dynamometer rests absolutely flat.

Even the smallest air gap will cause undesirable elasticity

and reduce the resonant frequency of the measuring

rig. All mountings must therefore be considered from

the vibration aspect also

 Mounting: The dynamometer may be clamped directly

with four M16 bolts (property class 12.9)

Tightening moment for 4 x M16 bolts = 280 N·m

 To assure an optimal connection between the dyna-

mometer and the machine, an additional mounting of

the measuring instrument with four M12 screws is rec-

ommended. This is the only way to achieve a high res-

onant frequency and an optimal dynamic behavior

Procedure:

 Remove the four lids (position 5 in Fig. 3) on the dy-

namometer top plate

 Clamp dynamometer with four M12 (property class

12.9) bolts through the top plate

Tightening moment = 130 N·m

 When placing the lids back loosen the vent screw

placed in the center of the lids so that the captured air

can escape. Press lids into their proper position and fix

the vent screws again

 Whenever possible, the connecting cable should be left

connected permanently to the dynamometer

4.3 Positioning of the Dynamometer

 The dynamometer and the cable are to be positioned

in such a manner that cooling lubricants completely

can drain off. This avoids the formation of aggressive

bacteria in the aged cooling lubricant, damaging the

dynamometer as well as the cable. Accordingly, be-

ware of cavities and corrugations

 Lay the connecting cable so that it cannot get cut off

or torn out when working

Assembly, Installation and Putting into Operation

9255C_002-615e-02.15 Page 13

4.4 Basic Circuitry and Cabling of the Measuring System

The electrical charges (in pC) delivered from the measuring

platform are converted by charge amplifiers into propor-

tional voltages, which may be displayed, recorded or

further processed with usual instruments.

The following rules should be observed when cabling the

measuring rig:

 The connecting cable from dynamometer to charge

amplifier must have high insulation and low frictional

electricity. Use only the specified cables therefore

 Ordinary cables may be used to link the charge ampli-

fiers with the display or evaluation instruments

 Make sure that all work with electrical connections is

done carefully and cleanly. Remove the protective caps

from the connections only immediately before connecting

a cable

 Cabling instructions for specific configurations are giv-

en in the two sections following

Quartz 3-Component Dynamometer Type 9255C

Page 14 9255C_002-615e-02.15

4.4.1 Force Measuring with 3 Components (F

, F

)

The illustration below shows the elements needed to connect

the dynamometer with a multichannel charge amplifier

(e.g. Type 5070Ax01xxx). It is a ground-insulated measur-

ing chain with 3-wire cable.

The connecting cable Type 1687B5/1689B5 and the

extension cable Type 1688B5 are allocated as follows:

Fig. 4: Allocation connecting cable Fig. 5: Allocation extension

Type 1687B5/1689B5 cable Type 1688B5

Assembly, Installation and Putting into Operation

9255C_002-615e-02.15 Page 15

4.4.2 3-Component Force Measurement

The design of a dynamometer ensures that the forces ap-

plied exert no moments on the individual force sensor. The

force sensor can therefore be loaded up to the maximum

defined measuring range (moment-free). With regard to

the zero point of a dynamometer, however, a force vector

whose line of action does not go through this zero point

will produce a moment. Moments cause some of these

sensors to be subjected to an additional load in one or

more directions.

For a 3-component force measurement with a dynamome-

ter consisting of four 3-component sensors, the output sig-

nals (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.

A 3-

onent d

namometer 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, alter-

natively, an individual sensor can receive the main part of

the force. If the force is applied far outside the dynamome-

ter then, according to the law of the lever, an individual

sensor can experience a multiple of the force to be meas-

ured. For applications of this kind, the load on an individual

sensor must be accurately calculated.

The

ollowin

rule of thumb a

lies to the measurin

range of a dynamometer

If the force application point of the resulting force vec-

tor is within a pyramid consisting of the cover plate

surface and a height corresponding to the shorter side

of the cover plate, then the maximum measuring range

of an individual force sensor applies for the entire plate.

If there is a possibility of the acting loads damaging the

dynamometer, please contact your Kistler Customer Service

Center, where an analysis can be carried out for your load

case.

Quartz 3-Component Dynamometer Type 9255C

Page 16 9255C_002-615e-02.15

4.4.3 Force and Moment Measuring with 6 Components (F

, F

, M

)

The illustration below shows the elements needed to con-

nect the dynamometer with an multichannel charge ampli-

fier or with several single amplifiers (such as Type

5070Ax1xx). It is a ground-insulated measuring chain with

8-wire cable.

The connecting cable Type 1677A5/1679A5 and the

extension cable Type 1678A5 are allocated as follows:

Fig. 6: Allocation connecting cable Type 1677A5/

1679A5 and extension cable Type 1678A5

Assembly, Installation and Putting into Operation

9255C_002-615e-02.15 Page 17

The individual forces and torques can be calculated as

follows:

= F

x1+2

+ F

x3+4

= F

y1+4

+ F

y2+3

= F

+ F

= b ⋅ (F

+ F

– F

) · kM

= a ⋅ (–F

+ F

– F

) ⋅ kM

= b ⋅ (–F

x1+2

+ F

x3+4

) + a ⋅ (F

y1+4

– F

y2+3

) ⋅ kM

a and b are the dynamometer constants in the above for-

mulas, while kM represent the correction factors.

The values for Type 9255C are:

a = 80 mm

b = 80 mm

Deviations occur when measuring the torques because a

dynamometer is not infinitely stiff. These deviations are

corrected by the correction factors kM

, kM

and kM

They are normally not provided but must rather be deter-

mined through a special calibration. The design of this spe-

cial calibration must be as close as possible to the real

measurement design to prevent measurement inaccuracies.

If the correction factors are available, then they must be in-

cluded in the calculation. Depending on the characteristics,

the charge amplifiers Type 5070A and 5080A offer the op-

tion to set the correction factors directly. Factor 1 is already

set for the correction factors kM

, kM

and kM

by default.

Depending on the analysis of the measuring results, the

distance between the cover plate surface and the sensor

center is the deciding factor. This distance is called az0.

The value for Type 9255C is: az0 = 48.5 mm

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Brand: Kistler

Model: 9255C

Type: Owner's manual

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Kistler 9255C Owner's manual

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