Kistler 9139AA Owner's manual

Instruction

Manual

Multicomponent

Dynamometer

up to

30 000 N

Type

9139AA

9139AA_002

-735e-06.15

Instruction

Manual

Multicomponent

Dynamometer up to

30 000 N

Type 9139AA

9139AA_002-735e-06.15

Multicomponent

Dynamometer

up to 30 000 N

Type 9139AA

Foreword

9139AA_002-735e-06.15 Page 1

Foreword

Thank you for choosing a Kistler quality product

characterized 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.

expressly provided herein, no part of this manual may be

reproduced for any purpose without the express prior

written 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]om

www.kistler.com

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 2 9139AA_002-735e-06.15

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 Basic Connection and Cabling of the Measuring System .................................................... 16

4.6 Measuring System for 3-Component Measurement (F

x

, F

y

, F

z

) ........................................... 17

4.7 3-Component Force Measurement .................................................................................... 18

4.8 Measuring System for 6-Component Measurement (Fx, Fy, Fz, Mx, My, Mz) .................. 19

5. Operation ..................................................................................................................................... 21

5.1 Range Selection .................................................................................................................. 21

5.2 Measuring Small Changes in Force ..................................................................................... 21

5.3 Useful Frequency Range ..................................................................................................... 23

5.4 Piezoelectric Force Measurement ....................................................................................... 25

5.5 Tips for Better Measuring Results ....................................................................................... 28

5.6 Measurement Signal Polarity .............................................................................................. 28

6. Maintenance ................................................................................................................................ 29

6.1 Re-calibrating the Device ................................................................................................... 29

6.2 Maintenance Work ............................................................................................................ 30

7. Fault Elimination .......................................................................................................................... 31

7.1 Troubleshooting ................................................................................................................. 31

7.2 What to Do if the Dynamometer is Faulty .......................................................................... 32

8. Technical Data ............................................................................................................................. 33

8.1 Dynamometer Type 9139AA.............................................................................................. 33

8.2 Dimensions ........................................................................................................................ 34

8.2.1 Dynamometer Type 9139AA Dimensions .............................................................. 34

Introduction

9139AA_002-735e-06.15 Page 3

9. Accessories ................................................................................................................................... 35

9.1 Included Accessories ........................................................................................................... 35

9.2 Optional Accessories ........................................................................................................... 35

10. Ordering Code .............................................................................................................................. 38

11. Appendix ...................................................................................................................................... 39

11.1 Glossary .............................................................................................................................. 39

11.2 Measurement Uncertainty .................................................................................................. 43

11.3 Linearity .............................................................................................................................. 44

11.4 Frequency Range ................................................................................................................ 46

11.5 Influence of Temperature .................................................................................................... 47

Total pages 48

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 4 9139AA_002-735e-06.15

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

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

9139AA_002-735e-06.15 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!

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 6 9139AA_002-735e-06.15

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 TΩ

(but at least

10 TΩ)

 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

9139AA_002-735e-06.15 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 notice.

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.

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 8 9139AA_002-735e-06.15

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 part of the force signal can be measured. The

useful frequency range mainly depends on the natural

frequency of the entire measurement setup.

Fig.1: Dynamometer Type 9139AA

The most important areas of application for the

multicomponent dynamometer are:

 General 3-component force measurement

 Cutting force measurement for example in:

 milling

 surface grinding

 drilling

General Device Description

9139AA_002-735e-06.15 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. There is practically no deflection during

measurement.

In these four force sensors, the applied force is split into

three components.

Fig.2: Force sensor setup in the multicomponent

dynamometer: quartz crystal plate pairs for the 3

measuring directions

For force measurement with 3 components, the individual

signals are brought together in the connecting cable.

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.

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 10 9139AA_002-735e-06.15

3.3 Dynamometer Construction

The dynamometer consists of four 3-component force

sensors, mounted under high preload between two base

plates and one cover plate.

This preload is the requirement for friction force

transmission.

The four force sensors are installed ground-isolated. This

largely eliminates ground loop problems.

The dynamometer is rustproof and protected against the

ingress of splash water and cooling agent. Together with

the (Type 1687B5 or Type 1677A5) connecting cable, 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

3

1

2

1

Mounting, Installation and Initial Startup

9139AA_002-735e-06.15 Page 11

4. Mounting, Installation and Initial Startup

4.1 Important Information

The Type 9139AA 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.

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 12 9139AA_002-735e-06.15

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 (M

A

): 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

Fig.3: Cable mounting with O-ring seal

1 Dynamometer

2 O-ring seal

3 M4x10 screw

4 Cable (high insulation)

2

3

4

1

Mounting, Installation and Initial Startup

9139AA_002-735e-06.15 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 two long sides of the base plates or the long sides

of the cover plate are used to align the dynamometer

on a magnetic plate or a machine table

Fig. 4: Alignment surfaces on base plates

Fig. 5: Alignment surfaces on the cover plate

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 14 9139AA_002-735e-06.15

The dynamometer can be mounted in two different ways.

a. With 8 M10 screws

For this type of mounting, 8 M10 threaded bores are

required on the assembly table. The tightening torque

is always 70 N·m, the strength class 12.9.

Fig. 6: Mounting with screws

b. On a magnetic plate

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

subsequently provide the assembly table with

mounting bores.

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

9139AA_002-735e-06.15 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

Multicomponent Dynamometer up to 30 000 N, Type 9139AA

Page 16 9139AA_002-735e-06.15

4.5 Basic Connection and Cabling of the Measuring System

Charge amplifiers convert the electric charges yielded by

the dynamometer (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 poor

in frictional electricity. Only the specified connecting

cables must be used

 Conventional cables can be used for the connection

between the charge amplifiers 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

Mounting, Installation and Initial Startup

9139AA_002-735e-06.15 Page 17

4.6 Measuring System for 3-Component Measurement (Fx, Fy, Fz)

The diagram below shows the elements required to connect

a dynamometer to a multichannel charge amplifier (e.g.

Type 5080Axx3x001). This is a ground-isolated measuring

chain with a 3-wire cable.

Dynamometer Connecting cable Multichannel charge amplifier

Type 9139AA Type 1687B5 Type 5080Axx3x001

Degree of protection EN 60529

Fig.7: Measuring system for 3-component

measurement Fx, Fy, Fz

Input Output

Input Signals Pin No.

Ground 1

X1 + 2 2

X3 + 4 3

Y1 + 4 4

Y2 + 3 5

Z1 6

Z2 7

Z3 8

Z4 9

Fig.8: Cable diagram for connecting cable Type 1687B5

Pin No. Output Signals

1 Ground

2 F

x

3 –

4 F

y

5 –

6 F

z

7 –

8 –

9 –

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Kistler 9139AA Owner's manual

Kistler 9139AA Owner's manual

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