Kistler 9129AA Owner's manual

Instruction

Manual

3-Component

Measuring System

for Cutting Force

Measurement

During Turning

Type 9129A...

9129A_002-444e-04.18

Instruction

Manual

3-Component

Measuring System

for Cutting Force

Measurement

During Turning

Type 9129A...

9129A_002-444e-04.18

Foreword

9129A_002-444e-04.18 Page 1

Foreword

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.

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.

Except as 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

3-Component Measuring System, Type 9129A...

Page 2 9129A_002-444e-04.18

Content

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

2.Important instruction ..................................................................................................................... 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

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

3.1What does a 3-component measuring system 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Installing the Dynamometer ............................................................................................... 12

4.3Mounting the measuring system ........................................................................................ 13

4.3.1Mounting examples ............................................................................................... 15

4.4Mounting lathe chisel in tool holder Type 9129AE ............................................................. 21

4.5Mounting measuring system with machine adapter Type 9129AB… on disk of turret ........ 22

4.5.1Removing positioning bolt and indexing pins ........................................................ 22

4.5.2Covering adapter locating holes ............................................................................ 24

4.5.3Re-inserting positioning bolts and indexing pins .................................................... 24

4.6Basic circuity and cabling of the measuring system ............................................................. 25

4.7Measuring chain ................................................................................................................. 25

4.83-component force measurement ...................................................................................... 26

5.Operation ..................................................................................................................................... 27

5.1Choosing range .................................................................................................................. 27

5.2Measuring small changes in force ....................................................................................... 27

5.3Useful frequency range ...................................................................................................... 29

5.4Piezoelectric force measurement ........................................................................................ 31

5.5Tips for better measurement results ................................................................................... 34

5.6Polarity of measurement signal........................................................................................... 34

6.Maintenance ................................................................................................................................ 35

6.1Recalibration of sensor ....................................................................................................... 35

6.2Maintenance procedure ..................................................................................................... 36

7.Troubleshooting ........................................................................................................................... 37

7.1Diagnosis and rectification of faults .................................................................................... 37

7.2In the case of a faulty Dynamometer ................................................................................. 38

8.Technical data .............................................................................................................................. 39

8.1Type 9129A… .................................................................................................................... 39

8.2Maximum measuring ranges .............................................................................................. 40

8.3Measuring system components .......................................................................................... 41

8.4Dimensions ........................................................................................................................ 42

8.4.1Dimensions Type 9129AA ..................................................................................... 42

Introduction

9129A_002-444e-04.18 Page 3

8.4.2Dimensions Type 9129AB… ................................................................................... 43

8.4.3Dimensions Type 9129AC… .................................................................................. 44

8.4.4Dimensions Type 9129AD… .................................................................................. 45

8.4.5Dimensions Type 9129AE… ................................................................................... 46

8.4.6Dimensions Type 9129AF40 .................................................................................. 47

9.Accessories ................................................................................................................................... 48

10.Ordering key ................................................................................................................................. 50

11.Annex ........................................................................................................................................... 52

11.1Glossary .............................................................................................................................. 52

11.2Measurement uncertainty ................................................................................................... 56

11.3Linearity .............................................................................................................................. 57

11.4Frequency range ................................................................................................................. 59

11.5Influence of temperature .................................................................................................... 60

11.6Index .................................................................................................................................. 62

Total pages: 62

3-Component Measuring System, Type 9129A...

Page 4 9129A_002-444e-04.18

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

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

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

extensive support organization.

Important instruction

9129A_002-444e-04.18 Page 5

2. Important instruction

It is absolutely essential to follow the instructions below,

which are intended to ensure your safety when working

with the instrument and guarantee a long, trouble-free

service life.

2.1 For your safety

 This dynamometer has been thoroughly tested and left

the factory in perfectly safe condition. To maintain this

condition and ensure safe operation the user must

follow the instructions and warnings in this manual.

 The dynamometer may only be mounted, operated and

maintained by persons familiar with it and suitably

qualified for their particular work.

 If it has to be assumed that safe operation is no longer

possible, take the sensor out of service and safeguard it

against accidental reuse.

It must be assumed that safe operation is no longer

possible:

 if the dynamometer is visibly damaged,

 if the dynamometer no longer works,

 after prolonged storage under adverse conditions

and

 after being severely stressed in transit.

For cutting force measurements, mount the

dynamometer on the machine tool as specified. See

Section 4.2 'Installing the Dynamometer' for details.

Fix all parts mounted on the top plate of the

dynamometer according to the forces expected!

3-Component Measuring System, Type 9129A...

Page 6 9129A_002-444e-04.18

2.2 How to treat the instrument

 Only work with the dynamometer under the specified

environmental and operating conditions.

 The insulation resistance of piezoelectric sensors is of

critical importance; it must be approximately 1014 (or at

least 1013) Ω. To achieve this value all connections must

be kept scrupulously clean and dry. The insulation

resistance can be measured with tester Type 5493.

 Protect the connector of the sensor against dirt and

never touch the front of it with your fingers. Put the

included cover on whenever the connection is not being

used.

 The cable for connecting the sensor to a charge

amplifier is a high-insulation type. Only use connecting

cables specified by Kistler.

 Once connected to the sensor it should remain in place

if possible.

 When not in use keep the sensor in the original

packaging to protect it.

 When performing long-time measurements, make sure

that the temperature of the dynamometer remains as

constant as possible.

Important instruction

9129A_002-444e-04.18 Page 7

2.3 Tips for using the instruction manual

We recommend you read through the entire manual

thoroughly. However, if you cannot spare the time and are

already familiar with Kistler dynamometers you can limit

yourself to the immediately required information.

We have tried to organize this manual clearly so the

required information is easily accessible.

Please keep the manual in a safe place where it is readily

available at all times.

If you lose it please contact your Kistler distributor for

prompt replacement.

All of the information and instructions in this manual are

subject to change at any time without prior notification.

2.4 What happens after modifications?

Equipment modifications generally result in changes to the

instruction manual. Please contact your Kistler distributor

regarding the means of updating of your documentation in

this case.

3-Component Measuring System, Type 9129A...

Page 8 9129A_002-444e-04.18

3. General description

3.1 What does a 3-component measuring system do?

For cutting force measurements, mount the 3-component

measuring system on the machine tool as specified. See

Section 4.2 Installing the Dynamometer for details.

 Machine adapters for disk-type turrets with:

- VDI tool holding fixtures ø30 mm, ø40 mm, ø50 mm

 - Coromant Capto C5, C6, C8 clamping unit

- Direct tool holding fixtures 20x40 mm, 25x50 mm,

¾"x1½", 1"x2"

 Tool holders for external turning tools:

20x20 mm, 25x25 mm, ¾"x¾", 1"x1"

 Tool holders for internal turning tools:

ø25 mm, ø32 mm, ø40 mm

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 force regardless of

its application point. Both the average value of the force

and the dynamic force increase may be measured. The

usable frequency range depends mainly on the resonance

frequency of the entire measuring rig (top plate,

foundation).

High sensitivity and calibrated partial ranges allow accurate

measurements even on small tools.

General description

9129A_002-444e-04.18 Page 9

3.2 Functional principle

The force to be measured is introduced through a cover

plate and distributed over the sensor arranged between

cover and base plate.

Each force sensor contains three pairs of quartz plates, one

of which is sensitive to compression in the z-direction and

the other two to shear in the x- and y-directions

respectively. Measurement is virtually displacement-free.

The force introduced into the sensor is split into three

components.

Fig. 1: Arrangement of force sensors in multicomponent

dynamometer: pairs of quartz crystal washers for

the three measurement directions

In the force measurement with 3 components, the

individual signals are fed together in the connecting cable.

Depending on the direction of the force, positive or

negative charges develop at the connections. Negative

charges result in positive voltages at the output of the

change amplifier and vice versa.

3-Component Measuring System, Type 9129A...

Page 10 9129A_002-444e-04.18

3.3 Design of the Dynamometer

The dynamometer consists of four 3-component force

sensors which are mounted under high preload between

the cover plate and the two lateral base plates.

This preload is necessary for transmission of the friction

forces.

1 2 1 3

The four force sensors are mounted ground-insulated.

Ground loop problems are largely eliminated consequently.

The dynamometer is rustproof and protected against

ingress of splash water and coolant. Together with the

connecting cable (Type 1687B…) the dynamometer meets

the requirements of degree of protection IP67.

The special sensor arrangement and signal connection

ensure that the dynamometer is insensitive to temperature

influences to the greatest possible extent.

1 Base plates

2 Cover plate

3 Connector

Assembly, installation and putting into operation

9129A_002-444e-04.18 Page 11

4. Assembly, installation and putting into operation

4.1 Important remarks

The multicomponent dynamometer Type 9129AA, on

which the measuring system Type 9129A… is based, is a

precision 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 chapters you will find information for

installing the dynamometer and basic information on the

layout of the measuring system.

3-Component Measuring System, Type 9129A...

Page 12 9129A_002-444e-04.18

4.2 Installing the Dynamometer

To install the force plate correctly please observe the

following points:

 The dynamometer must be installed only by persons

familiar with the device and sufficiently qualified for this

work.

 Connect the connecting cable first to the dynamometer.

Both connecting sides (dynamometer and cable) must

be cleaned with cleaning and insulation spray Type

1003. The O-ring is fitted to seal the connection. The

contact surfaces for the O-ring must be clean. Insert the

O-ring and bolt the flange of the cable to the summing

box with the two bolts and tighten until it fits.

Tightening torque (MA): 4,5 N·m

Fig. 2: Mounting of cable with O-ring seal

Cable

Screw M4x10

Assembly, installation and putting into operation

9129A_002-444e-04.18 Page 13

4.3 Mounting the measuring system

Before mounting the system, thoroughly clean all of the

surfaces involved.

Dynamometer Type 9129AA

 The first step is to mount the dynamometer on the

appropriate machine adapter.

Mounting screw tightening torque: 15 N·m

 If possible, ensure that the cable from the system

mounted in the lathe is not led out in the ejected chips

flow direction. Route the connecting cable in the lathe

so it cannot be pulled out or severed during turning.

Machine adapter for disk-type turret with VDI tool

holding fixture Type 9129AB…

 The VDI adapter must be mounted on the turret in

accordance with the manufacturer's instructions.

Alternatively, a flexible coolant hose can be installed on

one side of the machine adapter.

Machine adapter for disk-type turret with Coromant

Capto C… clamping unit Type 9129AC…

 The Capto adapter must be mounted on the turret in

accordance with the manufacturer's instructions.

Alternatively, a flexible coolant hose can be installed on

one side of the machine adapter.

Machine adapter with clamping wedge for disk-type turret

with direct tool holding fixture Type 9129AD…

 The clamping wedge is tightened with a torque of

15 N·m.

 Ensure the machine adapter butts up against the disk of

the turret as closely as possible.

The bearing surfaces of the clamping wedge and the slot

in the turret must be free from grease!

Werkzeughalter für Drehmeissel Typ 9129AE

Clean with degreasing agent

3-Component Measuring System, Type 9129A...

Page 14 9129A_002-444e-04.18

Tool holder for lathe chisel Type 9129AE…

 The tool holder is mounted on the cover plate of the

dynamometer with ten M6 screws.

Mounting screw tightening torque: 15 N·m

 When the machine adapter Type 9129AD… is being

used, only the tool holder corresponding to the size of

the lathe chisel may be mounted. This ensures the

cutting edge of the tool is always at the height of the

rotational axis.

Clamping screw tightening torque:

Type 9129AE0,75 and 9129AE20 5 N·m

Type 9129AE1 and 9129AE25 10 N·m

Tool holder for boring bars Type 9129AF40

 For disk-type turrets with radial VDI tool holding fixture

the system is mounted with the machine adapter Type

9129AB… .

 Two included reducing bushes allow use of 32 mm and

25 mm boring bars.

 For disk-type turrets without radial VDI tool holding

fixture you have to fabricate an interface plate (about

20 mm thick). This is mounted radially on the disk of

the turret (see page 17, Figure 5). The plate is provided

with eight M6 threaded holes matching the pattern of

holes in the dynamometer. The dynamometer is then

screwed onto the interface plate mounted on the turret.

The dynamometer, the machine adapter and the tool

holder are designed to ensure the cutting edge of the

mounted tool is always at the height of the centre of the

workpiece.

Caution!

With the measuring system mounted, machining may

only be carried out in the operating position of the tool.

The disk of the turret must never be swiveled with the

system mounted, as this would damage the connecting

cable.

Fig. 3: Type 9129A mounted on turret

Assembly, installation and putting into operation

9129A_002-444e-04.18 Page 15

4.3.1 Mounting examples

Example 1

Axially mounted dynamometer for external turning with

machine adapter Type 9129AB... (VDI tool holding fixture)

and tool holder Type 9129AE...

Direction of rotation of workpiece:

Fig. 4: Type 9129AA, 9129AB…, 9129AE20

3-Component Measuring System, Type 9129A...

Page 16 9129A_002-444e-04.18

Example 2

Axially mounted dynamometer for external turning with

machine adapter Type 9129AD... (direct tool holding

fixture) and tool holder Type 9129AE...

Direction of rotation of workpiece:

Fig. 5: Type 9129AA, 9129AD…, 9129AE1

Assembly, installation and putting into operation

9129A_002-444e-04.18 Page 17

Example 3

Radiallly mounted dynamometer for boring with machine

adapter Type 9129AB... (VDI tool holding fixture) and tool

holder for boring bars Type 9129AF40...

Fig. 6: Type 9129AB…, 9129AA, 9129AF40

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Kistler 9129AA Owner's manual

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