Kistler 9129AA Owner's manual

Brand: Kistler

Model: 9129AA

Type: Owner's manual

Instruction

Manual

Multicomponent

Dynamometer

–

10 … 10 kN

Mounting Plate

90x105 mm

Type 9129AA

9129AA_002-442e-03.15

Instruction

Manual

Multicomponent

Dynamometer

–10 … 10 kN

Mounting Plate

90x105 mm

Type 9129AA

9129AA_002-442e-03.15

Foreword

9129AA_002-442e-03.15 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 obliga-

tion to notify any person or organization of such changes

or improvements.

reserved. 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

Multicomponent Dynamometer, Type 9129AA

Page 2 9129AA_002-442e-03.15

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 is a Multicomponent Dynamometer Used For? ........................................................... 8

3.2 Principle of Operation .......................................................................................................... 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 Dynamometer Positioning .................................................................................................. 14

4.4 Basic Circuity and Cabling of the Measuring System .......................................................... 15

4.5 Measuring Chain ................................................................................................................ 15

4.6 Measuring System for 3-Component Measurement Fx, Fy, Fz .............................................. 16

4.7 3-Component Force Measurement .................................................................................... 17

4.8 Measuring System for 6-Component Measurement Fx, Fy, Fz, Mx, My, Mz .......................... 18

5. Operation ..................................................................................................................................... 20

5.1 Choosing Range ................................................................................................................. 20

5.2 Measuring Small Changes in Force ..................................................................................... 20

5.3 Useful Frequency Range ..................................................................................................... 22

5.4 Piezoelectric Force Measurement ....................................................................................... 24

5.5 Tips for Better Measurement Results .................................................................................. 27

5.6 Polarity of Measurement Signal .......................................................................................... 27

6. Maintenance ................................................................................................................................ 28

6.1 Recalibration of Sensor ....................................................................................................... 28

6.2 Maintenance Procedure ..................................................................................................... 29

7. Troubleshooting ........................................................................................................................... 30

7.1 Diagnosis and Rectification of Faults .................................................................................. 30

7.2 In the Case of a Faulty Dynamometer ................................................................................ 31

8. Technical Data ............................................................................................................................. 32

8.1 Dynamometer Type 9129AA.............................................................................................. 32

8.2 Dimensions of Dynamometer Type 9129AA ...................................................................... 33

8.3 Accessories ......................................................................................................................... 34

Introduction

9129AA_002-442e-03.15 Page 3

9. Annex ........................................................................................................................................... 36

9.1 Glossary .............................................................................................................................. 36

9.2 Measurement Uncertainty .................................................................................................. 40

9.3 Linearity .............................................................................................................................. 41

9.4 Frequency Range ................................................................................................................ 43

9.5 Influence of Temperature .................................................................................................... 44

10. Indexverzeichnis ........................................................................................................................... 46

Total pages: 46

Multicomponent Dynamometer, Type 9129AA

Page 4 9129AA_002-442e-03.15

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 Instruction

9129AA_002-442e-03.15 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 fol-

low the instructions and warnings in this manual.

 The dynamometer may only be mounted, operated and

maintained by persons familiar with it and suitably qual-

ified 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 dynamome-

ter 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 dynamom-

eter according to the forces expected!

Multicomponent Dynamometer, Type 9129AA

Page 6 9129AA_002-442e-03.15

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 re-

sistance 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 in-

cluded cover on whenever the connection is not being

used.

 The cable for connecting the sensor to a charge amplifi-

er 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 packag-

ing to protect it.

 When performing long-time measurements, make sure

that the temperature of the dynamometer remains as

constant as possible.

Important Instruction

9129AA_002-442e-03.15 Page 7

2.3 Tips for Using the Instruction Manual

We recommend you read through the entire manual thor-

oughly. However, if you cannot spare the time and are al-

ready familiar with Kistler dynamometers you can limit

yourself to the immediately required information.

We have tried to organize this manual clearly so the re-

quired 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.

Multicomponent Dynamometer, Type 9129AA

Page 8 9129AA_002-442e-03.15

3. General Description

3.1 What is a Multicomponent Dynamometer Used For?

The multicomponent force plate provides dynamic and

quasi-static measurement of the 3 orthogonal components

of a force (Fx, Fy, Fz) acting from any direction onto the top

plate.

With the aid of optional evaluation devices the 3 moments

Mx, My and Mz can be measured as well.

The force plate 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 us-

able frequency range depends mainly on the resonance

frequency of the entire measuring rig.

Fig. 1: Type 9129AA

Typical applications

 Measuring cutting forces involved in precision machin-

ing

 Multicomponent force measurement

 Measuring forces in confined spaces

 Measuring the three cutting forces Fc, Ff and Fp involved

in boring and external turning with turret lathes (see

data sheet 9129A_000-710e for Type 9129A...)

General Description

9129AA_002-442e-03.15 Page 9

3.2 Principle of Operation

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 respec-

tively. Measurement is virtually displacement-free.

The force introduced into the sensor is split into three

components.

Fig. 2: 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 individ-

ual signals are fed together in the connecting cable.

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

tive charges develop at the connections. Negative charges

result in positive voltages at the output of the change am-

plifier and vice versa.

Multicomponent Dynamometer, Type 9129AA

Page 10 9129AA_002-442e-03.15

3.3 Design of the Dynamometer

The dynamometer consists of four 3-component force sen-

sors 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 in-

gress of splash water and coolant. Together with the con-

necting cable (Type 1687B... or 1677A…) the dynamome-

ter meets the requirements of degree of protection IP67.

The special sensor arrangement and signal connection en-

sure that the dynamometer is insensitive to temperature in-

fluences to the greatest possible extent.

1 Base plates

2 Cover plate

3 Connector

Assembly, Installation and Putting Into Operation

9129AA_002-442e-03.15 Page 11

4. Assembly, Installation and Putting Into Operation

4.1 Important Remarks

The multicomponent dynamometer Type 9129AA is a pre-

cision instrument, but its inherent accuracy can be exploit-

ed 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 im-

pacts! 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 in-

stalling the dynamometer and basic information on the

layout of the measuring system.

Multicomponent Dynamometer, Type 9129AA

Page 12 9129AA_002-442e-03.15

4.2 Installing the Dynamometer

To install the force plate correctly please observe the fol-

lowing 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

 Before installing the dynamometer on a machine tool or

a test rig check the flatness of the installation surface.

Uneven contact surfaces cause internal distortions

which expose the individual force sensor to additional

strong axial load and can increase crosstalk.

Fig. 3: Mounting of cable with O-ring seal

Cable

Screw M4x10

Assembly, Installation and Putting Into Operation

9129AA_002-442e-03.15 Page 13

The bearing surfaces of the load sensing device (bases) are

finely machined. The device must therefore be installed on-

ly on surfaces which are ground or finished to comparable

standard. The specific alignment of the force sensors de-

mands extremely careful monitoring of the quality of the

mounting surfaces. Clean the bearing surfaces thoroughly

before assembling.

 Make sure that the force plate rests absolutely flat.

Even the smallest air gap will cause undesirable elastici-

ty and reduce the resonant frequency of the measuring

rig. All mountings must therefore be considered from

the vibration aspect also.

 Whenever possible, the connecting cable should be left

connected permanently to the dynamometer.

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 the table of the machining center.

Alignment surfaces on base plates

Alignment surfaces on cover plate

Multicomponent Dynamometer, Type 9129AA

Page 14 9129AA_002-442e-03.15

There are two different ways of mounting the dynamome-

ter.

a. With eight M6x35 screws

This method requires eight M6 threaded holes (mini-

mum thread reach: 12 mm) on the table. Each screw

must be tightened to a torque of 15 N·m, screw grade

12,9.

b. On a magnetic plate

A magnetic plate can be used to avoid any need to

adapt the lathe by drilling supplementary holes in its

table.

Caution!

This method can only be used if the process forces do not

exceed the magnetic forces. It is absolutely essential to

avoid the dynamometer slipping.

4.3 Dynamometer Positioning

 The dynamometer and the cables must be positioned so

that coolants can drain completely. This stops aggres-

sive 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

Hexagon socket screw

Tightening torque 15 N·m

Assembly, Installation and Putting Into Operation

9129AA_002-442e-03.15 Page 15

4.4 Basic Circuity and Cabling of the Measuring System

The electrical charge (pC) supplied by the dynamometer

are converted by charge amplifiers into proportional volt-

ages which can be displayed, recorded and processed with

the usual instruments.

Please note the following as regards connecting the

measuring system:

 The connecting cables from the dynamometer to the

charge amplifier must have a high level of insulation

and a low level of frictional electricity. Only the recom-

mended connecting cables should therefore be used.

 Ordinary cables can be used for the connection be-

tween the charge amplifiers and the display and evalua-

tion instruments.

 All electrical connections must be made cleanly and

with care. The connection cover caps should not be re-

moved until immediately before connecting the cable.

 Please follow the instructions for cabling specific con-

figurations in the two following sections.

4.5 Measuring Chain

1) See data sheet entitled Cables for Multicomponent Force Sensors, Dynamometers and Force Plates 1687B_000-545

2) See data sheet entitled Multichannel Charge Amplifiers for Multicomponent Force Measurement 5070A_000-485

Multicomponent Dynamometer, Type 9129AA

Page 16 9129AA_002-442e-03.15

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

The following diagram shows the elements required for

connecting the dynamometer to a multichannel charge am-

plifier (e.g. Type 5070Ax01xx) for 3-component measure-

ment. This measuring chain is ground-isolated and uses a 3-

core cable.

Type 9129AA Connecting cable Multichannel charge amplifier

Type 1687B5 Type 5070Ax01xx

Fig. 4: Measuring System for 3-Component Measurement

Fx, Fy, Fz

Fig. 5: Cable diagram connecting cable Type 1687B5

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

Pin No. Output signals

1 Ground

2 Fx

3 –

4 Fy

5 –

6 Fz

7 –

8 –

9 –

Out

Assembly, Installation and Putting Into Operation

9129AA_002-442e-03.15 Page 17

4.7 3-Component Force Measurement

The form of dynamometer construction ensures the acting

forces do not exert any moments on the individual force

link. The force link can therefore be loaded (without any

moments) up to the maximum defined measuring range.

However, a force whose line of action does not pass

through the zero of the dynamometer produces a moment

relative to this zero. These moments cause the sensors to

be subjected to an additional load in one or more direc-

tions.

For 3-component force measurement with a dynamometer

consisting of four 3-component force links, the output sig-

nals (Fx, Fy and Fz in each case) of these links are summed.

However, irrespective of the force application point, the

sum of the four force links always indicates the correct val-

ue.

A 3-component dynamometer measures the magnitude

and direction of the three components of the forces acting

on a dynamometer, but not their spatial location.

Depending on the position of the force application point,

the load is either distributed between all four force links or

an individual force link can take most of it. If the force acts

well outside the force plate, lever action can cause an indi-

vidual force link to be subjected to a multiple of the force

to be measured. For such applications the load on an indi-

vidual force link must be accurately calculated.

The measuring range of a force plate is given by the fol-

lowing rule of thumb:

If the point of application of the resultant force vector lies

within a pyramid formed by the surface of the cover plate

and having a height corresponding to the shorter side of

this plate, the maximum measuring range of an individual

force sensor applies.

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.

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Kistler 9129AA Owner's manual

Brand: Kistler

Model: 9129AA

Type: Owner's manual

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Kistler 9129AA Owner's manual

Kistler 9129AA Owner's manual

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