4

Measurement and calibration

of Dynamometer
Aim: Measurement and calibration of dynamometer.

Apparatus: i) Dynamometer ii) charge amplifier iii) DAQ system iv) Data logger system

Theory:
Forces and torques are measured using a dynamometer. Dynamometers can be designed
to measure forces and/or torques in one, two or three directions. In machining
applications, it is typical to use a three-component force dynamometer, or in the case of
drilling, a four-component dynamometer is often used to measure the three forces and the
torque about the drill axis. There are two basic types of dynamometers — strain-gage
and piezoelectric. Strain gauge type dynamometers are inexpensive but less accurate and
consistent, whereas, the piezoelectric type are highly accurate, reliable and consistent but
very expensive for high material cost and stringent construction.

Piezoelectric Dynamometers

A piezoelectric dynamometer consists of stacks of piezoelectric crystals oriented in the

directions of the forces to be measured (and offset from a reference axis for torque
measurement about that axis). The piezoelectric stacks can be subjected only to axial
compressive deflection; therefore, to measure tensile loads, they are installed under
compressive preload so that the net loading never becomes tensile. When a load is
applied and causes deformation in a piezoelectric stack, an electrical charge is generated.
The generated charge is then converted to a voltage by a charge amplifier. The voltage
signals can then be scaled to force levels knowing the sensitivity of the dynamometer, in
 Coulombs per force unit, as determined via calibration using known forces. Since
piezoelectric crystals are very stiff, force measurement can be achieved while introducing
negligibly small deformations. As a result, piezoelectric dynamometers are very stiff
compared to strain-gage based dynamometers. Of course, piezoelectric dynameters are
also more expensive as are their associated electronics (charge amplifier).

The multicomponent dyanamometer provides dynamic and quasistatic measurements of

three orthogonal components of force ( ) acting from any direction on to the top
plate as well as the moments MZ.

The dynamometer has high rigidity and hence high natural frequency. 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. Both the average
value of force and dynamic force increase may be measured. The usable frequency range
depends on mainly on the resonance frequency of the entire measuring rig.

Fig: 4-component Piezoelectric Dynamometer

Most important applications for the multicomponent dynamometer are:

 Measuring feed force, side force and moment in drilling taping etc.
 Measuring cutting forces in milling and grinding and turning high sensitivity and
calibrated part ranges allow exact measurements even on small tools and when
grinding.
 Measurements on wind tunnel models.
 Ergonomic measurements
 Testing of torque wenches
 Testing of springs (Torsion)
  Measurements on small thrust bearings slip clutches etc.
 Measurements of starting torque of small motors and step mototrs
 Measurements in ergonomics

Functional Principle:
The force and the moment acting on the dynamometer are transmitted through the top
plate to a 4-component load washer.

This 4-component sensor contains 3 pairs of quart rings, where by one is sensitive to
compression and the other two are sensitive to shear either in X-direction and Y-direction
resp. An additional set of shear sensitive quartz plates is arranged on such a way to yield
an electric charge proportional to the moment acting about the axis of sensor. The
acting force is directly resolved into its three components. The charge yielded by the
quartz plates are collected with electrodes connected to the connector of the sensor.

Depending upon the direction of the force and moments, positive or negative charges
occur at the connections. Negative charges give positive voltages at the output of the
charge amplifier and vice versa.

Construction:
The dynamometer consists of a 4-component load washer sandwiched under high preload
between a baseplate and top plate. This preload is needed to transmit the friction forces.
1) 4-component sensor
2) Base plate
3) Top plate
4) Connecting plug
5) Preloaded screw

The sensor is mounted ground insulated. Ground loop problems are largely eliminated in
consequence.

The dynamometer is rustproof and protected against ingress of splash water and coolant.
Together with the connecting cable type 1677A5/1679A5 the dynamometer meets the
requirements of protection class IP67.

Measurement of cutting force(s) is based on three basic principles:

(a) Measurement of elastic deflection of a body subjected to the cutting force

(b) Measurement of elastic deformation, i.e. strain induced by the force

(c) Measurement of pressure developed in a medium by the force. The type of the transducer
depends upon how that deflection, strain or pressure is detected and quantified.

Measuring cutting forces by pressure caused by the force

Piezoelectric transducer for measuring force or pressure

This type of transducer functions in two ways:

• The force creates hydraulic pressure (through a diaphragm or piston) which is monitored
directly by pressure gauge
 • The force causes pressure on a piezoelectric crystal and produces an emf proportional to the
force or pressure as indicated in fig.

Here, emf = λ*t*P

Where

λ = voltage sensitivity of the crystal

t = thickness of the crystal

p = pressure

Observation Table:

Time Mz Fz Fx Fy
second Nm N N N
0 -0.0305176 -14.0381 1.52588 5.79834
1 -0.0488281 -13.4277 1.37329 4.57764
5 -0.0244141 -11.5967 1.52588 4.42505
10 -0.0244141 -3.66211 1.37329 3.8147
15 -0.0183105 -1.2207 1.98364 4.11987
20 -0.0305176 -8.54492 1.37329 4.42505
25 -0.0427246 -5.49316 1.52588 4.42505
30 -0.0366211 -7.32422 1.37329 3.96729

Result:
Conclusion:
We have performed experiment on dynamometer using standard weights and find out
forces in each direction also errors associated with it.