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Applications
Measuring andanalyzing pressure,force and acceleration
2 www.kistler.com
measure.
analyze.
innovate.
Kistler in Brief
Kistler Instrumente AG enjoys a world-wide reputation as a leading supplier ofmeasurement technology. Kistler sensors use the piezoelectric effect, piezoresistive or capacitive, to measurepressure, force and acceleration.
Our aim
The top priority at Kistler is to satisfythe needs and requirements of our customers. This includes developingleading-edge products and helping ourcustomers to obtain optimum resultsfrom their application.
Our philosophy
Our success is based on innovativetechnologies, precise knowledge of themarket and a comprehensive range ofservices.
measure. analyze. innovate.
measure.Our core strength is the use of sensorsto measure physical magnitudes.
analyze.The magnitudes measured have no intrinsic significance. It is only throughanalysis and evaluation of the measure-ments that a process can be under-stood. To this end, we supply our customers with all the necessary hard-ware and software.
innovate.The information obtained in this wayconstitutes the basis for innovative products and serves to open up newhorizons.
Successful research
Over the years, Kistler's heavy invest-ment in research and development hasgenerated a number of revolutionaryinnovations: • the world's first commercial quartz
sensor• the patented two-wire constant
current technology constituting thebasis for today's sensors with integrated microelectronic circuitry
• the first high-temperature pressuresensors (up to 350°C, polystablequartz slice)
• the first three-component force measuring sensors.
These innovations resulted in solutionsto numerous measuring problems forthe first time.
Comprehensive services
Kistler also supplies a comprehensiverange of services, including technicaladvice for all applications, calibrationand repair services, as well as regulartraining.
Kistler today
Established in Wintherthur (Switzer-land) in 1959, Kistler currently employs650 staff worldwide, around 15% ofwhom are engaged in research anddevelopment.
In addition to its headquarters in Swit-zerland, Kistler is represented in over50 countries and has group companiesin Austria, Denmark, Finland, France,Germany, Italy, Norway, the Nether-lands, Sweden, the United Kingdom,Japan, the USA, the Peoples’ Republicof China, India, Korea, Singapore andTaiwan.
Products Pressure 4
Force 5
Acceleration 6
Electronics and Software 7
Applications Engines 8Research and Development,Cylinder Pressure Monitoring
Vehicles 12Suspension, Safety,Tires, Road and Traffic
Manufacturing 16Research,Process Monitoring,Product testing
Plastics processing 20Injection Molding,Extrusion
Biomechanics 24Gait Analysis, Balance,Performance
Acceleration Applications 26Automotive/Transportation,Aerospace and Military,Condition Monitoring
Other Applications 28Chemicals/Pharmaceuticals, Explosives, Pneumatics and Hydraulics,Conveyances and Transport
Tailor-made 30System Solutions
Service to Order 34 3www.kistler.com
Contents
4
Pressure
In piezoelectric pressure sensors, thepressure acts on the surface of a dia-phragm which converts it into a pro-portional force. This force is transmit-ted to a crystal, giving rise to an electriccharge on the opposing surfaces.
In piezoresistive sensors, the pressure is converted into an electrical signal by the elastic bending of a diaphragmmade of monocrystalline silicon. A Wheatstone bridge consisting of semiconductor resistances diffused inthe diaphragm is thereby detuned inproportion to the pressure.
With both types of sensors, the outputsignal (the electric charge measured inpC or the voltage) is exactly propor-tional to the pressure applied. Piezo-electric sensors can be used to makeonly quasi-static and not static measure-ments. On the other hand, they areideal for the precise measurement offast processes, such as combustion
Kistler sensors measure
pressures accurately and
precisely over a wide range,
even under extreme
environmental conditions.
6041A
ThermoComp®,water-cooled pressuresensor with measuringrange 0 ... 250 bar.
pressure in an engine. Piezoresistivesensors, on the other hand, are perfectfor measuring static pressures.
Typical applications
• Dynamic measurement of cylinderpressure and fuel injection pressure inthe development of internal combus-tion engines
• Continuous monitoring of cylinderpressure in large diesel engines
• Measuring explosive pressures in thedevelopment of air bags
• Regulating cavity pressure in injectionmolding so as to maximize moldingquality and minimize scrap
www.kistler.com
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Force
Single and multi-componentforce sensors
With Kistler quartz sensors, forces can be measured both directly andindirectly. With direct measurement,the sensor is placed directly in the pathof the force, which results in high accuracy, irrespective of the point ofapplication of the force. Where thesensor cannot be placed directly in thepath of the force, indirect measure-ment is used, with a large part of theforce being passed through a shunt.Where the force acts in only one direc-tion, it can be measured with a single-component force sensor. Forces actingon various axes require the use of multi-component sensors.
Typical applications
• Quality assurance in manufacturingand assembly
• Monitoring of presses• Measuring cutting forces in
metal-cutting machining• Biomechanics• Product testing• Material testing• Dynamic weighing of moving vehicles• Wheel force measurement
Forces move masses –
Kistler sensors detect forces
with infinite resolution and
are extremely rugged.
When subjected to a mechanical load,quartz produces an electrical charge indirect proportion to the force acting on it. In other words, the quartz actsboth as a spring element and as atransducer. The force to be measuredgenerates the signal directly. The out-put signal of a piezo crystal is exactly linear and free from hysteresis, as wellas offering a wide measuring range. Asquartz is highly rigid, the measuringdeflection is very small, generally wit-hin a few micrometers. Thanks to theirhigh natural frequency, quartz sensorsare excellent for measuring ultra-fasthigh frequency processes in the micro-second range.
9333
Press Force Sensor with measuring rangeup to 120 kN.
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Acceleration
• It is necessary to determine thetorsional behavior of vehicle bodies,the stability of machine anchorings,the vibrational behavior of the suppor-ting structure of roller coasters.
For dynamic applications, Kistler hasbeen making use of piezoelectric sensors for many years. These sensorsare highly reliable and they can be usedto measure frequencies over a very wide range, from minimal amplitudesin the µg range to enormous shocksmeasuring thousands of g. To measurestatic or low frequency acceleration,micro machined silicon sensors are thetechnology of choice. Their measuringprinciple is based on a change in capacitance of the measuring elementin proportion to acceleration.
Typical applications
• Monitoring the vibration of rotationalmachines such as pumps and turbines
• Modal analysis in vehicle and aircraftdevelopment
• Measuring shock in car crash testing• Seismic measurements in tunnel
construction• Machine tool monitoring• General vibration measurement in the
laboratory
The same Kistler sensor can
be used to detect changes
in velocity from moderate to
lightning speeds.
Kistler sensors provide valuableinformation in countless applications.For example:
• The vibration signal generated byturbines or engines provides valuableinformation on the condition of various moving parts.
• The dynamic behavior of aircraftwings needs to be tested andchecked.
• The bogies of high-speed trains haveto be kept in position.
8795A…
K-Shear® triaxial ac-celerometer with ameasuring range of ± 50 g
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Electronics and Software
Typical applications
• Measuring instruments for researchlaboratories
• Automation components for OEM• Measuring instruments and control
devices for production
Measuring magnitudes is
the first task. Analyzing the
results is the next.
Kistler products help to give
us completely new insights.
5015A…
Universal charge meter with a measur-ing range from± 2 to 2 200 000 pC.
Even ultra-precise measurements donot in themselves constitute useful information. This is only achieved withthe analysis and evaluation of the data.Kistler's electronic instruments andsoftware products specifically designedfor the various applications provide youwith valuable support and new know-ledge.
While our instruments deliver highperformance, they are simple to operate.We offer you support, as necessary,with the installation and maintenanceof measuring systems throughout theirservice life.
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Accurate knowledge and
analysis of combustion
chamber pressures are
essential for the develop-
ment of modern internal
combustion engines.
For over 40 years, Kistler has been theinnovator and market leader in enginemeasuring technology. Our pioneeringachievements include the developmentof the world’s first M10 and M8 water-cooled sensors, as well as the miniaturepressure sensor with M5 thread. Ourprecision sensors provide indications andmeasurements of cylinder pressures, injection pressures as well as intake andexhaust pressures.
Thanks to the extreme miniaturizationof its piezoelectric sensors, Kistler is also able to offer new measuring sparkplugs and measuring glow plugs, whichallow pressures to be measured with-out need for additional cylinder headbores.
For signal conditioning, Kistler supplieshigh precision measuring amplifiers foruse in the laboratory and on the testbed. The latest generation amplifiers allow the construction of modular andcomputer-controlled systems.
Piezoelectric sensors are ideal for measuring combustion pressure, wherethe advantages of wide temperaturerange, small dimensions, high measu-ring dynamics and long service life areof high importance.
Piezoresistive sensors are used for measuring injection pressures as well asfor intake and exhaust measurements;they allow both static and dynamicmeasurements. These sensors measurepressure with a resistance bridge diffused in silicon.
Kistler In Practice:Engines
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Water-cooled sensor
6041A, 6061B
Standard sensor forprecision measure-ments, low thermalshock error, M8 andM10 mountingthread.
Miniature pressure
sensor 6052B1
Small, accurate, uncooled sensor forextremely confinedspaces. Front sealingwith M5 thread.
Measuring spark
plug 6117B…
No indicating borenecessary, virtuallyfront flush sensormounting. Availablefor all standard heatvalues and with M14thread.
Miniature pressure
sensor 6001
Small, accurate,uncooled pressuresensor for universalapplications, shoulder-sealing with 5.55 mmfront diameter.
Miniature pressure-
probe 6055BB…,
6057A…
Extremely small (4 mm diameter)uncooled pressuresensor. Mainly usedin glow plug adapters.
Combustion
ApplicationAs cylinder pressure measurement hasto cope with very rapid dynamic pro-cesses associated with high loads, thesensor must exhibit good thermalshock behavior and knock resistance,as well as excellent linearity.
The piezoelectric principle has proved aworldwide success in precision cylinderpressure measurement. Uncooled orwater-cooled sensors are mounted in a separate indicating bore in the engine.Measuring spark plugs or glow plugadapters are also used for pressuremeasurements on production engines.
Use/purpose• To improve efficiency• To reduce fuel consumption• To reduce exhaust emissions• To increase knock resistance• To improve performance• To improve cold starting behavior
Gas exchange
ApplicationLow-pressure indication for intake andexhaust measurements is an importantpart of engine measurement technology,the main tool for this purpose beingstatic and dynamic measuring piezo-resistive pressure sensors. Kistler offersa wide range of water-cooled and vibration-damped adapters. Switchingadapters which incorporate atmosphericpressure are also available for use withpiezoresistive sensors.
Use/purpose• To optimize volumetric efficiency• To optimize and analyze gas
exchanges• To obtain absolute cylinder pressure
measurements during the gasexchange cycle
• To optimize the intake manifold• To optimize valve control times
Rugged pressure
sensor 6125B…
Uncooled pressuresensor, ground-insulated, front flushmounting, shoulder-sealing, front 6.2 mmdiameter.
Research and Development
Kistler pressure sensors, along withcomputer-controlled simulation tools,play a key role in the developmentof modern, high-performance, low-emission combustion engines. For example, the development of new methods of combustion, such as directinjection in diesel engines, would havebeen impossible without the precise recording of the pressure curve in thecylinder. Meanwhile, low-pressure indication has become established asan essential tool in the optimization of the gas exchange elements (e.g.intake manifold, exhaust system andvalve control).
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Injection
ApplicationAs the injection process has a consider-able influence on the fuel mixture, injection pressures and timing must beoptimized in order to match the engine.Piezoresistive high-pressure sensorswith measuring ranges up to 5 000 barare used for this purpose. In addition,Kistler supplies easily mounted clampadapters for simple measurement takendirectly at the injection line.
Use/purpose• To improve efficiency• To improve particle emission in
diesel engines• To improve mixture formation• To improve combustion• To improve exhaust emissions• To optimize injection nozzles
Knock detection
ApplicationKnocking superimposes strong vibra-tions on the cylinder pressure curve;this can lead to engine damage withina short time. However, to obtain highperformance and low fuel consump-tion, the engine has to be operated asclose as possible to the knock limit. Tocalibrate knock control in the electronicengine management system, it is essen-tial to have reliable measurements ofthe onset of knocking, particularly athigh speeds. The sensor characteristicsrequired here are stability and high resonance frequency.
Use/purpose• To optimize the electronic engine
management system• To improve engine performance• To reduce exhaust emissions• To prevent engine damage• To match the electronic engine
management system to differenttypes of fuel
7013C…, 7613C…
Sensor with low thermal shock errorand very long servicelife. Suitable for usein industrial condi-tions (dirt, humidityetc).
Crank angle encoder
2613B…
System for measuringthe crank angle of thecrankshaft for crank-shaft-synchronouscylinder pressuremeasurements up to20 000 1/min.
Glow plug adapter
6535Q…
No indicator bore necessary, customer-specific design,M8/M10 thread.
High-pressure sensor
4067…
Standard piezoresistivesensor for measuringinjection pressures upto 5 000 bar,M10 thread.
6013CA, 6613CA
Rugged sensor withM10 thread for con-tinuous monitoringand control of gasengines. Integratedcharge amplifier withrange switching.
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Gas engines
ApplicationTo minimize emissions and maximizeefficiency in the operation of gas engines, the combustion curve must beoptimized for each individual cylinder.The best way of doing this is by regula-ting the cylinder pressure. To this end,Kistler has developed a continuousoperation sensor specifically designedfor the control of gas engines. Its excel-lent long-term stability and low short-term drift make it suitable for difficultmeasuring tasks.
Use/purpose• To detect/control knock• To detect faults• To limit peak pressure• To calculate the performance of
individual cylinders
Diesel engines
ApplicationKistler has developed the extra long-life 6613 for continuous cylinder pres-sure monitoring. This rugged sensor isparticularly suitable for large engines.
The 6613 is primarily suitable for ma-nufacturers of evaluation systems.
For startup and maintenance, Kistleroffers handy and easy to operate measuring instruments and software.
Use/purpose• To reduce fuel consumption• To optimize maintenance intervals• To detect damage at an early stage
Cylinder Pressure Monitoring
Cylinder pressure monitoring is the keyto the efficient operation of large dieselengines and gas engines. It allows faultsand wear to be detected and correctedat an early stage. Kistler offers the rightsensor for every application, from simple peak pressure measurement tothe more demanding online monitoring.
6302A, 6352A…
Small, rugged measu-ring probe for conti-nuous monitoring ofgas and diesel engi-nes. Available withcharge output or in-tegrated amplifier.
6229A, 6729A
For measurements ondiesel engine injectionsystems and for usein hydraulic test bedson large engines.Integral impedanceconverter.
2515A
Handheld peak-pressuremeasuring instrumentfor slow and medium-fast running diesel engines. Memory for 20recordings and PC soft-ware for evaluating thecylinder pressure curve.
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To improve vehicle safety,
it is essential to understand
the critical processes invol-
ved. By measuring pressure,
force and acceleration,
Kistler sensors create the
basis for improvements.
Nowadays in motor vehicle engineering,improvements are possible only withaccurate measurement of the criticalparameters. Kistler offers the automo-tive industry a broad spectrum of sensors for the measurement of force,strain, torque, pressure and acceleration.These are used in the development ofvehicles and tires, as well as in crashtesting and in restraint systems.
Kistler sensors supply the data neededfor constant improvements in safety,whether on the active side (tires, suspension, braking systems) or thepassive side (crash systems, drivingcomfort, road load monitoring).
Chassis/Suspension
The safety of a vehicle is highly depen-dent on the design of chassis and sus-pension. Unsprung masses, i.e. wheelsand wheel suspension, have a great influence on vehicle handling. Develop-ment engineers strive for a compromisewhich best combines good handling,high cornering speeds and passengercomfort.
In 1981, Kistler introduced the firstrotating wheel dynamometers into the market. Equipped with quartz sensors, for the first time they enabledmeasurements to be made on vehiclesat speeds up to 200 km/h. However, as these first dynamometers were muchheavier than a standard wheel, they affected the vehicle's handling charac-teristics. Today, Kistler's six-componentmeasuring wheels only add about threekilograms to the weight of the vehicle.Yet, thanks to ultra-lightweight cons-truction using high strength alloys, theyare sturdy enough to measure forcesand frequencies far exceeding the nor-mal operating range of a passenger car.Kistler's rotating wheel dynamometersalso help development engineers to im-prove ABS and traction control systems,when quartz and silicon sensors simul-taneously detect the pressure in thebraking and hydraulic systems and inthe control valves.
RoaDyn® P106
9294A
1-component measuring wheel for heavy pas-senger vehicles, light commercial vehicles andSUVs. For measuring drive and braking mo-ments. The signals are transmitted by wireless.
Kistler In Practice:Vehicles
Hub
Rim
Measuringwheel
Hub adapter
Rimadapter
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Dynamics
ApplicationThe Kistler measuring wheel illustratedbelow on Page 12 represents the cur-rent state of the art, with a single sen-sor making it possible to carry out dri-ve, braking and coasting tests as wellas statutory acceptance tests. The sen-sor is screwed to an aluminium produc-tion rim and can be fitted easily to anycar in the shortest possible time. Thedata measured are transmitted by wire-less to a receiver and control unit.
Use/purposeEven at the lowest torques, the Kistlersingle-component measuring wheelprovides the highest resolution withouthaving to compromise its rugged de-sign.
Strength
ApplicationNo matter how sophisticated the methods of calculation, the operationalstrength of car components and entirevehicles needs to be constantly testedon the test bed. The data recorded onthe test track can be introduced on thetest bed in a compressed form andused to load components until they fail.
Use/purposeKistler sensors and measuring wheelsenable accurate monitoring of all forcesintroduced. Thanks to their ruggedconstruction, piezoelectric sensors areparticularly suitable for use under theseextreme conditions.
Comfort
ApplicationThe bogies of high-speed trains arecomplex electromechanical systemswhich need to absorb the loads gene-rated by high-speed motion and, at thesame time, to ensure the safety andcomfort of passengers. Multi-axis accelerometers sensors are built intothese bogies to measure vibration andforces acting on the railcars in differentterrains and to draw the appropriateconclusions. Continuous monitoring of vibration also enables changes to bedetected and remedied immediatelywithout having to wait through normalservicing intervals.
Use/purposeTo maintain a constant high speedthrough curves and over difficult terrain, thus reducing journey timesand helping the railroad to competewith other forms of transport. To in-crease passenger safety and comfort by stabilizing the railcar. To minimizerolling stock breakdowns, downtimesand wear, thus making rail travel morereliable and extending the service lifeof the equipment.
RoaDyn® S625
9266A1
6-component strain gage measuring wheel forpassenger vehicles, light weight carbon fiberdesign.
RoaDyn® V6HT
9274A
6-component strain gage measuring wheel formedium and large trucks. For measuring all for-ces and moments acting on the wheel.
Accelerometers
Single axis and multi-axis sensors provide reliable measurements from 0 Hz to 20 kHz.
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Tires
Tires – the ”legs of the car” – have anenormous influence not only on safetybut also on efficiency and comfort. For the development of new tires andthe improvement of existing ones,manufacturers the world over rely onKistler's Fixed Wheel Dynamometers.The high rigidity of the quartz dynamo-meter allows accurate force and torquemeasurements to be taken over a rangeof several hundred hertz. The data obtained provides information on theinteraction between tyres and road.
There is a choice between two standardversions: one for car tires with forcestypically up to 30 kN and a version fortrucks with forces up to 70 kN.
ApplicationOver a hundred of Kistler's fixed wheeldynamometers have been sold. Theyare used by almost every manufacturerof tire test beds, as well as by univer-sities and research laboratories engagedin fundamental research testing.
Use/purposeTire data characteristics – such as rollresistance, slip angle, directional sta-bility, noise and damping – provide ma-nufacturers with information which isvital for the continued improvement oftheir products.
Crash barrier, Ford Motor Co.
Crash barrier with swiveling facility, equipped with 3-component sensors.
SmartCrash® barrier Audi AG
World innovation with integrated electronicsand digital preprocessing.
Vehicles
Safety
Passive safety defines the behavior ofa vehicle in the event of any impact,whether from the front, side or rear.
Vehicles are designed with the utmostcare using powerful CAD tools, but,when it comes to safety, nothing canbe left to chance. Only crash testingunder the most realistic conditions possible can provide the informationneeded.
For over 25 years, car manufacturerssuch as Audi, Ford, Volvo, Daimler-Chrysler and BMW have relied on Kist-ler force measuring plates. And withgood reason! The characteristics ofpiezoelectric measuring instruments areperfectly suited to the requirements ofcrash-test measurement. Their sensitivityis independent of the center of pressureand, despite the wide measuring range,the resolution is large enough to detecteven small changes in force. Customersalso appreciate the way that Kistler tailors every measuring device to theirown individual requirements. For example, to equip the Volvo safetycenter, Kistler has just developed cornersegments for offset crash tests whichare capable of measuring forces of upto 1.5 MN in two directions simul-taneously.
Crash
ApplicationKistler's modular measuring systempermits a flexible response to all customer requirements. Each segmentconsists of a baseplate with several for-ce measuring plates and a charge am-plifier module. The segments formingthe crash barrier come from the factoryfully wired so that the system can berapidly installed on the anchor plate.The charge amplifiers, which are con-trolled via a common bus, feed themeasurands as analog signals to be recorded on the computer.
Use/purposeThe rugged construction of Kistlercrash barriers guarantees reliable measurements even after thousands of tests.
Vehicle components
ApplicationKistler sensors can be used in dummiesand restraining devices (safety belts,airbags) as well as in helmet testing.
RoaDyn® P530
9295A…
This measuring hub measures forces and mo-ments acting on the tires.
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Road surfaces
ApplicationKistler Lineas force sensors can beincorporated into all standard road sur-faces. The elastic properties of Lineassensors and their response to abrasioncorrespond largely to those of the roadsurface itself. This is important becausethe quality of a WIM system equallydepends on how well the sensor charac-teristics conform to those of the road-wear characteristics.
Use/purpose• Road surfaces and substructures need
to be protected against overloadedand badly loaded vehicles
• Repairs are not only costly but alsoresult in traffic congestion
• The recording and eliminationof overloaded or wrongly loadedvehicles results in a long term improvement in traffic safety
Weight measurement
ApplicationIn tire research, dynamic measurementof wheel load distribution is an impor-tant means of assessing force and pressure distribution within the treadcontact. It is also important in roadbuilding research to investigate the factors involved in serious damage tothe road surface.
Modulas sensors are indispensable forroad surface management systems andfor research into related phenomenasuch as cracking and rutting.
Use/purpose• Collecting statistical data (number of
vehicles, classification, loading etc.)• Protection against overload (pre-
selection, overload monitoring, bridgeand building protection)
• Road tolls• Road surface research (cracking and
rutting) • Road surface management systems
Road and Traffic
Kistler measuring technology not onlycontributes to the active and passivesafety of vehicles but also helps to pro-tect roads against overloaded vehicles.Overall weight is not the sole factor.Damage to road surfaces and substruc-ture comes mainly from excessive wheeland axle loads, stress is increasing tothe fourth power of the wheel load.
The Kistler WIM (”Weigh in Motion”)system allows axle loads to be deter-mined as vehicles drive past. Thanksto WIM, overloaded vehicles can betaken off the road promptly, therebypreserving the road surface, avoidingexpensive maintenance work and trafficcongestion and increasing road safety.
Lineas®
9195C…
Only worldwide WIM sensor which can becontour shaped after installation.
Modulas
9197A5
32-channel quartz sensor.
Charge amplifiers
5153A…
9/18-channel chargeamplifier for Lineassensors.
Charge amplfiers
5151A…
32-channel chargeamplifier for Modulassensor.
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PLC
F
Kistler In Practice: Manufacturing
Recorded data permits
repeatability, thus allowing
the quality of manufactured
products to be increased and
documented.
Precision and accurate process moni-toring are of great importance inindustrial production. Sensors permitprocesses to be measured by recordingthe forces, torques, strains and vibra-tions in machinery and tools. When this data is analyzed and recorded, the manufacturing processes become repeatable, thus allowing product quality to be monitored, documentedand improved.
Kistler piezoelectric sensors offer varioustechnical advantages. As well as havinga wide measuring range which makesthem highly resistant to overload, theyare ideal for recording rapid processesand have a practically unlimited servicelife.
To obtain optimum results, the measuring system must be designed tofit the application. This includes thesensor, cable, charge amplifier and theappropriate indicating and evaluationinstruments. Kistler measuring techno-logy permits measurement, monitoringand control of a whole range of manu-facturing processes.
1-component Press
Force Sensor 9343
Ready to install forcesensor, three calibra-ted measuring rangesfor 100, 10 and 1 %.
Charge meter
5015A…
Flexible configuration.The measurands (force,pressure, etc.) are shown in the display.
Highly sensitive force
sensor 9205
Measurement of thesmallest tensile andcompression forces0 … ± 50 N.
1-component load
washer 9021A
Universally applicablefor maximum forcesfrom 7.5 to 1 200 kN.
Control Monitor
CoMo View® 5863A2
Web server for pro-duction monitoring ofmanufacturing pro-cesses.
Miniature force sen-
sor 9211A…
Extremely compactdesign, only 6 mmdiameter.
Analog signal [V/mm]
Displacement sensor
Control signals
Charge amplifier,Control monitor
Machinecontrol
Force sensor Lw
Electricalcharge [pC/N] Analog signal [V/N]
17www.kistler.com
Primary Forming
ApplicationThe correct proportion of force andpressure is crucially important in forminga shapeless substance into a solid body(e.g. pressing powder into tablets,pellets, sinter tools, or die-casting metals under pressure). Kistler's flexibleand reliable measuring technology serves to optimize the shape, densityand strength of the manufactured parts.
Use/purpose• To achieve minimum tolerances
Re-forming
ApplicationWhether coining, rolling, deep drawing,forging, punching or pressing of metalparts: Kistler force measurement sensorspermit prompt detection of errors, forexample defective parts or non-con-forming materials arising from varyingpress forces.
Use/purpose• Kistler measuring technology detects
errors in dimensions, material charac-teristics and the positioning of fed-inparts
• Machines and tools are protectedagainst overload by online monitoringof the process forces
1 or 3-component
force sensor 9602
Integrated electroniccircuitry, manualmeasuring rangeswitching 1:5.
HighSens strain sen-
sor 9232A…
Measurement of forces at machinesurfaces, highly sensitive.
Industrial charge am-
plifier ICAM, 5073A…
1, 2, 3 or 4 channels,rugged case rated atIP65.
Longitudinal measu-
ring pin 9243A…
Measurement of forces and strain instructures, mountingin M10 thread.
SlimLine force sensor
9133B…
Compact design, with integrated cablefor mounting in structures.
VarioComp force
sensor 9601A…
Number of measuringaxes, cable or connector variationsas requested by thecustomer.
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Assembly and Joining
ApplicationIn longitudinal presswork, clinching orbonding (i.e. in the permanent joiningof parts), the consistency of large scaleproduction is best monitored bymeasuring the force applied, using piezoelectric sensors positioned directlyin the force flux. Alternatively, the qua-lity can be monitored indirectly bystrain measurement.
Metal Cutting Machining
ApplicationThe aim of metal-cutting machining(i.e. turning, milling, grinding or boring)is to achieve processes which are as fully automatic and reliable as possible.One to three-component force measur-ing sensors are fitted in the base plateof a turret-type tool head. Theymeasure the machining force whichsupplies the necessary information oncutting, feed and passive forces. At thesame time, they protect machine toolsagainst overload or tool collisions andprevent unnecessary wear.
Use/purpose• Kistler measuring technology
optimizes the machining process,making it safer and more efficient
Typical areas of application:• Force measurement during the
crimping of cable ends ensures fault-free electrical connection.
• Automated systems carry out assembly operations with force andtorque monitoring, thereby guaran-teeing consistently high quality ofthe mass-produced products.
• Measurement of the electrode clamping force in spot welding optimizes the welded joint, e.g. in vehicle body construction.
• Screw tightening with torque-con-trolled assembly operations,thereby ensuring the fault-freemanufacture and documentation ofsafety components such as airbags or steering columns.
• Measurement of force-proportionalstrain on structures of wobble rivetingmachines ensures high strength joining of components.
Use/purpose• The joining process can be docu-
mented• ”Conforming” and ”non-conforming”
parts are detected objectively• Constant monitoring of the condition
of the machine
Control Monitor
5859A…
CoMo II-S for processmonitoring of a force-displacement curve during manufacture.
19www.kistler.com
Product Testing
Testing machinesApplicationHigh quality products require qualifiedtest methods. Kistler's wide productrange enables optimum measurementsolutions in the widest variety oftesting systems. Kistler equipmentmeasures tensile forces in materialtesting machines, records impact forcesand accelerations in crash test systems,or analyzes forces and vibration on vehicle test beds.
Use/purposeThese measurements are ultra-precise,the compact and enormously rigid construction of Kistler force sensorsallowing highly dynamic processes tobe recorded.
Switches and connectorsApplicationsQuantity production of connectors,springs or contact elements requires reliable error detection. End products of the highest quality can be producedby means of a test interval – in full or in the form of random sampling – torecord the force or torque function.
Use/purposeSafety components (e.g. the plugconnections of airbag systems) need tobe absolutely reliable. Equally, contactelements (relays) need to function reliably even after thousands of cycles.It is thanks to Kistler spring-force measuring technology that millions ofPC users can rely on their mouse tokeep clicking without fail.
3-component force
sensor 9067B
Compact design, forforce measurement inthe X, Y and Z axes.
3-component quartz
force link 9377B
Preloaded and calibrated, for measuring tensile andcompression forces.
Reaction torque sen-
sor 9349A
Torque measurementof ±1 ... ±1’000 N·m,2 calibrated measuringranges of 100, 10 %.
2-comp. dynamome-
ter 9125A…
Cutting force measu-rement on a rotatingtool, up to max. 25 000 1/min.
3-comp. dynamome-
ter 9257B…
Force measurementwith high resolution,high natural frequency,splash-proof IP67.
Multichannel charge
amplifier 5070A…
For 4 … 8 indepen-dent measuring chan-nels, remote control-lable via IEEE-488 orRS-232C.
20 www.kistler.com
Kistler In Practice:Plastics Processing
Injection Molding
In injection molding, the processes inthe mold determine the characteristicsof the finished product. There is noway of observing or precisely calculatingthese processes. Mold cavity pressure isthe only quantity to describe the entireprocess from the injection phase,through the compression and holdingpressure phase, to the residual coolingtime. Mold cavity pressure correlateswith all the characteristics of the moldedpart, such as dimensions, burs, sinkmarks, blowholes, shrinkage, distortion,weight and morphology.
Optimum molding characteristics areachieved when the mold cavity pressureexhibits a constant gradient during theinjection phase. At the moment of volumetric filling, a switch must be madefrom the speed-regulated injectionphase to the pressure-regulated holding-pressure phase. At this point in time,the pressure in the mold is marked by a characteristic kink in the curve. Thesubsequent compression phase is followed by the holding-pressure phasein which the volume contraction isequalized. At the time of ejection fromthe mold, the pressure must have fallento the ambient pressure. Kistler putsthese scientific findings to good use in developing systems for process opti-mization, monitoring and control.
Kistler products are used to
monitor and control proces-
ses on the basis of pressure
and temperature measure-
ment, thus permitting an
increase in both quality and
productivity.
To optimize, monitor and controlprocesses, pressure and temperaturecurves must be accurately measuredand evaluated. In this regard, the dyna-mics of the sensors and the recordinglocation are of critical importance. Kistler sensors are applied preciselywhere the products are manufactured,i.e. – in the mold, while miniaturizationallows them to be used in complex com-ponents.
High precision electronic circuitry isneeded to condition and evaluate thesensor signals, and for this reason manyOEMs use Kistler charge amplifiers. Inaddition to amplification of the signals,these amplifiers are increasingly employed to carry out more complexcontrol operations.
Kistler system technology optimizes,monitors and controls processes on the basis of pressure and temperaturemeasurements. This minimizes waste,improves quality, reduces cycle times,shortens set-up times and, in short,brings about a considerable increase in productivity. In cooperation with research organizations, Kistler is constantly engaged in developing newmethods to increase the efficiency ofplastics processing operations.
Pressure sensor
6157B…
Mold cavity pressuresensor with4 mm diameter,for extremely high mold temperature.
Pressure sensor
6159A…
Mold cavity pressuresensor with2.5 mm diameter,for extremely high mold temperature.
21www.kistler.com
Nozzle pressure measurement
ApplicationSensors in the nozzle or screw ante-chamber enable the melt pressure andmelt temperature to be recorded. Theinjection work can be calculated fromthe integral of the melt pressure overthe screw travel. This result provides information on the viscosity of the ma-terial. With hydraulic injection moldingmachines, the melt pressure is used asan optional control variable alongsidethe hydraulic pressure. This achievesreproducible process control. Inmachines with an electric drive, the meltpressure is the only suitable control variable.
Use/purpose• Monitoring of material fluctuations
(viscosity)• Optional control variable with
hydraulic machines to increase reproducibility
• Control variable in electrical machines
Tie-bar strain measurement
ApplicationHigh closing forces are especially im-portant in injection molding machinesused for manufacturing large moldedparts. Here, the loading on the tie barsneeds to be known in order to preventexpensive breakdowns. Kistler longitu-dinal measuring pins screwed into thecenter of the tie bar expand in propor-tion to the closing forces, thus servingto measure the strain. This measuringprinciple can be used to control closingforces in all machine sizes.
Use/purpose• Monitoring and control of the closing
force• Protection of the tie bar against
overload• Mold protection• Detection of structural faults in molds
(squareness, rigidity)
Mold cavity pressure
ApplicationDirect measurementDirect measurement in the cavity isthe preferred option for recording moldcavity pressure as it is highly accurateand has advantages in processes invol-ving large quantities. Since the plasticmelt is in direct contact with the sensor,there is no need for pins or transmissionmedia. Moreover, the front of mostsensors can be adapted to the surfaceof the cavity so that no impressions areleft on the molded part.
Use/purpose• Extremely precise measurement• Melt temperatures up to 450 °C• Free positioning in the cavity• Absolutely rigid mounting
ApplicationIndirect measurementWith indirect measurement, the pressurein the cavity is transmitted via an ejectorpin to a force sensor. The cavity pressu-re can be calculated by means ofthe diameter of the pin and the force measured. This option is used whenthere is no space available to install a di-rect-measuring sensor.
Use/purpose• Used for small spaces• Used only for process optimization• No need to dismantle when changing
mold inserts
Pressure sensor
6183AE…
Mold cavity pressuresensor with single-wiretechnology, particularlyfor multiple tools, frontdiameter of 1 mm.
Pressure temperature
sensor 6190A…
Combined mold cavity pressure andcontact temperaturesensor, 4 mm diameter.
Force sensor
9211A…
For indirect measure-ment of the moldcavity pressure via anejector pin, 6 mmdiameter.
Melt pressure sensor
4085A…
Combined nozzlepressure and temperature sensorwith 1/2” thread.
Measuring tongue
9221A…
For indirect measure-ment of the moldcavity pressure via an ejector pin.
Time
The change in volume on cooling of the melt is compensated by additional holding pressure.
Gate sealing
Atmospheric pressureStart of shrinkage (until
ambient temperatureis reached).
Cavity is volu-metrically filled
Melt reaches sensor positionInjection start
Mol
d ca
vity
pre
ssur
e
22 www.kistler.com
100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
0 2 4 6 8 10 12Time Min
Cycle No.: 7
Mean
Max
Cavity 1Cavity 2Cavity 3Cavity 4
x–t OnLine
0
PlasticsProcessing
Measuring amplifier
ApplicationAmplifiers convert the signals from sensors into voltages and currents, theircircuitry needing to meet the highestaccuracy requirements. Rugged chargeamplifiers now exist which are capablenot only of coping with signal conver-sion under severe production conditionsbut can also carry out control tasks. A further development of the industrialcharge amplifier comes equipped witha special fuzzy-logic chip, which detectsthe volumetric filling of the cavity andautomatically switches the moldingmachine from the injection pressure tothe holding pressure phase. This reducesthe setting-up time and leads to higherreproducibility of the process. Moldedpart characteristics are kept within anarrow tolerance band and scrap isconsiderably reduced.
Signal conditioners are used in applica-tion technology as well as research anddevelopment. They allow the recordingof up to 32 variables from the injectionmolding process and can be adapted toany measuring task.
Use/purpose: Charge amplifier• Ultra accurate• Built for industrial applications
SMARTAmp:• Shortens the set-up phase• Achieves high process consistency
Use/purpose: Signal conditioner• High flexibility for laboratory systems• Recording of the most diverse
quantities
Process monitoring and analysis
ApplicationThe continuous monitoring of mold cavity pressure allows all process fluc-tuations to be detected. Thus, changesin the characteristics of the molded part– due for example to fluctuations inviscosity or machine wear – can bedetected and corrected directly, so thatscrap is minimized. In addition to pro-cess monitoring, with many injection-specific functions, the DataFlow soft-ware facilitates documentation of theproduc-tion process, enabling manufac-turers to meet this important obligationto their customers.
Process analysis represents an importantstep in process optimization. Optimummolded part qualities are achieved onlywhen the cavity pressure curve matchesthe ideal curve. Kistler systems allowsimple analysis and thus appropriateand rapid optimization of the injectionmolding process.
Use/purpose• Automatically detects material and
process fluctuations• Automatically documents the produc-
tion process• Simplifies optimization
Process control
ApplicationProcess control systems automaticallydetect changes in the process and inthe quality of the molded part, as wellas automatically correcting the machineadjustment parameters. Thus, optimumquality is guaranteed at all times andwithout manual intervention. Over thelong term, these systems minimizecosts and maximize productivity. Kistlerapplies only state-of-the-art technologyto achieve these aims. The SMARTAmpcharge amplifier uses fuzzy logic toanalyze cavity pressure for fully auto-matic optimization of the switch pointfrom injection to holding pressure inthe production process.
Use/purpose• Fully automatic compensation of
process and material fluctuations• Minimization of scrap rates• Maximum productivity
Charge amplifier
5049A…
Industrial charge amplifier with fuzzylogic for volumetricswitching.
Signal conditioner
2859A…
Modular signal conditioning systemfor industrial use.
DataFlow
2805A…
System for processmonitoring, documentation andanalysis.
Charge amplifier
5039A…
Industrial chargeamplifier.
Signal conditioner
2853A…
Modular laboratorysystem for signal conditioning.
23www.kistler.com
Melt pressure measurement
ApplicationKistler's piezoresistive sensors are usedto measure the pressure and tempera-ture of the melt. They have a ruggeddiaphragm, which measures thepressure directly without a couplingagent and transfers it to the measuringelement. In consequence, these sensorsare particularly suitable for abrasivemedia, for foodstuffs and for the manu-facture of compounds for finished partswhich come into contact with food-stuffs. The separate or integral signalamplifiers, which come with analog ordigital compensation, are readily incor-porated into machine control systems.
Use/purpose• Rugged, long-life technology• Suitable for use in the food industry• For use in the manufacture of
compounds approved for contactwith foodstuffs
• Both digital and analog signals• Compatible with existing systems and
equipment• Innovative solutions at the forefront
of technology
Compounding
ApplicationIn contrast to compounding on a kneader, extrusion-mixed compoundsare manufactured continuously. Boththermoplastic and elastomer compoundsare manufactured on such systems,which are used in both injection moldingand the extrusion of end products.Pressure and temperature monitoringin the individual loading areas providespecific information on the homo-genization process and the loading ofthe compounds.
Extrusion
The dynamic pressure at the extruderhead is the significant quantity whichprovides information on the conditionof the melt. The melt pressure deter-mines the quality of the end productwith regard to its dimensions, its fillingand its warping in the cooling or vulca-nizing process. By integrating pressuremeasuring sensors in the machine control system, considerably higher efficiency is achieved by reducingstart-up waste and scrap.
Melt pressure sensor
4090B…, 4091B…
100 to 2 000 bar, with rugged diaphragm and various amplifiers toform a completemeasuring system.
Digital compensating
amplifier 4620A…
Digital compensationfor maximum accuracy. Analog and digital output for pressure andtemperature.
Melt pressure sensor
4096A…, 4097A…
200 to 2 000 bar withintegrated amplifier,rugged diaphragmand analog output,optionally withtemperature measurement.
24 www.kistler.com
High performance force plate
9281C…
Multicomponent force plate with a wide range of applications and excellent measuring dynamics, 400 x 600 mm.
Kistler In Practice: Biomechanics
Kistler force plates are used
to supply precise information
on the magnitude and
behavior of the forces acting
on the body, whether to
improve physical performance
or for medical diagnosis.
Biomechanics is a relatively new science;it describes the processes involved inthe movements of living beings. Suchmovements depend on the applicationof forces and, as these are often invisibleto the naked eye, orthopedists, athletesand their trainers, shoe manufacturers,ergonomists, neurologists and manyother specialists, all rely on data suppliedby Kistler force plates. The equipmentprovides them with precise informationon the magnitude and behavior of theforces acting on the body, whether toimprove performance or for medicaldiagnosis.
Human beings may have started towalk upright over a million years agobut it is only since 1969 that it has been possible to measure and analyzegait accurately and reliably. In thatyear, Kistler brought out the first forceplates to become available on the market. This pioneering achievement
in measuring technology now forms part of the standard equipment ofspecialists in biomechanics all over theworld.
Kistler force plates enable forces actingbetween foot and ground to be recor-ded accurately and in real time duringwalking, standing, running, jumpingand sliding. The Bioware® softwaredeveloped by Kistler processes thesignals and supplies information on theresulting force and its direction, thecenter of pressure, the frictional forcesand the torques, as well as performanceand energy.
Kistler force plates are used in threemain areas:• Gait analysis in orthopedics, prosthetics
and rehabilitation• Measurement and analysis of perfor-
mance and stresses in sport, in ergonomics and in the developmentof shoes and floor coverings
• Measurement and analysis of balance(posturography) in neurology,psychology and pharmacology, as well as orthopedics
eccen
tric
concen
tric
flight p
hase
Landing
Force
Speed
Height of jump
Performance
3
2
1
403020100
0210
0,30,20,1
25www.kistler.com
Gait Analysis
ApplicationAccurate, quantifiable information iswhat is needed for the reliable diagnosisof human gait and that is exactly whatKistler force plates provide. They detectthe slightest variations and asymmetriesin force behavior and so are able toprovide the specialist with valuable additional information.
Use/purpose• Accurate, quantifiable information
for research, diagnosis and therapy• Easy to install and use
Balance
ApplicationWe control our balance with tiny,completely unconscious movements,minimal changes in forces or shifts inthe center of pressure determining safety and stability. It is only patientswith impaired balance who come torealize what a complex task it is tostand upright and walk. Thanks to theirhighly sensitive piezoelectric sensors,Kistler force plates are particularly suitable for measurements in this domain.
Use/purpose• Detecting and quantifying various
pathologies in neurology and orthopaedics
• Examining the effectiveness of medication
Performance
ApplicationThe level of performance in top classsport is enormous. Winning requiresnot just talent and a bit of luck but,above all, optimum preparationthrough intensive training. Force, stamina, coordination – the limits arebeing extended all the time. The difference between winning and losingis constantly diminishing and so, too,is the difference between health andinjury.
Whether in training or in competition,athletes can use Kistler force plates toreach their physical limits in a controlledmanner. The equipment permits targeted, monitored training and showthe athletes how they are progressing.
The Kistler Quattro Jump force plateis used routinely in performance diagnosis. It quantifies explosive forceand stamina by means of standardizedjumps irrespective of the type of sport.
Use/purpose• To optimize training programs in
preparation for competition• To adjust the intensity of training
after an injury• Benchmarking• To make selections and compare
performances within the team
High performance force plate
9287B…
Multicomponent force plate; its large dimensions make it particularly suitable forsports research, 600 x 900 mm.
Slimline force plate
9286B…
Flat, mobile 3-component force plate, particularly suitable for gait and balance analysis. Modular system allowing very simpleassembly, 400 x 600 mm.
Quattro Jump force plate system
9290A…
One-component force plate with software forsports performance diagnosis, 900 x 900 mm.
www.kistler.com26
Kistler In Practice: Acceleration
Accelerometers are used in
every avenue of the dynamic
test environment and Kistler
has developed families of
products covering this
expansive range of applica-
tions.
From ultra low movement encounteredin wafer fabrication technology toshock spectra reconstruction experien-ced in pyrotechnic separation eventstudies, and everywhere between, anoptimal sensor solution is available. Sta-tic events are captured with the K-Be-am static and low frequency productofferings. Very high frequency activityis routinely measured using any ofseveral miniature piezoelectric singleaxis or triaxial types. Many sensingtechnologies including piezoceramic,natural quartz and variable capacitanceapproaches have been extensively ex-plored and are employed as needed toaccommodate the demands of the ap-plications.
27www.kistler.com
Condition Monitoring
ApplicationKistler accelerometers are used in a wide variety of condition monitoringapplications, such as damage detectionand predictive maintenance. It is impor-tant to detect equipment malfunctionbefore expensive catastrophic failure orsafety issues occur. Other conditionmonitoring applications include tilt/angle sensing, bearing/rotating machi-nery diagnostics, shipping recorders forpackaging industry, elevator and activecontrol, robotics, sports/medical, civilengineering structures including bridge/dam/buildings and roads. Accelero-meters used in this category include K-Shear piezoelectric and K-Beam capacitive accelerometers.
Use/purpose• robust and hermetically-sealed to
guarantee reliable measurement• high sensitivity to ensure reliable
signals• ground-isolated to prevent ground
loops
Aerospace and Military
Application Very demanding applications are encountered in the military and aero-space industry where any error maypresent a life-threatening situation.This category also covers a tremendousrange of applications and nearly all accelerometer product offerings havebeen used in these important investiga-tions. Flutter testing, rocket launch paddynamics, aircraft EMA, ammunitioninvestigations, helicopter rotor reactions,etc. are a few of the common measure-ments performed.
Use/purpose • high sensitivity to ensure reliable
signals• ruggedly built to guarantee long
service life• hermetically sealed to withstand
the toughest environments
Automotive/Transportation
Application Ride quality has been receiving tremen-dous attention in recent years. Newvehicle designs are presenting less noiseto the occupants and the subtle detailsof the intricacies of road/tire interac-tion, bump & jar response, and theoverall feel of the ride are importantto every customer. The K-Beam familycovers the low to mid frequency rangeof many investigations and the manypiezoelectric offerings extend into thehigher frequency areas of interest.
Use/purpose • light in mass to generate minimum
extra load• high sensitivity to ensure reliable
signals• ruggedly built to guarantee long
service life
K-Beam® 8310A…
Capacitive sensor forlow frequencies.
Piezotron® acoustic
emission sensor
8152B…
Rugged sensor foracoustic emissions up to 900 kHz.
K-Beam® 8393A…
Triaxial sensor for lowfrequencies.
K-Shear® 8794A…
Universal triaxial sensor for up to 500 g.
Impulse force
hammer 9722A…
To analyze the dynamic behavior ofmechanical structures.
K-Shear® 8702B…
Universal accelerationsensor for up to 500 g.
www.kistler.com28
Chemicals/Pharmaceuticals
ApplicationTypical areas of application for Kistlerpressure transmitters in the chemicaland pharmaceutical industries include:autoclaves, off-shore installations, high-pressure/high-temperature applications,plastics production plant (see also pp.20–23), as well as in processing plantfor paints, varnishes and adhesives.
Use/purpose• Explosion-proof sensors• Rugged construction• Field bus connection
Food
ApplicationKistler's piezoresistive pressure-measur-ing sensors are used in dispensing andfilling systems, in flushing and cleaningsystems, in homogenizers and sterilizers,in food extrusion and in countless othersectors of the food industry.
Use/purpose• High repeatability• High density• Food and Drug Administration
approval
Kistler In Practice: Other Applications
Kistler sensors are used to
monitor a whole range of
equipment and instruments.
They are distinguished by
high resolution and overload
resistance and OEMs can
rely on them completely.
In addition to many applications in piezoelectric technology, Kistler has developed piezoresistive and capacitivepressure sensors for a whole range ofuses. Kistler pressure measuringtechnology is universally successful inmany areas: in mechanical engineering,in instrumentation, in the chemicalindustry, in research, in transport, in theenergy sector, in medicine and in thefood industry. Other typical areas ofapplication include heating/air condi-tioning/ventilation, the textile industry,packaging, printing, oil and gas suppliesand construction.
29www.kistler.com
Expolsives
ApplicationKistler's front-sealing high-pressuresensors are regarded as state-of-the-artworldwide. They are used, for example,in the development of airbag ignitioncaps or in weapons technology fortesting and development purposes.Type 6215, for example, is the NATOstandard for acceptance testing of ammunition.
Use/purpose• High repeatability of measurands
thanks to very low mounting sensitivity
• Very good linearity over the entiremeasuring range
• Long service life as a result of frontsealing and optimized diaphragmdesign
• Insensitivity to contamination
Pneumatics and Hydraulics
ApplicationKistler sensors and transmitters coverpressures from 0.2 to 3 000 bar and atemperature range from –40 to 300 °C.The sensors in the accuracy classes0.05 to 2% FS and are highly compa-tible with most standard media.Piezoresistive silicon and ceramic sen-sors are used for the rather lower pres-sures in pneumatics. Typical applicationsinclude train braking systems, controlsystems, closure systems, safety bar-riers, compressors, transmission controlsystems, etc.
The sensors used in hydraulics have tomeet stringent requirements – long service life, frequent load changes andimpacts reaching into the overloadrange. Kistler's piezoresistive siliconsensors are able to meet these require-ments, thanks to a fully welded cons-truction and an integrated deflector.Typical applications include hydraulicunits, mechanical engineering, injectionmolding machines, hydraulic elevators,etc.
Use/purpose • Large selection• Optimum cost-efficiency• Extremely long service life
Conveyances and Transport
ApplicationKistler sensors are used to increase the safety and comfort of railroads andcableways, measuring for examplebraking pressure and braking force.Other applications include vibrationmeasurement, derailment detection,acceleration measurement in tiltingtrains, clamping force monitoring onendless ropeways, etc.
Use/purpose • Special force-measuring sensors for
periodical testing of block brakes anddisk brakes
• Derailment prevention through detection of the excessive vibrationgenerated when wheels leave the rail
• Clamping-force measurement forcoupled chair and cable car lifts (a legal requirement in many countries)
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High-pressure sensor
4065A…
Sensor for static and dynamicmeasurementup to 1000 bar.
High-pressure sensor
6229A…
Rugged, dynamicsensor for measure-ments in injection systems.
Pressure sensor
Ceramet
Suitable for OEMapplications.
OEM pressure sensor
RES15A…
The small diameterand high temperatureapplication of thissensor make it idealfor ”down hole” applications.
Measuring brake
shoe
Comes with two special force-measuringelements for testingrolling stock brakingsystems.
Pressure transmitter
RAG 25…
Rugged hydraulictransmitter.
30 www.kistler.com
Kistler In Practice:Tailor-made System Solutions
Kistler designs specific
system solutions tailor-made
to customer requirements.
Where standard components
do not provide the best
solution to a problem, Kistler
also develops customized
products.
Sensors are the key components formodern equipment and systems. How-ever, measuring technology covers farmore than ”just” sensors. Producing ameasuring system for individual tasksalso requires customized signal process-ing and evaluation, plus the relevantinterfaces.
The ‘mechatronic’ approach – i.e. aninterdisciplinary approach drawing together mechanical engineering, electronics and information technology– helps to see ideas and problems fromdifferent aspects, and thus to developnew measuring solutions. This is howKistler goes about producing customizedmeasuring systems.
In this regard, we distinguish between• Systems assembled from standard
components and• Solutions which we tailor to customer
requirements.
Systems comprising standardcomponents
The selection of the right sensors and,in particular, their installation are just asimportant as their accuracy and quality.We advise our customers on the evalua-tion, design and commissioning of thedesired measuring system, relying onour wide and comprehensive range ofsensors, along with our modular elec-tronic systems for signal conditioningand software for measurement analysis.
Accurate analysis of the process variables is crucial for integrated qualitymonitoring during the production process. Extensive measurements arefrequently taken in advance, thus making it possible to determine quality-relevant quantities and to define theirevaluation. We provide test engineersand hire equipment to our customersto conduct such preliminary testing.
Force measurement during skiing
Two identical dynamometers, installed betweenbinding and ski, measure the forces and mo-ments which are transferred by the skier to theski.
Force measurement in a wind tunnel
Six-component balance for wing models constructed using standard three-componentforce sensors.
31www.kistler.com
Instrument for detecting cavitation invacuum pumpsCavitation is an abnormal flow processin liquid pumps caused by sudden con-densation of vapor during compression.This process generates noise and soo-ner or later will result in destruction ofthe pump.
Kistler's Type 4672 cavitation detector,which was developed in close coopera-tion with a well-known manufacturerof vacuum systems for the chemicalindustry, is used to detect cavitation inliquid ring vacuum pumps. Detection isachieved by the evaluation of a dyna-mic component superimposed on thepressure signal using a special vectoralgorithm. The piezoresistive trans-mitter (Type 4285AE1VO166), usedto measure the pressure, is mounteddirectly in the pump suction nozzle.Since cavitation varies from one pumpto the next, the instrument was deve-loped in such a way that the pump-specific cavitation point can simply beprogrammed in.
Standard components individually tailored to customer requirementsMany components from our wide rangecan be tailored exactly to customer requirements by simple adjustments or adaptations. Hence, we are able to respond quickly and easily to any individual measuring requirements byusing standard components.
Crash force measurement
In this aircraft landing gear system, the reactionforces from the landing gear are measured witha special three-component force plate.
Machining process monitoring
Multi-component load washers measure themachining forces at the tool spindle, thus permitting safe and reliable process monitoring.
Cavitation detector
4672
Pressure transmitter and evaluation unit withvisual display of the cavitation condition.
32 www.kistler.com
Tailor-made System Solutions
Development of tailor-madesystems
Kistler has experienced engineers onhand for the definition, developmentand production of customized solutions.They develop tailored systems for applications in research, developmentor production where an optimum solu-tion cannot be obtained with the use of standard components. If produced in sufficient quantity, these application-specific measuring systems can offer an advantageous cost/benefit ratio.Areas of application cover conventionalmechanical and system engineering, aswell as materials processing, automationand the automotive industry.
Crash barrier with
corner sensors
Kistler also offers op-timum solutions forchallenging applicati-ons.
33www.kistler.com
Measuring system foravalanche research in Davos
Scientists at the Federal Institute forSnow and Avalanche Research in Davos (Switzerland) wanted to recordthe course of avalanches as they racedownhill and to measure the forcesexerted when they impact with ob-stacles. For this purpose, a test zonemeasuring more than 2.5 km was established in the Valléee de la Sionnein collaboration with Mettler & Fuchs.
Various structures were erected in themiddle of the avalanche path, includingvarious masts, a steel wall and a galleryroof. These structures were equippedwith Kistler sensors for measuring forces and velocities. The object is touse the data from field tests to checkthe validity of the theoretical guidelinesand to calibrate and improve the com-puter programs used to calculate drysnow and dense flow avalanches.Scientists from France, Spain and Austriaare already using this spectacular systemfor their own experiments.
Study into muscular atrophy
Patients who are bedridden for a lengthyperiod suffer considerable muscularatrophy. This problem is even morepronounced in astronauts who spenda long time in weightless conditions.The Zurich Polytechnic laboratory forbiomechanics directed by ProfessorStüssi has investigated these conditionsin a large project. The Torque VelocityDynamometer (TVD) was developed ina very short time in collaboration withthe European Space Agency (ESA),Kistler and other partners. This com-pact high-performance instrument fortraining and measuring enabled astro-nauts to carry out a selective analysis of the atrophy of various muscles inweightless conditions. Once again,Kistler sensors displayed their enormousloading capacity in the most confinedspace. The results of the study shouldhelp, on the one hand, to reduce muscular atrophy in bedridden patientsand, on the other hand, to allow longermanned space flights.
Measuring vibration forces
The main drive system of satellitelaunch vehicles produces heavy vibrationduring the launch phase. To ensurethat the satellite remains undamagedwhile being transported into space,pre-flight simulations are carried out onthe satellite or its individual components.Vibration tests are of particular impor-tance. The components are tested fortheir suitability on a vibrating table. If a component vibrates at its natural frequency, there is a danger that it willbe destroyed. The standard proceduretoday is to monitor and check vibrationforces with accelerometer in combina-tion with a 3-component force-measur-ing device, in order to measure thereaction forces on the componentsimultaneously. To this end, a large number of 3-com-ponent force-sensors are mounted onthe test object or special dynamometersare employed as well. If the componentvibrates at its natural frequency duringthe vibration test, vibration forces in-crease rapidly. These forces are limitedby damping (notching) individual frequency ranges of the stimulation.This procedure is generally referred toas ”force limited vibration testing”.
Wheel bearing forces
Special version for measuring forces at wheelbearings of street cars, locomotives and trams.
TVD (Torque Velocity Dynamometer)
TVD with foot HIF (human interface) for measuring muscular atrophy.
Measurement of vibration forces
Space satellites and their components are subjected to vibration testing. Vibration forcesare measured with a special multi-componentdynamometer. The force measurementmonitors the vibration process.
34 www.kistler.com
Kistler – Service to Order
Customer satisfaction is our
top priority. For this reason,
we offer you a comprehensive
range of services. If we can
be of assistance, please do
not hesitate to talk to us.
35www.kistler.com
Technical advice
Experienced specialists from every areaof application are at the disposal of ourcustomers. More particularly, Kistlerconsultancy services include the identi-fication and definition of the measure-ment task, the development of the solution, the selection of the appropriatemeasuring system and the planning ofthe installation.
Test equipment
Kistler provides its customers with ren-tal equipment to help solve specific ap-plication problems.
Repair service
In the event of the failure of a measuringsystem, Kistler specialists help to keepdowntimes of machinery or productionlines to a minimum.
Calibration
Kistler offers a calibration service forthe periodic testing of measuring accu-racy. If necessary, this service can becarried out on site. Kistler keeps a com-prehensive record to show which sensors have been calibrated, as wellas when and how. Kistler also has awhole series of instruments for equipping calibration laboratories.
Information
In order to keep customers constantlyaware of the latest information, Kistlerpasses on its specialist knowledge atexhibitions, trade fairs, conferences,symposia and seminars. Communicationsin the form of data sheets, brochures,reprints, operating instructions and application descriptions are also avail-able to our customers in printed orelectronic form.
Training
Kistler trains its engineers thoroughly at its own training center so that theirknowledge corresponds to the lateststate of the art. Kistler also holds regularseminars for customers on special subject areas.
Testing and rental equipment
To ensure that problems are solved quickly inspecial cases, our customers can use Kistlertesting and rental equipment.
Calibration
Our calibration service (SCS) is available to cu-stomers for the periodic testing of measuringaccuracy.
Training
Regular training ensures that Kistler engineersare always familiar with the current state oftechnology.
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, Kis
tler
Inst
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AustriaKistler GmbHLemböckgasse 49fAT-1230 WienTel. +43 1 867 48 67 0Fax +43 1 867 48 67 [email protected]
ItalyKistler Italia s.r.l.Via Ruggero di Lauria, 12/BIT-20149 MilanoTel. +39 02 481 27 51Fax +39 02 481 28 [email protected]
United KingdomKistler Instruments Ltd.Alresford House, Mill LaneAlton, Hampshire GU34 2QJTel. +44 1420 54 44 77Fax +44 1420 54 44 [email protected]
Korea, Republic ofKistler Korea Co., Ltd.Gyeonggi Venture AnyangTechnical College Center 801572-5, Anyang-Dong, Manan-Gu,Anyang-City, Gyeonggi-Do, Korea, 430-731Tel. +82 31 465 6013Fax +82 31 441 [email protected]
SingaporeKistler Instruments (Pte) Ltd.50 Bukit Batok Street 23#04-06 Midview BuildingSingapore 659578Tel. +65 6316 7331Fax +65 6316 [email protected]
TaiwanKistler Representative Office in TaiwanRoom 9, 8F, No. 6, Lane 180Sec. 6, Mincyuan E. RoadTaipei 114Tel. +886 2 7721 2121Fax +886 2 7721 [email protected]
ThailandKistler Instruments (Thailand) Co., Ltd.662/43-46 Rama III RoadBangpongpang, YannawaBangkok 10120, Thailand Tel. +66 2293 0221Fax +66 2293 [email protected]
Europe
GermanyKistler Instrumente GmbHDaimlerstrasse 6DE-73760 OstfildernTel. +49 711 34 07 0 Fax +49 711 34 07 [email protected]
FranceKistler FranceZA de Courtabœuf 115, avenue du HoggarFR-91953 Les Ulis cedexTel. +33 1 69 18 81 81Fax +33 1 69 18 81 [email protected]
Switzerland/LiechtensteinKistler Instrumente AG Verkauf SchweizEulachstr. 22CH-8408 WinterthurTel. +41 52 224 12 32Fax +41 52 224 14 [email protected]
Asia
JapanKistler Japan Co., Ltd.MT Building2-7-5, ShibadaimonMinato-ku, Tokyo 105-0012Tel. +81 3 35 78 02 71Fax +81 3 35 78 02 [email protected]
China, People’s Republic ofKistler China Ltd.Room 925, Yuan Chen Xin BuildingNo. 12 E1, Yuminlu Road DeshengmenwaiBeijing 100029Tel. +86 10 8225 2163Fax +86 10 8225 [email protected]
IndiaKistler Instruments (Pte) Ltd.India Liaison Office2B Century Plaza560/562 Anna SalaiTeynampet, Chennai 600 018Tel. +91 44 4213 2089Fax +91 44 4213 [email protected]
Kistler worldwide
Denmark/Finland/Norway/SwedenKistler Nordic ABAminogatan 34SE-431 53 MölndalTel. +46 31 871 566Fax +46 31 871 [email protected]
NetherlandsKistler B.V. NederlandLeeghwaterstraat 25NL-2811 DT ReeuwijkTel. +31 182 304 444 Fax +31 182 304 [email protected]
America
USA/Canada/MexicoKistler Instrument Corp.75 John Glenn DriveAmherst, NY 14228-2171Tel. +1 716 691 5100Fax +1 716 691 [email protected]
Other countries
Kistler Instrumente AGExport SalesEulachstr. 22CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 15 [email protected]
Headquarters
SwitzerlandKistler Instrumente AGEulachstrasse 22, CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 14 [email protected]
www.kistler.com
