9238B

9238B KISTLER | Alldatasheet

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Surface Strain Transmitter for indirect measurement of process forces 9238B_000-822e-02.23 © 2010 ... 2023 Kistler Group, Eulachstraße 22, 8408 Winterthur, Switzerland protected by various intellectual property rights. For more details visit www.kistler.com This information corresponds to the current state of knowledge. Kistler reserves the right to make technical changes. Liability for consequential damage resulting from the use of Kistler products is excluded. Type 9238B... This transmitter with an integral fully-digital charge amplifier is particularly suitable for measuring dynamic and quasistatic forces on stationary or moving machine parts. The transmitter uses indirect force measurement to sense the force-propor - tional strain on machinery or structural surfaces.

• Easy user-friendly parameter configuration via integral serial interface using ManuWare PC program
• Two fully programmable independent measuring ranges (adjustable between ±20 µε and ±800 µε), switchable under load
• Adjustable FSO voltage (±1 ... 10 V), offset voltage (±9 V) and output signal polarity
• Low-resistance voltage output from integral charge ampli- fier
• Extremely easy mounting and IP67 protection for industrial use

Description

The strain of the basic material acts via the two contact sur - faces on the sensor as a change in distance. The sensor housing behaves as an elastic transmission element that converts the change in distance into a force. The sensor's piezoelectric ele - ments in shear generate an electric charge Q [pC] proportional to this force. The strain transmitter's integral electronics then convert this charge into an analog voltage signal. The particular advantages of piezotechnology compared with the familiar foil strain gage technology are high sensitivity, high overload resistance, virtually unlimited service life and high load cycle stability. The measurement signal can be processed as a relative value. For absolute value measurements (e.g. in N or kN) the strain sensor must be calibrated against an appropriate reference. Excitation voltage and measuring cycle control, range switching and communications interface data are carried to the transmit - ter via the same cable used to transmit the measurement signal. The amplifier parameters are configured entirely via the integral serial interface using the included ManuWare PC program. For test purposes it is also possible to transmit digital measurement data (at a rate <20 Hz) and display it on the screen using ManuWare. The industrial design is rated at IP67 and careful fabrication of the sensor allow use in dirty and wet environments.

Applications

The strain sensor Type 9238B… can be used for monitoring all types of machinery with a gap frame, such as mechanical pres- ses and automatic assembly machines. Its ease of mounting makes it ideal for retrofitting to existing machinery. Specific applications include:

• Machine monitoring, such as protecting mechanical presses against overload
• Quality assurance in production runs for joining processes such as wobble riveting, clinching and resistance spot weld- ing
• Monitoring machine tools, such as prompt detection of tool breakage or tool collision ε Patent No. US 7,694,577 B2

Surface Strain Sensor – robust surface strain sensor for indirect measurement of process forces Type 9238B... 9238B_000-822e-02.23 © 2010 ... 2023 Kistler Group, Eulachstraße 22, 8408 Winterthur, Switzerland protected by various intellectual property rights. For more details visit www.kistler.com This information corresponds to the current state of knowledge. Kistler reserves the right to make technical changes. Liability for consequential damage resulting from the use of Kistler products is excluded. Technichal data Measuring ranges, preset Measuring range I με –500 ... 500 Measuring range II με –50 ... 50 Calibrated measuring range με 0 ... –500 Sensitivity (at 10 V FSO) Measuring range I/II mV/με 20/200 Linearity % FSO ≤±2 Mechanical overload1) με ±1 000 Measuring ranges, fully pogrammable Programmable measuring range I/II2) from με –20 ... 20 to με –800 ... 800 Programmable output voltage2) from V –1 ... 1 to V –10 ... 10 Resultant sensitivity mV/με ±1,25 ... 500 Adjustment error % FS <0,5 Output Output voltage limit V ±10,5 Maximum output current mA ±1 Output resistance Ω ≈10 Amplifier characteristics Zero error (in reset condition) mV <±15 Noise (0,1 ... 1 MHz) mVpp <30 Measure jump mV <±25 Frequency range (–3 dB) kHz ≈0 ... 1 Drift at 20 °C (at FSO) mV/s <±2 Polarity switching2) yes Offset voltage2) V ±9 Maximum resolution mV ±5 Control signals Control voltage VDC 3,2 ... 30 Current consumption mA <±1 Reset/Measure switching (pin 3) Reset V 3,2... 30 (or disconnected) Measure V 0 ... 0,6 Delay ms <10 Measuring range switching (pin 5) Measuring range I V 3,2 ... 30 (or disconnected) Measuring range II V 0 ... 0,6 Delay ms <2 RS-232C serial interface EIA standard RS-232C Baud rate bps 115 200 Data bits 8 Stop bit 1 Parity none Software handshake no Max. cable length m 5 General technical data Excitation voltage VDC 18 ... 30 Current (no load) mA <70 Operating temperature range °C –10 ... 70 Storage temperature range °C –20 ... 80 Weight (without cable) g 190 Protection rating (DIN40050)3) – IP67 Connector4) – M12x1 8-way, shielded 1) The strain transmitter is not irreparably damaged by an overload, but does have to be remounted and re-calibrated. 2) Adjustable via RS-232C 3) With cable connected 4) Compatible with LUMBERG, Escha, Binder, Hirschmann and Lemo connectors and cables The transmitter conforms to EMC standards EN61000-6-3 (emission) and EN61000-6-2 (immunity).

Surface Strain Sensor – robust surface strain sensor for indirect measurement of process forces Type 9238B... 9238B_000-822e-02.23 © 2010 ... 2023 Kistler Group, Eulachstraße 22, 8408 Winterthur, Switzerland protected by various intellectual property rights. For more details visit www.kistler.com This information corresponds to the current state of knowledge. Kistler reserves the right to make technical changes. Liability for consequential damage resulting from the use of Kistler products is excluded. Dimensions Strain transmitter with connecting cable Types 1787A… and 1789A... Fig. 1: Dimensions of Type 9238B... Pin allocation Pin allocation for strain transmitter with connecting cable Type 1787A… or 1789A... Mounting

• Machine the surface at the measuring point (N7; Ra 1,6 mi- crons) and tap the M6 female thread (see Fig. 3).
• Align the sensor relative to the structure of the machine. Position the measuring axis to record the maximum strain curve (Fig. 4).
• Secure the transmitter with a single screw with pre-greased thread and head bearing surface. Preload the screw to a torque of 14 N·m (Fig. 5)
• The cable run close to the transmitter should be as free from tension or compression forces as possible. Transmission of cable movements or vibration to the sensor must be avoided. Colors of individual conductors of 8-way connecting cable Type 1787A… and 1789A… (Ref.: LUMBERG Germany) Pin Signal Core color

1 Exct GND white

2 Signal GND brown

4 Signal Out yellow

5 / Range || grey

6 RS-232C_Rx pink

7 RS-232C_Tx blue

Fig. 2: Pin allocation Fig. 3: Preparing the mounting surface 1 7 Fig. 5: Mounting with 6-point socket head cap screw Fig. 4: Aligning sensor to the maximum strain axis Screw M6x30 (Mat. No. 65012719) Tightening torque 14 N·m Head lubricated Thread lubricated Gap (0,6) between contact surface and sensor housing Cable clip (Mat. No. 65007942) Screw (Mat. No. 65012709) Flat washer (Mat. No. 65013269)

Surface Strain Sensor – robust surface strain sensor for indirect measurement of process forces Type 9238B... 9238B_000-822e-02.23 © 2010 ... 2023 Kistler Group, Eulachstraße 22, 8408 Winterthur, Switzerland protected by various intellectual property rights. For more details visit www.kistler.com This information corresponds to the current state of knowledge. Kistler reserves the right to make technical changes. Liability for consequential damage resulting from the use of Kistler products is excluded. Configuring charge amplifier The transmitter's parameters are configured entirely via the integral serial interface (RS-232C) using the ManuWare PC program on the included CD (see Fig. 7). This program's user- friendly interface allows easy and convenient configuration of the transmitter to suit the current measurement requirements. For test purposes it is also possible to transmit digital measure- ment data (at a rate <20 Hz) and display it graphically with the software. Fig. 6: Block circuit diagram Fig. 7: ManuWare interface for parameter configuration and test measurements Configuration examples Example 1 Input signal of –300 ... 300 µε with positive output signal of 0 ... 10 V

• Measuring range of input signal set to 300 µε
• FSO set to 5 V
• Offset voltage set to 5 V
• Polarity of output signal not inverted Example 2 Input signal of 0 ... –60 µε with life zero at 1 V and 8 V FSO
• Measuring range of input signal set to 60 µε
• FSO set to 8 V
• Offset voltage set to 1 V
• Polarity of output signal inverted Example 3 Input signal of 500 ... –500 µε with life zero at 1 V and 9 V FSO
• Measuring range of input signal set to 500 µε
• FSO set to 9 V
• Offset voltage set to 1 V
• Polarity of output signal not inverted -300 300 [µε] Output voltage Strain [µε] Strain Output voltage [µε] Strain Output voltage

Surface Strain Sensor – robust surface strain sensor for indirect measurement of process forces Type 9238B... 9238B_000-822e-02.23 © 2010 ... 2023 Kistler Group, Eulachstraße 22, 8408 Winterthur, Switzerland protected by various intellectual property rights. For more details visit www.kistler.com This information corresponds to the current state of knowledge. Kistler reserves the right to make technical changes. Liability for consequential damage resulting from the use of Kistler products is excluded. Typical applications Fig. 8: Indirect force measurement on knuckle joint Measuring range Standard calibration 1 (measuring range I = ±500 με/II = ±50 με) Custom calibration available on request Ordering key Type 9238B10 Included accessories Type/Mat. No.

• Protective cap for connector 65008335
• Program CD with - ManuWare parameter configuration program, - Flash loader for firmware updates, - Firmware Mounting accessories
• 6-point socket head cap screw 65012719 M6x30 (DIN 912)
• Special grease, tube, 5 g 18000009 Optional accessories Type Shielded cable connection to machine control system
• Connecting cable 1787A5 M12 8-pin neg. connector straight – unterminated, 5 m cable length
• Connecting cable 1789A5 M12 8-pin neg. angle connector right-angled – unterminated, 5 m cable length
• Intermediate service cable 1787A-1 with RS-232C branch for programming the transmitter
• Mounting set for preparation of the 9431B clamping surface for strain sensors Fig. 9: Indirect electrode force measurement on spot welding machine