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_ In trend: Product tests in real conditions

_ Measurement technology of today – Automation technology for tomorrow

_ Seven misconceptions about testing of electric motors

… for particularly tough conditions

Trends, products, applications

And action: Stunt-proof measurement technology

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HBM hotline.com 3 2012 HBM hotline.com 3 2012

In this issue

Publisher HBM Test and Measurement

Im Tiefen See 45

D-64293 Darmstadt, Germany

Email: [email protected]

www.hbm.com

Editorial

Imprint

Technology trends

Product tests under real conditions: challenging data acquisition 4

espressoDAQ Global Application Contest 13

A lifestyle airplane for land, water, snow 14

Seven misconceptions about testing of electric motors 16

Measurement technology today: automation technology tomorrow 20

New products

For use in rough environments: QuantumX in rugged design 6

Measuring speed without contact – with the EGPS-200 7

SomatCR: From ice cold to white hot 7

Mechanical quantities firmly in hand – with QuantumX MX1615 8

QuantumX MX879 Multi-I/O module: Reacting to measurement results in real time 9

Precision at its peak: DMP41 10

Measurement without speed limits: 1 kV data acquisition card for Genesis HighSpeed 12

Precise and rugged: S-shaped S2M force transducer 18

T40B: High resolution even at lower speeds 22

Effectively using the piezo effect – with the piezoelectric measurement technology from HBM 26

Customer solutions

Volvo CE: Construction machines being tested 6

Efficient processes thanks to standardized measurement technology 9

Serving a greener automotive industry 23

It all comes down to the right quantity of force 24

Dear reader,

Engineers require reliable data about how

test objects behave in actual application

conditions. Measurements therefore need

to be implemented on site. This applies both

to prototypes and for special investiga-

tions in series. The resulting data provides

an important contribution to optimization

of the products with regard to safety, reli-

ability, efficiency and structural durability,

while also helping to correctly depict ambi-

ent conditions and model assumptions for

laboratory tests.

High requirements: Rugged and precise Outdoor measurements pose very specific

challenges to measurement technology:

almost like using measurement technol-

ogy ‘stuntmen’. Sensors and data loggers

are subject to extreme vibrations, impacts,

dust, liquids, temperatures and temperature

fluctuations. In addition, there is usually

only a single chance to acquire all neces-

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Editorial

sary data. This is where the data acquisition

systems of our SoMat series and the new

extremely rugged QuantumX modules really

show their strengths. They deliver precise

measurement results even under difficult

ambient conditions.

Proven in practiceTherefore, Volvo CE relies on the SoMat

eDAQ rugged measuring amplifier system

from HBM when testing its new loader

types to continuously reduce the fuel con-

sumption of their construction machines.

The developers of the AKOYA light aircraft

are also relying on our measuring ampli-

fier. The compact, ultra-rugged measuring

amplifier SoMat eDAQ, which is insensitive

to vibrations, is installed directly in the air-

craft. It determines, for instance, the effect

of a small wave – less than 10 centimeters

high – on the aircraft landing at 110 kilo-

meters per hour when it comes into contact

with the water.

Our new action stars“Precision in rugged enclosures – Measure-

ment technology for use in extreme condi-

tions”, this summarizes the requirements

for our products by an increasing number

of demanding customers. We have accept-

ed this challenge and present innovative

new products to you today with SomatCR,

EGPS-200 and the rugged version of the

QuantumX modules – for the action scenes

of your measurement tasks. In addition, we

will look at interesting customer applica-

tions in this edition of HBMhotline and il-

luminate automation trends for you.

Enjoy your reading.

Yours truly,

Andreas Hüllhorst

Andreas Hüllhorst President HBM Group

iInfo

!Alert

operate & analyseprocess

transmit

acquire

notify

GSMUMTSLTE

Data acquisition

Mobile notification

Data server

InternetWifi / LAN

Download

44


Technology trends

Testing under real conditions is particularly important, especially

when developing vehicles. Prototypes are not just exhaustively

tested on a vehicle manufacturer’s site. Now the trend is toward

long-term tests on site on the customer’s premises.

This requires precision data acquisition systems, specially developed

for use in rough condition, which can also securely transmit data

over wide distances. Unattended data acquisition poses high de-

mands on measurement technology, but offers numerous applica-

tion options.

Numerous application optionsWhether in development, customer service or during maintenance –

companies in commercial vehicle production in particular benefit

from on-site data acquisition:

• Vehicle optimization

Information on how vehicles are used under real conditions can

be used to optimize and improve future models.

• Good customer service

Data acquired under real application conditions can be used to

adapt products more precisely for the customer. For instance,

would a smaller or larger model be more suitable for the

customer?

• Advanced warning systems

Service and maintenance divisions benefit from the possibil-

ity of error traceability. In addition, anticipatory maintenance

measures can be introduced and advanced warning systems

implemented on the basis of the acquired data.

Product tests under real conditions: challenging data acquisitionConstant user feedback on the behavior of a product under real conditions – that is what product developers and sales teams want. This is no longer wishful thinking thanks to the current rugged data acquisition systems and the possibility of data transmission even from the most distant of sites. Just the opposite, product tests under real conditions are easily achieved.

iInfo

!Alert

operate & analyseprocess

transmit

acquire

notify

GSMUMTSLTE

Data acquisition

Mobile notification

Data server

InternetWifi / LAN

Download

55


Technology trends

Product tests under real conditions: challenging data acquisition

The challengesHBM’s rugged data acquisition systems are used in numerous

mobile installations around the world, but the requirements of

these systems are high.

• Weak point infrastructure

Some infrastructure, such as mobile phone networks, are not

always available in remote test sites. The data transmission

solutions must be designed to deal with interruptions and be

able to restore the connection without any data loss even

with larger files. HBM’s reliable data recorders are an excellent

solution.

• Open interface challenges

Open interface configurations are required to take into

account various infrastructures. Data acquisition systems from

HBM have Ethernet interfaces and can therefore be used in all

available networks from UMTS, GPRS, 3G or 4G up to LAN.

• Storage and analysis solutions

As large data quantities have to be transmitted on site during

product tests, the storage and analysis solutions must meet the

processing requirements. Data storage, analysis and reporting

can be automated with the help of suitable software such as

nCode Automation.

Christof Salcher, HBM

Read the complete trend article at

www.hbm.com/trend-producttesting

6


Technology trends

Specially developed for applications in rough environ-

ments, the QuantumX MX840A, MX410, MX460 and

MX1601 modules are now also available in ultra-rugged

designs.

The new modules offer optimal prerequisites for acquir-

ing highly reliable measurement data, even in rough field

applications – ensured through intensive ambient testing.

Typical application areas are mobile measurements and

tests in vehicles, stationary measurements and tests on

buildings.

The main parameters in operating condition:

_ Designed to degree of protection IP67 (dust, water)

_ Extended temperature range from -35 to 80 °C

_ Vibration/oscillation resistance up to minimum 10 g

_ Shock resistant up to 75 g

more … www.hbm.com/quantumx

QuantumX in rugged design

For use in rough environmentsVehicle behavior in real conditions plays a decisive role in the devel-

opment of construction machines. This is why Volvo CE tests its con-

struction machines both on their own test grounds and in long-term

tests at the customer's premises.

The Swedish company relies on

the SoMat eDAQ rugged data

acquisition system from HBM

for their mobile data acquisition.

“The system is directly installed in

the loader, so it must be able to

withstand extremely rough hand-

ling. In a single test, we may use

between 10 and 200 channels, depending on the situation, to deter-

mine parameters such as pressure, strain, temperature, position and

acceleration”, explains Lennart Skogh, test engineer and test driver

for Volvo CE in Eskilstuna.

The results of the data analysis are used as the basis for the

development of future loaders with economic fuel consumption and

improved driving characteristics.

Testing Volvo CE’s construction machines

7


Technology trends

The precision GPS receiver EGPS-200 was developed special-

ly for contactless speed measurements in vehicle testing,

such as within the scope of brake tests. Tests require rapid

signals and intelligent control.

The precision GPS receiver EGPS-200 links data from GPS

and inertia sensors, thus achieving a stable speed update

rate at 200 Hz for maximum reliability and accuracy. In-

formation about the test vehicle is delivered every 5 milli-

seconds – together with position data.

EGPS-200 is an encapsulated, compact module for use in

temperature ranges between -20 and +65 °C, achieving

IP67 degree of protection. The device is optimally suited

for applications together with the data acquisition systems

SoMat eDAQ or eDAQlite from HBM.

more … www.hbm.com/egps200

Measuring speed without contact

You want to acquire temperature data in rough environ-

ments on the move? The compact thermo-module SomatCR

can be used in extreme temperature ranges between -40

and 80 °C, attaining IP67 degree of protection. This enables

high-precision data acquisition of the test object directly

without any cable connections and complex test structures.

The thermo-module is easy to install and optimally suited

to industrial applications, e.g. temperature measurements

on pumps, gear units or generators. Up to 16 thermo-trans-

ducers can be connected to the module, with just one CAN

connection – a space and time-saving solution!

SomatCR modules are compatible with the data acquisition

systems SoMat eDAQ and eDAQlite from HBM.

Find the video of the new SomatCR at

www.hbm.com/somat-cr

From ice cold to white hot

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8


Mechanical parameters under control

Material investigations, load data deter-

mination, loading tests, monitoring tests

or general stress analyses – QuantumX

MX1615 can record relevant physical pa-

rameters and is versatile in use.

The SG-bridge amplifier has a unique chan-

nel density and integrates perfectly in the

modular QuantumX data acquisition sys-

tem. All channels are designed for 10 V or

30 V voltage signals and the connection of

Pt100. They support TEDS and can there-

fore be automatically parameterized.

Ruggedly against interference effectsThe SG-bridge amplifier is characterized

by the use of patented technology, based

on 4, 5 or 6 wire technology with carrier

frequency method (CF) and cyclical auto-

adjustment on all channels for quasi-static

measurements. This makes the MX1615

particularly robust against electromagnetic

and thermal interference effects such as

inverters, high currents, electric machines

or temperature effects. Alternatively all

bridge circuits can be supplied with direct

voltage at the click of a mouse and so used

for dynamic measurements.

Close up to the measuring pointEven long distances to the measuring point

can be bridged by the QuantumX MX1615.

The amplifier is rapidly integrated via Ether-

net TCP/IP and can be installed close to the

measuring point so that sensor leads can be

as short as possible.

more … www.hbm.com/mx1615

Simply perfect for experimental stress analysis: up to 16 transducers or strain gauges (SG) in full, half or quarter bridge configuration can be connected to the SG-bridge amplifier MX1615.

New products For experimental stress analysis: QuantumX MX1615

9


The MX879 Multi-I/O module is equipped with a flexible math-

ematics unit enabling real time calculations. Any analog inputs or

bus signals from connected modules can be directly added and out-

put together – ideal when timely reactions are required. In addition,

the function library includes the signal analyses for monitoring of

limit values and peak values.

Comprehensive software package for simple operation The software package includes drivers for programmers in

LabVIEW™ * and Visual Studio .NET. Simple parameterization, opera-

tion, visualization and analysis right up to automatic report creation

is possible with the software tool catman®EASY from HBM. Calcu-

lations and reactions can therefore also be implemented online

using a PC.

more … www.hbm.com/quantumx

Reacting to measurement results in real time

* LabVIEW is a registered trademark of National Instruments Corporation

QuantumX MX879 Multi-I/O module New products

Arburg injection molding machines ensure top quality worldwide in plastic molding. The

company relies on the QuantumX measuring amplifier system in all areas of their product

life cycle.

QuantumX MX840A is used in production during flexible end assembly on a mobile mea-

suring carriage. QuantumX MX440A is used as a service tool for setting up and adjusting

the injection molding machines.

This creates a company-wide data pool that ensures transparency and offers significant

efficiency and quality gains.

Efficient processes thanks to standardized measurement technology

Measuring and actively testing – the QuantumX MX879 Multi-I/O module allows the user to react in real time during system tests. It has eight freely parameterizable analog outputs (± 10 V) and 32 digital inputs/outputs.

The flexible measuring carriage with touch screen operation and WLAN integration in use.

The all-rounder from Arburg: The latest generation of injection molding machines

10


Precision at its peak: DMP41For over 30 years digital precision measuring devices from HBM have been in high demand for users in industry, research and science, and especially for national metrological institutes. No wonder as they guaranteeextremely high resolution, peak accuracy and long-term stability.Now the DMP41 amplifier follows this tradition.

Accuracy class

New products Digital data acquisition system for long-term peak accuracy

0.0005

11


With an accuracy of 5 ppm, the digital data acquisition sys-

tem DMP41 is essential in high-precision measurements for

traceability of mechanical quantities such as force, weight,

torque and pressure. In addition, the amplifier for strain gauge

based transducers is optimally suited to record the smallest of

changes under high static loading during the production of

high-precision elements.

New functionalities and more comfortIn comparison to the predecessor model DMP40, the DMP41 has

numerous new functionalities and offers the user more user-

friendliness.

_ Improved connectivity and more comfortable

operation

The data acquisition system has Ethernet and USB

interfaces, as well as a completely reworked user interface

with touchscreen.

_ Up to six simultaneous measuring points

Complex calibration tasks are now even easier to

implement with the DMP41. This is ensured with up to six

completely simultaneous measuring points that are always

available for highly precise measurements.

_ Your choice: DP15P or MS connection

Each channel can be equipped with its own transducer

via a DP15P or MS connection. Making applications

for standard measurements is even easier. Transducers

available in the laboratory can be immediately connected

to the new DMP41 without an adapter cable.

Production of transducers based on strain gauges.

... and in the pressure laboratory.

Minimal measurement uncertaintyThe entire measurement chain benefits from the DMP41’s ex-

tremely low measurement uncertainty. This is because the mea-

surement uncertainty impacts on the overall accuracy of the

measurement chain and is a particular advantage when high

nominal (rated) loads require larger and significantly more

expensive transducers.

With the DMP41 the overall accuracy of the measurement chain

can be assumed to correspond closely to that of the transducer.

This means that the measurement uncertainty of the data ac-

quisition system can be effectively ignored ensuring that users

can place higher trust in the new digital measuring device’s pre-

cision when, for example, comparing the measurement results

of various national metrological institutes.

André Schäfer, HBM more … www.hbm.com/dmp41

New products Digital data acquisition system for long-term peak accuracy

DMP41 in use in the torque laboratory …

12

HBM hotline.com 3 2012

New products New isolated data acquisition card for Genesis HighSpeed

The new isolated 1 kV data acquisition card

is specially designed for high input voltages.

Thanks to the six input channels for voltages

between ± 20 mV and ± 1000 V, users can now

measure very small electric voltages and sig-

nals up to 1000 V at sampling rates of up to 2

MS/s – and all that with just one data acquisi-

tion card. The measurement accuracy here is

significantly higher than in standard solutions

with sensor heads.

A sure thingThe 1 kV data acquisition card was designed

to easily meet the IEC61010 safety standards.

Similarly, the isolation as per category CAT II

(600 VRMS) or CAT III (300 VRMS) ensures

secure and reliable measurement results, even

in the most demanding electrical application

environments.

Fast and continuousComprehensive data acquisition and trigger

modes also guarantee security and precision

even at the highest data rates. All channels ac-

quire measurement data at a maximum speed

of 2 MS/s and continuously save them to hard

drive.

Power engineering, motors and generatorsThe performance characteristics of the new

1 kV data acquisition card make it highly suit-

able for applications in power engineering,

power electronics in electric motors or gen-

erators.

Appropriate analyses of the data can easily be

resolved with Perception software in conjunc-

tion with the Genesis HighSpeed series for the

calculation of effective, reactive and apparent

power.

more … www.hbm.com/daq-card

Secure and powerful: The new 1 kV data acquisition card

A wide spectrum: Data acquisition cards for Genesis HighSpeed

HBM’s modular Genesis HighSpeed transient and data recorders are the first choice when mechanical or electrical signals need to be acquired rapidly. Measurements are guaranteed without speed limits and with the highest possible precision. Now the latest isolated 1 kV data acquisition amplifier card for the Genesis HighSpeed series significantly expands application options.

Measurement without a speed limit: 1000 V with 2 MS/s sampling rate

HBM hotline.com 3 2012

Fascinating measurement projects, innovative applications and interesting technical issues:

Vote for your favorite project! Help determine the winner of the espressoDAQ Global

Application Contest!

Be it force, pressure, temperature or voltage – espressoDAQ provides you with the right

amplifier.

Find out more at … www.hbm.com/espressodaq-contest

To know is to measure. What would you like to measure?

We are looking for the 2012 espressoDAQ

measurement project – and have already

got numerous proposals. Now it’s your

turn!

measure and predict with confidence

Global Application Contest

Gal

yna

Andr

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Your vote counts!

14

The aim of the new, ultra-modern AKOYA light airplane is to make flying a pleasure again. The AKOYA is special: the two-seater airplane takes off and lands as easily on the ground as on water or snow, without any conversion. On-board safety and comfort is ensured through the use of strain gauges from HBM and the ultra-rugged SoMat eDAQlite data acquisition system.

The AKOYA light airplane currently being developed by the French

company LISA Airplanes is a most unusual modern aviation project.

It is made from cutting edge composite materials and can land on

nearly any surface – on water, snow and the ground – without any

conversion.

The developers‘ concept and motivation to make flying a pleasure

again has lead to outstanding innovations provided by the AKOYA.

Hopping from point to point without any extensive preparations or

limitations is easy with owners of an AKOYA light airplane always

ready to take off on a spontaneous pleasure trip. This is why AKOYA

also stands for pure high technology. The light airplane is equipped

with so called multi access technology, which sets new standards

and is already patented.

This technology comprises:

_ ‘Seafoil’ technology: Two hydrofoils located under the

fuselage provide good stability on the water and enable

fast and easy take-off.

_ Skis-in concept: A combination of retractable landing

gear and skis placed midway up the wheel. This allows

landing on snow-covered or rough surfaces.

_ Pivoting wings enable the airplane to be easily

maneuvered or transported.

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Technology trends AKOYA by LISA Airplanes – tested with HBM measurement technology

A ‘lifestyle’ airplane for take-off and landing on the ground, on water and snow


15

Measurement technology in support of safety and comfortComprehensive structural and component tests are always key to

the development of a new airplane. This is particularly true for the

AKOYA since the operational behavior of the many composite ma-

terials used needs to be thoroughly tested. The particularly light-

weight and easily moldable composite materials give the airplane

flexibility and stability.

LISA Airplanes has opted for HBM‘s ultra-rugged SoMat eDAQlite

system for measurement data acquisition. The full compact data

acquisition system is insensitive to vibration and can be directly in-

stalled in the airplane.

SoMat eDAQlite supports LISA Airplanes in gaining more precise in-

sights in the stresses affecting the airplane‘s structures during the

various phases of flight. Multiple eDAQlite DAQ cards and modules

(e.g. ELCPU, ELBRG, ELDIO) acquire data from strain gauges installed

on the wings (installed in quarter-, half- and full-brige configura-

tion) and a wide range of other measurement data, for example GPS

coordinates.

HBM also has supplied the strain gauges. “The high resolution of-

fered by SoMat eDAQlite allows us to determine how even small

waves of less than 10 centimeters affect the airplane landing on the

water surface at 110 km/h”, explains Laurent Vallet, Head of Devel-

opment at LISA Airplanes.

LISA Airplanes also takes measurements to find ways to increase

comfort during the flight. Installed strain gauges provide useful data

to make flying more convenient and enjoyable for pilots.

AKOYA – the next generationThe first AKOYA airplanes will take off next year. LISA Airplane‘s pio-

neers are already thinking of further developments such as HY-BIRD,

a hybrid airplane. Aviation pioneers continue to look for new chal-

lenges – and place their trust in reliable results from HBM.

more … www.hbmhotline.com

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Technology trends AKOYA by LISA Airplanes – tested with HBM measurement technology

A ‘lifestyle’ airplane for take-off and landing on the ground, on water and snow


Luc Bernole (left), one of the founders of LISA Airplanes, on board the AKOYA light airplane.

16


Technology trends New eDrive testing solution: T12 and Genesis HighSpeed

Seven misconceptions about testing of electric motorsThe time has come to rethink the testing of electric motor power output. We reveal the seven major misconceptions about eDrive testing – and how you can enhance your testing of electric motors and make it more reliable.

GEN2i data recorder and T12 torque transducer

HBM‘s eDrive testing solution

Your benefits: Continuous storage of all raw data

Synchronous data acquisition

Storage of all data in a standardized

system

Power calculation per half cycle

Real-time visualization of results

HBM test and measurement equipment in a test bench for combustion engines and electric motors at Technische Universität Darmstadt, Institute for Internal Combustion Engines and Powertrain Systems (Institut für Verbrennungskraftmaschinen und Fahrzeugantriebe)

testing by HBM

17


7Technology trends New eDrive testing solution: T12 and Genesis HighSpeed

Seven misconceptions about testing of electric motorsMisconception no. 1: “Further development of battery technology will be the solution”

Modern electric cars have a maximum range of 100 km. Extending the range through further development of battery technology is

limited by chemical conditions. Alternative methods need to be found to extend the range of electric cars, for example, the use of lighter

materials or increases in motor efficiency through higher energy yield.

Misconception no. 2: “Electric motors do not have any efficiency reserves”

Today‘s electric motors used in the automotive sector have an energy conversion efficiency of only 50 to 60%. Nearly half of the energy

input is not converted to propulsion but wasted as heat. Power tests on the drive train of electrically driven vehicles help make motors

and other components more efficient and increase efficiency.

Misconception no. 3: “Power tests performed on electric motors are identical to tests on combustion engines” While power tests on combustion engines primarily record mechanical signals, the testing of electric motors also involves measurement

of the electrical signals between inverter and motor. This challenges the test setup since there must not be any phase delay when

recording different signals, otherwise the analyses will be worthless.

Misconception no. 4: “Power tests do not provide any raw data” Users need raw data for verifying measurement results and power data in detail. Power meters used up to now, however, provide only

computed power data. HBM‘s new eDrive testing solution gives users full access to the raw data.


Misconception no. 5: “Test and measurement equipment requires high investment”

Incorrect! The right test setup enables cost savings to be achieved when configuring the test bench. It is more cost-efficient to use, for

example, Genesis HighSpeed and Perception than to fit a test bench with a multichannel power meter.

Misconception no. 6: “Test data processing takes hours”

Power meters require relatively long data processing times. This is why valuable details of highly dynamic motor tests are often not

identified. HBM‘s Perception software allows extremely fast data processing and computation of the power data per electrical ‘half cycle’.

Misconception no. 7: “There is no alternative to power meters”

There is an alternative to conventional power testing on electric motors that gives full access to synchronously acquired,

raw mechanical and electrical data:

• HBM‘sT12digitaltorquetransducerensuresreliableandhighlyprecise

acquisition of torque and rotational speed.

• TheGenesisHighSpeeddataacquisitionsystemsynchronouslyrecordsthe

electrical signal of inverter and motor as well as the digital signals from

the torque transducer.

• UsersofPerceptionsoftwarehavedirectaccesstotheirrawdata

for convenient analysis.

100%

1818


New products Precise and rugged: S-shaped S2M force transducer

Precision is the key to new applications

The S2M force transducer for measuring static and dynamic ten-

sile and compressive forces is a so-called S-type. The performance

specification used during the design of the transducer stipulated

significantly better accuracy and – in comparison to the predeces-

sor model S2 – an improved degree of protection in order to expand

application areas. This was achieved with IP67 degree of protec-

tion IP67. Performance was also improved. Linearity errors, relative

reversibility errors and temperature influences are less than 0.02%

relative to the end value.

The high level of accuracy required for mass production products for

industrial use is combined with ruggedness. In addition to the IP67

degree of protection, the S2M has an overload stop for tensile and

compressive loading. The limit force here lies at 1000% of the nomi-

nal force, even a tenfold overload will not damage the transducer.

In comparison to the S2, the S2M force transducer is also available

with a nominal force of 10 N at an output signal of 2 mV/V.

The trend – whether in OEM applications, experimental sectors or in production monitoring – is focusing on precision, particularly in industrial force transducers. The new S-shaped S2M transducer from HBM now achieves an accuracy class of 0.02. It therefore sets new standards in the class of nominal forces between 10 and 1000 N.

Monitoring a process

with a standard force transducer

… with S2M

Component spread

Yield

1919


New products Precise and rugged: S-shaped S2M force transducer

Efficient in useThe advantages of the S2M are evident during measure-

ment in a partial load area. If the transducer is used at 5%

of the nominal force, the measurement can still be imple-

mented with an accuracy of 0.4%.

Following the successful introduction of the S9M force

transducer for large nominal forces, the S2M now means

that economic and rugged force transducers are available

for the nominal force range between 10 N and 50 kN.

Thomas Kleckers, HBM

more … www.hbm.com/s2m

S2M in the application ...

The advantages are clear:

_ Because of the minimum influence of temperature

on the zero point, the same force transducer can

be used for various measurement tasks – even if it

is operated way below its nominal force.

_ In addition, a higher nominal force can be used

without hesitation if dynamic properties such as

a higher oscillation width or greater stiffness are

required – a significant economic advantage.

_ More precise measurements allow a smaller error

band to be used in good / bad decisions: The

number of good parts and therefore the yield rises

even though the tolerance limits stay the same.

IT Environment

Cost optimizationin manufacturing

ProductionEnvironment

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20


Technology trends More efficiency at all levels – with the entire measurement chain from HBM

Whether in the test environment, production or service and main-

tenance – automated sequences ensure added efficiency and lower

costs in all areas. The automation of test and production facilities for

instance permanently saves money by saving power, using resources

more carefully or by improving production sequences and thus

product quality.

Systems that are intelligently equipped also help to avoid expensive

production downtimes. Automation technology not only makes the

service and maintenance of systems easier and faster, it also signals

potential risks for production long before they turn into real prob-

lems.

Development cycles need to be shortened and costs reduced

for companies to remain competitive today. At the same

time, raw materials, energy and the workforce are getting

more expensive. It is necessary to improve the efficiency of

the process without influencing the quality of the product.

Automation is the answer to these numerous challenges. The

measurement technology of today needs to get ready for the

demands of automation technology tomorrow – from the

sensor to the software.

Measurement technology today: automation technology tomorrow

High requirements for measurement technologyAs a part of automation technology – be it interfaces, data transmission rates or integration capa-

bility – measurement technology must meet high requirements in order to keep ahead. The latest

technology is necessary.

• Industrial Ethernet is on the advance

The implementation of real time-based Ethernet interfaces, EtherCat and Profinet for

instance, provides users with a real jump in performance. Industrial Ethernet

is therefore rapidly forging ahead in production automation.

An industrial amplifier also needs to fit seamlessly into this

concept. This is why the modular PMX amplifiers from HBM

have an Industrial Ethernet connection as standard and are

therefore ready for all applicable standards in automation

technology.

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21


Technology trends More efficiency at all levels – with the entire measurement chain from HBM

Production or test bench* STEP7 is a registered trademark of Siemens AG

** TwinCAT is a registered trademark of Beckhoff Automation GmbH

Individual user interface through PMX command libraries (API)

Up to 20 PMX

Ethernet TCP/IP

100 MBit/s EtherCAT/ ProfiNET

Industrial amplifier PMX

Machine control and programming with standard tools such as STEP7* or TwinCAT**

• Monitoring test benches in real time

Users are informed about critical operating states in time through the monitoring of test

benches in real time. This reduces downtimes, avoids damage and reduces costs. In addition,

self-diagnosis makes handling easier and also draws attention to operating errors and set-

tings outside the specifications.

This however requires precise measurement data that can provide information at all

times about the status of the test bench. Torque transducers from HBM, such as the

T40B with the EtherCAT interface module TIM-EC, are a solution. This is a good example

of state-of-the-art measurement technology making efficient automation possible

via real time Ethernet.

• Software that connects

Automation does not just involve hardware: software is also necessary.

One example is the availability of web servers or open program libraries

that permit system integrators to integrate devices into existing system

landscapes.

As a practical example devices can be easily integrated in complex test

benches with the open command set of the PMX amplifier. The control of

all components is implemented via a uniform operator interface. The inte-

grated PMX web server also enables mobile service applications and remote

access via network and WLAN.

Michael Guckes, HBM more … www.hbmhotline.com

PMX software impresses with usability and flexibility.


2222

Optical measuring systems rapidly reach their limits in the industrial environment due to moisture, condensation, dust, oil and grease. This is why HBM now offers an extremely robust integrated magnetic speed measuring system with high resolution in the form of the T40B torque transducer.

The output pulse count of the T40B torque

transducer is 1024 pulses per revolution

across all measurement ranges. This enables

a high resolution to be achieved, even at

low speeds.

The speed measuring system withstands

even the high rotational accelerations gen-

erally present in test benches. It can be

used without restrictions for the maximum

specified speed of the torque transducer.

The metallic carrier of the magnetized plas-

tic ring is fully integrated. This saves space

and significantly simplifies the installation

outlay.

Wear-free measured value acquisitionThe speed measuring system is contactless

and wear-free sampling of a magnetized

rotor is achieved by means of a magneto-

resistive AMR sensor. Due to this principle,

fluctuations in the field strength have no

influence on the signal quality over a wide

range. The result is noise-immune signals

with high quality. This allows a working dis-

tance of up to 2.5 mm between the rotor

and stator to be realized. The measuring sys-

tem therefore evidences very high tolerance

against mechanical vibrations that generally

occur in the test bench environment.

Highly precise signal evaluationTwo square-wave signals, phase-shifted by

90° are available as the output signal at the

stator to record the speed. Appropriate flank

evaluation of both tracks allows the direc-

tion of rotation to be detected. Optionally, a

reference pulse is available as another signal

to measure the angle of rotation. Angle ac-

curacy of up to 0.1° can be achieved through

the appropriate evaluation of all signals. The

output signal is configured as a symmetrical

5V-RS422 complementary signal.

Maximum flexibility The T40B offers users the highest possible

flexibility. The stator has the standard fre-

quency and voltage interface. In addition,

the TMC digital interface is integrated. The

transducer can therefore be used in 'Stand-

alone operation' or integrated in combi-

nation with the TIM40 interface module

and the new TIM-EC EtherCAT interface

module as a high-performance measure-

ment chain in various field bus-based test

bench concepts.

Markus Haller, HBM

more … www.hbm.com/t40b

High resolution even at lower speeds

New products T40B with magnetic speed measuring system and reference pulse

23


Serving a greener automotive industry

The demands on energy efficiency and the CO2 balance of motors

are constantly increasing. New regulations must be complied with

and flexible solutions found at the same time in order to ensure

product quality over the long term. A manufacturer of water, oil

and vacuum pumps for thermal engines therefore decided to use

a complete solution from HBM.

Precision force measurement in minimal space The sensor choice fell on the CFW piezoelectric force washer from

HBM. The transducer allows the press-fitting of a bearing, a cap

or a seal with the same electric press.

Flexibility and traceabilityAn MP85A was also used by the pump manufacturer. This ampli-

fier can be very flexibly integrated in the automation, enabling

traceability. The amplifier's FASTpress Suite software includes a

new module that automatically generates production measure-

ment reports which can be sent by email or printed out and which

is used to monitor all production steps – including remote moni-

toring.

Everything in view – with the right softwareSoftware completes the end of the measurement chain – once

again from HBM. EASYmonitor CE visualization software, installed

on a standard Siemens MP277 operating unit, displays the re-

sults in real time to the head of the production line. And HBM

EASYteach supports the user in detecting and avoiding

production deviations through traceability data.


The automotive industry has to adapt production and assembly processes in the face of the rapid changes in European environmental standards. New regulations have to be implemented while still remaining competitive. This is why industrial measurement technology from HBM is at the heart of a greener automotive industry.

EASYmonitor CE visualization software delivers results in real time.

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Maximum security in production – with the MP85A FASTpress amplifier from HBM.

The bonus package for automation: MP85A and FASTpress Suite Customer solutions

2424


Customer solutions Precision at high speeds: Quality assurance with PMX

The customers of Dorst Technologies, a

leading supplier of machines and systems

for the production of ceramic and powder

metallurgical products, include automo-

tive suppliers, ceramics producers, tool

manufacturers and medical technology

companies. The new EP 70 M model, a 70

tonnes strong servo-motor driven powder

press, presses iron metal powder, for in-

stance, into a solid product such as a gear-

wheel.

“It is important in this production process

that the individual segments of, for exam-

ple, a gearwheel – hub, web, tooth – all have

the same density. The better this occurs

automatically, the higher the quality of

the molded part”, explained Herbert Gröbl,

development head of control technology

at Dorst Technologies. The density distri-

bution is important because the parts are

only sintered – a special type of heat treat-

ment – after pressing. Cracks may occur in

the molded part affecting its function if the

density distribution varies.

Exact measurement, precise con-trolThe density distribution in turn depends

on the force distribution that acts through

the press stamp via the forming tool on

the powder. The forces in the individual

segments must therefore be constantly

measured during the process in order to

control it precisely and immediately cor-

rect any deviations. Type SLB700A/06 strain

transducers from HBM take over this task in

the EP 70 M. Their small size is an advantage

because they can be placed directly on the

piston of the stamp to measure even small

signals very precisely.

Two strain transducers are placed offset by

180 degrees on the piston to compensate

for bending influences because the screw

press generates force through a rotation

that is converted into a linear movement.

This then moves the individual stamps to

or away from each other. "This is a chal-

lenge for measurement as the rotary motion

is superimposed on the signal of the force

used", explained Gröbl.

The more precisely powder presses can apply force, the higher the quality of the produced molded parts. The pressure must be accurately measured for exact control. Dorst Technologies has elected to use HBM’s PMX amplifier platform which has been specially developed for industrial use, to design a new series of powder presses.

Two SLB700A/06 strain transducers, capable of very precisely recording even minute signals, are attached to each of the powder press stamps.

Dorst Technologies, based in Kochel am See, is one of the market leaders in the development of machines and systems for the production of ceramic and powder metallurgical products.

It all comes down to the right quantity of force

2525


Customer solutions Precision at high speeds: Quality assurance with PMX

Perfectly integrated: The PMX amplifier integrates optimally in the powder press system.

Herbert Gröbl, development head of control technology at Dorst Technologies

PMX amplifier – The new industry standard for measurement technology

“We can eliminate this, but it is very com-

plicated. This is why we have decided to

measure simultaneously at two points so

that the signals produced by the rotation

cancel each other out. We then developed

the new test rig together with HBM.” Dorst

Technologies therefore decided on the PMX

amplifier platform from HBM as this can be

adapted to the requirements of the applica-

tion because of its modular structure.

Synchronous signals The PMX amplifier converts the strain trans-

ducer measurements into a load signal. In

total eight signals are produced – four by

the top stamps and four by the bottom

stamps – that are transmitted directly by

the PMX in real time synchronously via

ProfiNet IRT (Isynchronous RealTime) to the

control system of the press. "This is a great

advantage of the amplifier, that we can di-

rectly integrate it via the ProfiNet IRT in-

terface into our control system, allowing us

to obtain a high level of data quality and

exclude data loss", said Gröbl.

PMX is optimally integrated in the press sys-

tem. With a sampling rate of up to 19.2 kHz

and measured value resolution of 24 bit, the

amplifier offers peak precision at very high

speeds for optimal quality assurance. The

rugged construction and high interference

immunity means that the amplifier platform

can be used near strong generators or in an

environment with strong machine vibrations.


26


Using the piezo effect efficiently – with piezoelectric measurement technology from HBM

Due to their characteristics, piezoelectric sensors are predestined

for use in industry. They are characterized by their robustness, high

natural frequency and excellent overload capacity, even under dif-

ficult application conditions.

A space-saving solution: PACEline CLPForce measurements in the smallest of spaces are possible with the

piezoelectric PACEline CLP force washer. Whether in welding ma-

chines or cable production machines – the low profile of the piezo-

electric force washer allows it to be easily integrated in systems and

machines.

The CLP/7 kN is only 3 mm high and even the measuring ring with a nominal force of 62 kN is just 4 mm high.

In order to efficiently utilize the piezoelectric effect, precise piezoelectric measurement technology is required – from the sensor via the charge amplifier to the accessories. The piezoelectric PACEline product family from HBM is constantly being expanded and optimized in order to offer users perfect solutions for their measurement tasks. The proof lies in the new CLP force washers and the optimized CMD600 and CMA charge amplifiers.

CMA: Extended measuring range for high resolutionUsers of the PACEline CMA charge amplifier profit from the higher

resolution through extended measuring ranges. CMA is now also

available for the following measuring ranges, whereby the measuring

range of the sensors can be appropriately selected for the amplifier:

• 1,000 pC• 2,000 pC• 5,000 pC

• 20,000 pC• 2,000,000 pC• 5,000,000 pC

The PACEline CMA charge amplifier ensures safe transmission of

piezoelectric force transducer data. This is implemented via signal

conditioning to ± 10 V analog standard signals. Sensors are imme-

diately recognized thanks to integrated TEDS functionality. Two

calibrated measuring ranges over 100% and 20% of the nominal

force are available for checking overload-critical sections and safe

measurement in the partial load area.

The extended measuring ranges allow PACEline CMA to achieve a greater resolution of the measurement signal.

New products New products in the PACEline family

27


Using the piezo effect efficiently – with piezoelectric measurement technology from HBM

Signal behavior of the CMD600 with active high-pass filter

The CMD600 charge amplifier for piezoelectric force transducers is now additionally equipped with an integrated high-pass filter.

CMD600 with integrated high-pass filterThe PACEline CMD600 digital charge amplifier now has an integrat-

ed high-pass filter, which can be used to effectively suppress the

natural drift of piezoelectric sensors. No signal loss occurs in fast,

dynamic processes as only the static and quasi-static signal parts are

filtered. The advantage: the charge amplifier is not overloaded, even

during long measurement runs, and the reset signal is not required

in dynamic, recurring measurements.

PACEline CMD600 guarantees flexible use in numerous applica-

tions in laboratory and production areas. The digital charge ampli-

fier measures force, torque and pressure signals up to frequencies

of 30 kHz very rapidly and can be used with piezoelectric sensors

up to maximum 600,000 pC.

With peak and limit values, and digital inputs/outputs, the CMD600

also has universal monitoring options for measurement and test

processes.

Short delivery times and constant availability HBM offers the entire piezoelectric measurement chain from one

source – from the pre-stressing sets via force transducers and

charge amplifiers right up to the accessories.

In addition to high precision and quality, users of HBM piezoelec-

tric measurement technology profit from excellent service: Short

delivery times and constant availability are guaranteed through

sale from stock.

more … www.hbm.com/paceline

New products New products in the PACEline family

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HBM Test and Measurement

www.hbm.com Email: [email protected]

Tel. +49 6151 803-0 Fax +49 6151 803-9100

measure and predict with confidence

From now on, you can find useful tips and tricks from our experts

at www.hbm.com/tips on the topic of measurement data acquisi-

tion. A large collection of technical articles, tutorials, checklists and

videos are at your disposal. Expand your measurement technology

knowledge!

www.hbm.com/tips

Tips & tricks: Measurement technology know-how for you!

New at HBM.com

Documents

HBMhotline 3/2012