Kistler MiniDyn 9119AA2 User manual

Instruction
Manual
MiniDyn
Multicomponent
Dynamometer
Type 9119AA2
9119AA2_002-623e-04.18

Instruction
Manual
MiniDyn
Multicomponent
Dynamometer
Type 9119AA2
9119AA2_002-623e-04.18

Foreword
9119AA2_002-623e-04.18 Page 1
Foreword
Thank you for choosing a Kistler quality product
characterized by technical innovation, precision and long
life.
Information in this document is subject to change without
notice. Kistler reserves the right to change or improve its
products and make changes in the content without
obligation to notify any person or organization of such
changes or improvements.
©2013 … 2018 Kistler Group. All rights reserved. Kistler
Group products are protected by various intellectual
property rights. For more details visit .www.kistler.com
The Kistler Group includes Kistler Holding AG and all its
subsidiaries in Europe, Asia, the Americas and Australia.
Except as expressly provided herein, no part of this manual
may be reproduced for any purpose without the express
prior written consent of Kistler Group.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. [phone]
Fax [phone]
[email protected]om
www.kistler.com

MiniDyn Multicomponent Dynamometer Type 9119AA2
Page 2 9119AA2_002-623e-04.18
Content
1.Introduction ................................................................................................................................... 4
2.Important information.................................................................................................................... 5
2.1For your safety ..................................................................................................................... 5
2.2Hints for handling this device ............................................................................................... 6
2.3Tips on using the instruction manual .................................................................................... 7
2.4What happens when there are changes?.............................................................................. 7
3.General device description............................................................................................................. 8
3.1What is a Multicomponent Dynamometer used for?............................................................ 8
3.2Functional principle .............................................................................................................. 9
3.3Dynamometer construction................................................................................................ 10
4.Mounting, installation and initial startup .................................................................................... 11
4.1Important information........................................................................................................ 11
4.2Mounting the Dynamometer.............................................................................................. 12
4.3Mounting the measuring system ........................................................................................ 15
4.3.1Mounting the machine adapter ............................................................................. 15
4.3.2Mounting the toolholder ....................................................................................... 16
4.4Mounting examples ........................................................................................................... 17
4.5Mounting the lathe tool in toolholder Type 9119AE…....................................................... 23
4.6Mounting the measuring system with machine adapter Type 9119AB… to the turret disk. 24
4.6.1Removing positioning bolts and indexing pins....................................................... 24
4.6.2Covering the locating holes for the adapter........................................................... 26
4.6.3Fitting positioning bolts and indexing pins............................................................. 26
4.7Basic connection and cabling of the measuring system....................................................... 27
4.8Dynamometer positioning.................................................................................................. 27
4.9Basic connection and cabling of the measuring system....................................................... 28
4.10Measuring system for 3-component measurement (Fx, Fy, Fz) .......................................... 29
4.113-Component force measurement ..................................................................................... 30
4.12Measuring system for 6-component measurement (Fx, Fy, Fz, Mx, My, Mz)..................... 31
5.Operation..................................................................................................................................... 33
5.1Range selection .................................................................................................................. 33
5.2Measuring small changes in force....................................................................................... 33
5.3Useful frequency range ...................................................................................................... 35
5.4Piezoelectric force measurement ........................................................................................ 37
5.5Tips for better measuring results ........................................................................................ 40
5.6Measurement signal polarity .............................................................................................. 40
6.Maintenance ................................................................................................................................ 41
6.1Re-calibrating the device .................................................................................................... 41
6.2Maintenance work ............................................................................................................. 42
7.Fault elimination.......................................................................................................................... 43
7.1Troubleshooting ................................................................................................................. 43
7.2What to do if the Dynamometer is faulty ........................................................................... 44
8.Technical data .............................................................................................................................. 45

Content
9119AA2_002-623e-04.18 Page 3
8.1MiniDyn Type 9119AA2, general setup (without machine and tool adapters) ...................45
8.2MiniDyn Type 9119AA2, setup for force measurement when turning (with machine and
tool adapters)......................................................................................................................46
8.3Maximum measuring ranges...............................................................................................47
8.4Dimensions .........................................................................................................................48
8.4.1Dynamometer Type 9119AA2 dimensions .............................................................48
8.4.2Type 9119AB… dimensions ...................................................................................49
8.4.3Type 9119AC... dimensions ...................................................................................50
8.4.4Type 9119AH… dimensions...................................................................................51
8.4.5Type 9119AE… dimensions ...................................................................................52
8.4.6Type 9119AF16 dimensions ...................................................................................53
8.5Measuring system components...........................................................................................54
9.Accessories ...................................................................................................................................55
9.1Included accessories ............................................................................................................55
9.2Optional accessories............................................................................................................55
10.Ordering code...............................................................................................................................58
11.Appendix ......................................................................................................................................59
11.1Glossary ..............................................................................................................................59
11.2Measurement Uncertainty ..................................................................................................63
11.3Linearity..............................................................................................................................64
11.4Frequency range .................................................................................................................66
11.5Influence of temperature ....................................................................................................67
Total pages 68

MiniDyn Multicomponent Dynamometer, Type 9119AA2
Page 4 9119AA2_002-623e-04.18
1. Introduction
Please take the time to thoroughly read this instruction
manual. It will help you with the installation, maintenance,
and use of this product.
To the extent permitted by law Kistler does not accept any
liability if this instruction manual is not followed or
products other than those listed under
Accessories are
used.
Kistler offers a wide range of products for use in measuring
technology:
Piezoelectric sensors for measuring force, torque, strain,
pressure, acceleration, shock, vibration and acoustic-
emission
Strain gage sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems as well as
software for specific measurement applications
Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions for
the application fields engines, vehicles, manufacturing,
plastics and biomechanics sectors.
Our product and application brochures will provide you
with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found
either on-line or in this manual, please contact Kistler's
extensive support organization.

Important information
9119AA2_002-623e-04.18 Page 5
2. Important information
It is essential to follow the instructions below for your own
personal safety when working and to ensure long-lasting,
trouble-free operation of the device.
2.1 For your safety
This device has been thoroughly tested and was
perfectly safe when it left the factory. To keep it in this
condition and ensure risk-free operation, the user must
observe the information and warnings contained in this
Instruction Manual.
The dynamometer must only be installed, operated and
repaired by persons who are familiar with the device
and who are suitably qualified for their particular work.
If you believe that the device can no longer be operated
without risk, it must be taken out of operation and
secured to prevent accidental operation.
You should believe that the device can no longer be
operated without risk,
if there are visible signs of damage on the device,
if the device is no longer working,
after prolonged storage under adverse conditions,
if mishandled during transportation
When measuring the cutting force, fasten the
dynamometer to the machine tool as specified! Details
can be found in the 4.2 "Mounting the dynamometer"
chapter.
Fasten all the parts mounted on the cover plate of the
dynamometer in accordance with the forces that are
expected!

MiniDyn Multicomponent Dynamometer, Type 9119AA2
Page 6 9119AA2_002-623e-04.18
2.2 Hints for handling this device
You must only work with the dynamometer in spe-
cified environmental and operating conditions.
Insulation resistance is crucial for piezoelectric
measurements; it must be about 100 TΩ
(but at least
10 TΩ)
To obtain this value, all the plug connections must be
kept scrupulously clean and dry
The insulation resistance can be measured with a Type
5493 insulation tester
Protect the device signal output against conta-mination
and do not touch it with your fingers. Put on the
supplied cover if the connection is not assigned
The connecting cable (connecting cable from the
dynamometer to the charge amplifier input) has high
insulation. Only specified connecting cables must be
used
The connecting cable should not be removed from the
dynamometer
When the dynamometer is not being used, keep it in
the supplied packing case to protect it
During long-term measurements, make sure that the
dynamometer temperature stays as constant as possible

Important information
9119AA2_002-623e-04.18 Page 7
2.3 Tips on using the instruction manual
We always recommend that you read the entire Instruction
Manual. But if you are in a hurry and are already familiar
with Kistler dynamometers, you only have to read the
particular information you need.
We have tried to design this manual to make it easy for
you to directly access the information you are looking for.
Keep this Instruction Manual in a safe place, where it will
always be close at hand.
Should you lose the manual, contact your Kistler customer
service department to obtain an immediate replacement.
All the information and instructions in this manual may be
changed at any time without prior notice.
2.4 What happens when there are changes?
Modifications to the device usually result in changes to the
Instruction Manual. Ask your Kistler customer service
department about the update options for your
documentation.

MiniDyn Multicomponent Dynamometer, Type 9119AA2
Page 8 9119AA2_002-623e-04.18
3. General device description
3.1 What is a Multicomponent Dynamometer used for?
The multicomponent dynamometer is used for dynamic
and quasistatic measurement of the 3 orthogonal
components of any force acting on the cover plate (Fx, Fy
and Fz).
The dynamometer is extremely rigid and therefore has a
high natural frequency. The high resolution allows the
smallest dynamic changes of large forces to be measured.
The dynamometer measures the active force, irrespective
of its application point. Both the average force value and
the dynamic increase in force can be measured. The useful
frequency range mainly depends on the natural frequency
of the entire measurement setup.
Fig. 1: MiniDyn Type 9119AA2
The most important areas of application for the
multicomponent dynamometer are:
General 3-component force measurement of small
forces
Force measurement in confined spaces
Cutting force measurement in precision machining,
such as:
precision machining
micromachining
ultra-high precision machining of brittle, hard
materials
Measurement of the three forces F
c
, F
f
and F
p
when
turning outside and inside diameters with turret lathes

General device description
9119AA2_002-623e-04.18 Page 9
3.2 Functional principle
The force to be measured is applied via a cover plate and
distributed to four, 3-component force sensors arranged
between the cover plate and the two base plates.
Each force sensor contains three quartz crystal plate pairs,
of which one is sensitive to pressure in the z direction and
the other two are sensitive to shear in the x and y
directions. There is practically no deflection during
measurement.
In these four force sensors, the applied force is split into
three components.
Fig. 2: Force sensor setup in the multicomponent
dynamometer: quartz crystal plate pairs for the 3
measuring directions
For force measurement with 3 components, the individual
signals are brought together in the connecting cable.
Positive or negative charges are produced at the
connections, depending on the direction of the force.
Negative charges produce positive voltages at the charge
amplifier output, and vice versa.

MiniDyn Multicomponent Dynamometer, Type 9119AA2
Page 10 9119AA2_002-623e-04.18
3.3 Dynamometer construction
The dynamometer consists of four 3-component force
sensors, mounted under high preload between two base
plates and one cover plate.
This preload is the requirement for friction force
transmission.
The four force sensors are installed ground-isolated. This
largely eliminates ground loop problems.
The dynamometer is rustproof and protected against the
ingress of splash water and cooling agent. Together with
the (Type 1687B5 or Type 1677A5) connecting cable, the
dynamometer meets the requirements of degree of
protection IP67.
As a result of the specific sensor location and signal
connection, the dynamometer is largely insensitive to
temperature shifts.
1Base plates
2Cover plate
3Connector
12 3
1

Mounting, installation and initial startup
9119AA2_002-623e-04.18 Page 11
4. Mounting, installation and initial startup
4.1 Important information
The Type 9119AA2 multicomponent dynamometer is a
precision instrument, with inherent accuracy that will only
remain useful and intact if the device is carefully handled. It
is therefore important to observe the following instructions:
Do not drop the dynamometer and do not subject it to
sharp blows! The maximum force of this type of shock
could exceed the device measuring range and cause
lasting deformation
Do not use a hammer to position the workpieces, as
striking the workpieces will also cause deformation
The chapters that follow contain information about
dynamometer installation. This Type 9119AA2
multicomponent dynamometer can be used for general
force measuring tasks and cutting force measurements or,
more specifically, for measuring forces during turning.
Appropriate machine and tool adapters are available.

MiniDyn Multicomponent Dynamometer, Type 9119AA2
Page 12 9119AA2_002-623e-04.18
4.2 Mounting the Dynamometer
To mount the dynamometer properly, please note the
following:
The dynamometer must only be installed by persons
who are familiar with the device and who are suitably
qualified for this work
The connecting cable is first connected to the
dynamometer. Both sides of the connector (the
dynamometer and the cable) are cleaned with Type
1003 cleaning and insulating spray. The enclosed O-
ring is used for sealing. The bearing surfaces for the O-
ring must be clean. The O-ring is inserted and the cable
flange screwed to the dynamometer with two screws,
and tightened until seated
Tightening torque (M
A
): 4.5 N·m
Before mounting the dynamometer on a machine tool
or a testing device, check that the mounting surface is
flat. Uneven bearing surfaces cause inner distortion,
which additionally exposes the individual force sensors
to high shear loads and can increase crosstalk
Fig. 3: Cable mounting with O-ring seal
1 2 3
3
4
1Dynamometer
2O-ring seal
3M4x10 screw
4Cable (high insulation

Mounting, installation and initial startup
9119AA2_002-623e-04.18 Page 13
The bottom surface of the dynamometer is ground, i.e.
precision machined. The device must therefore only be
installed on mounting surfaces that are ground or
machined to the same standard. The specific alignment of
the force sensors requires the quality of the mounting
surface to be meticulously monitored. Thoroughly clean
the bearing surfaces before assembly.
Make sure that the dynamometer is resting completely
flat. Even the tiniest air gap can produce unwanted
elasticity and lead to a reduction in the resonance
frequency of the measuring arrangement. Please
therefore pay attention to the oscillation aspects of the
assemblies as well.
If possible, the connecting cable should always stay
connected to the dynamometer.
Install the connecting cable so that it can neither shear
off nor be pulled out when working.
The two long sides of the base plates or the long sides
of the cover plate are used to align the dynamometer
on a magnetic plate or a machine table.
Alignment surfaces on base plates
Alignment surfaces on the cover plate

MiniDyn Multicomponent Dynamometer, Typ 9119AA2
Page 14 9119AA2_002-623e-04.18
The dynamometer can be mounted in two different ways.
a. With 8 M4x25 screws
For this type of mounting, 8 M4 threaded bores
(minimum thread length: 12 mm) are required on the
assembly table. The tightening torque is always 4.3
N·m, the strength class 12.9.
b. On a magnetic plate
If a magnetic plate is used, there is no need to
subsequently provide the assembly table with
mounting bores.
Beware!
With this type of mounting, the process forces must not be
greater than the magnetic forces. It is essential to stop the
dynamometer slipping in order to prevent damage to the
measuring instrument.

Mounting, installation and initial startup
9119AA2_002-623e-04.18 Page 15
4.3 Mounting the measuring system
4.3.1 Mounting the machine adapter
Thoroughly clean all the mounting surfaces before
assembly.
Dynamometer Type 9119AA2
First the dynamometer is fitted onto the appropriate
machine adapter
Mounting screw tightening torque: 4,3 N·m.
If possible, make sure that when the system is fitted in
the machine, the cable outlet does not run in the
direction of chip flow. Install the connecting cable in the
machine so that it can neither shear off nor be pulled
out when working
Machine adapter for disk turret with VDI toolholder Type
9119AB…
The VDI adapter must be attached to the turret in
accordance with the manufacturer's instructions. A
flexible cooling agent hose can be installed on one side
of the machine adapter as an option
Machine adapter for disk turret with Coromant
Capto toolholder Type 9119AC…
The Capto adapter must be attached to the turret in
accordance with the manufacturer's instructions. A
flexible cooling agent hose can be installed on one side
of the machine adapter as an option
Machine adapter for disk turret with HSK-T toolholder
Type 9119AH…
The HSK-T adapter must be attached to the turret in
accordance with the manufacturer's instructions. A
flexible cooling agent hose can be installed on one side
of the machine adapter as an option

MiniDyn Multicomponent Dynamometer, Typ 9119AA2
Page 16 9119AA2_002-623e-04.18
4.3.2 Mounting the toolholder
Thoroughly clean all the mounting surfaces before
assembly.
Toolholder for lathe tool Type 9119AE…
The toolholder is fitted to the cover plate of the
dynamometer by 6 M5 screws.
Mounting screw tightening torque: 10 N·m
Clamping screw tightening torque:
Type Threshold
9119AE08
9119AE10
9119AE12
9119AE16
9119AE20
4,0
4,0
5,0
5,0
5,0
9119AE0,31
9119AE0,38
9119AE0,50
9119AE0,63
4,0
4,0
5,0
5,0
Toolholder for boring bars Type 9119AF16
Three reducing sleeves are supplied and allow 16 mm,
12 mm, 10 mm and 8 mm boring bars to be used
The dynamometer, the machine adapter and the toolholder
are designed so that the fitted tool and its cutting corner
are always the same height as the center of the workpiece.
Beware!
It is only possible to work in the tool working position
with the installed measuring system. The turret disk
must never be rotated with the installed system.

Mounting, installation and initial startup
9119AA2_002-623e-04.18 Page 17
4.4 Mounting examples
Example 1
Axially mounted dynamometer for turning the outside
diameter with machine adapter Type 9119AB30S (VDI
toolholder) and toolholder Type 9119AE16.
Workpiece direction of rotation:
Fig. 4: Type 9119AA2, 9119AB30S, 9119AE16