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Instruction
Manual
9001C_002-928e-12.20
Piezoelectric Force Sensors,
Ring Force Transducers
Types 9001C ... 9091C,
9101C ... 9107C,
9130C ... 9137C
Page 1
9001C_002-928e-12.20
Thank you for choosing a Kistler quality product charac-
terized 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.
© 2020 Kistler Group. Kistler Group products are protected
by various intellectual property rights. For more details visit
www.kistler.com. The Kistler Group includes Kistler Hol-
ding AG and all its subsidiaries in Europe, Asia, the Ameri-
cas and Australia.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
info@kistler.com
www.kistler.com
Foreword
Foreword
Piezoelectric Force Sensors, Ring Force Transducers
9001C_002-928e-12.20Page 2 Page 39001C_002-928e-12.20
Content
1. Introduction .................................................................................................................................4
2. Important instructions................................................................................................................5
2.1 For your safety....................................................................................................................5
2.2 Disposal instructions for electrical and electronic equipment .............................................6
2.3 Unpacking...........................................................................................................................6
2.4 Notes on handling the sensor.............................................................................................6
2.5 Tips on use of manual ........................................................................................................7
3. General.........................................................................................................................................8
3.1 Applications ........................................................................................................................8
3.2 Sensor design and principle of operation ...........................................................................9
4. Mounting....................................................................................................................................11
4.1 General aspects of mounting ...........................................................................................11
4.1.1 Pretension and preload .......................................................................................11
4.1.2 Sensor in direct path of force ..............................................................................13
4.1.3 Sensor in force shunt .........................................................................................13
4.2 Structural design and force contact ..................................................................................14
4.2.1 Examples.............................................................................................................14
4.3 Effect of elasticity conditions on the measurements.........................................................17
4.3.1 Calculations related to engagement of force.......................................................18
4.3.2 Examples.............................................................................................................21
4.4 Mounting example ............................................................................................................24
4.5 Installation of sensor family 90x1C and 910xC ................................................................25
4.5.1 Type 9422A: mounting for compression forces only ...........................................25
4.5.2 Type 9420A: Mounting for both compression and tensile forces.........................27
4.6 Installation of big force sensors Type 9081C and 9091C .................................................29
4.7 Installation of a Slimline Sensor Types 9130C … 9137C .................................................30
4.7.1 Direct force path mounting ..................................................................................30
4.7.2 Type 9410A: mounting in force shunt mode........................................................31
5. Measurement.............................................................................................................................33
5.1 Basic arrangement of a measuring system ......................................................................33
5.2 Range selection and threshold .........................................................................................34
5.3 Measuring high-frequency phenomena ............................................................................35
5.4 Measuring quasistatic phenomena...................................................................................35
5.5 Instructions and safety precautions ..................................................................................36
Total pages 55
6. Calibration and maintenance...................................................................................................37
6.1 In-Situ calibration of force sensors ...................................................................................37
6.1.1 Working point calibration by peak value comparison ..........................................37
6.1.1.1 Test system requirements....................................................................38
6.1.1.2 Reference sensor installation ..............................................................38
6.1.1.3 Load application...................................................................................39
6.1.1.4 Calibration process worksheet.............................................................40
6.1.2 Kistler calibration service.....................................................................................43
7. Troubleshooting........................................................................................................................44
7.1 Diagnosisandrecticationoffaults ..................................................................................44
7.2 Repairing Load Washer ....................................................................................................45
8. Technical data ...........................................................................................................................46
8.1 Optional accessories ........................................................................................................46
9. Appendix....................................................................................................................................47
9.1 Glossary ...........................................................................................................................47
9.2 Measurement uncertainty .................................................................................................50
9.3 Linearity ............................................................................................................................51
9.4 Frequency range ..............................................................................................................53
9.5 Inuenceoftemperature...................................................................................................54
Piezoelectric Force Sensors, Ring Force Transducers Important instructions
9001C_002-928e-12.20Page 4 Page 59001C_002-928e-12.20
1. Introduction
Thank you for choosing a quality product from Kistler.
Please read through this manual thoroughly to enable you
to fully exploit the various features of your product.
To the extent permitted by law Kistler accepts no liability
if this instruction manual is not followed or products other
than those listed under Accessories are used.
Kistler offers a wide range of measurement products
through to turnkey solutions:
Piezoelectric sensors for measuring pressure, force,
torque, strain, acceleration, shock and vibration
Strain gage sensor systems for measuring force and
torque
Piezoelectric pressure sensors and transmitters with
matchingmeasuringampliers
Matching measuring ampliers (charge ampliers, pi-
ezoresistive ampliers, etc.), displays and charge ca-
librators
Electronic control, monitoring and evaluation units as
wellassoftwareforspecicmeasurementapplications
Datatransmissionmodules(telemetry)
Kistler also develops and produces measuring solutions
fortheapplicationelds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.
2. Important instructions
It is absolutely essential to follow the instructions below,
which are intended to ensure your safety when working
with the equipment and guarantee a long, trouble-free
service life.
2.1 For your safety
Kistler force sensors have been thoroughly tested and
left the factory in perfectly safe condition. To maintain
this condition and ensure safe operation the user must
follow the instructions and warnings in this manual
Piezoelectric force sensors may only be mounted, used
and maintained by persons familiar with the equipment
andsuitablyqualiedfortheirparticularwork
If it has to be assumed that safe operation is no longer
possible, switch the equipment off and ensure it cannot
be switched on again inadvertently
It must be assumed that safe operation is no longer
possible when the product
shows visible signs of damage,
has been overloaded
is no longer operating,
has been in lengthy storage under unsuitable
conditions
has been subjected to rough transport conditions.
Mount the ring force transducer as specified. See section 4
„Mounting“ for details.
Secure all of the parts mounted on the force sensors
against the anticipated forces.
Piezoelectric Force Sensors, Ring Force Transducers Important instructions
9001C_002-928e-12.20Page 6 Page 79001C_002-928e-12.20
2.2 Disposal instructions for electrical and electronic equipment
Do not discard old electronic equipment in municipal trash.
For disposal at end of life, please return this product to
the nearest authorized electronic waste disposal service or
contact your Kistler sales office for instructions.
2.3 Unpacking
Check all of the packaging for any damage in transit,
which must be reported to the freight forwarder and the
responsible Kistler distributor.
Please check also for the completeness of the delivery
and report any missing parts to the responsible Kistler dis-
tributor.
2.4 Notes on handling the sensor
The specied environmental and operating require-
ments must be met when working with the sensor
The insulation resistance of piezoelectric sensors is of
criticalimportance;itmustmeetthevaluespeciedin
thedatasheet(upto1014 W).Toachievethisvalueall
plug connections must be kept scrupulously clean and
dry. The insulation resistance can be measured with
the corresponding insulation tester from Kistler
Protect all connector or cable parts between sensor
andchargeamplieragainstanydirt,andinparticular
make absolutely sure you never touch the front of any
connectorwithyourngers.Puttheincludedcoveron
if a connection is not being used
The cable for connecting the sensor to a charge amp-
lierisahigh-insulationtype.Ifnotincluded,useonly
suitable connecting cables or accesories specied by
Kistler
2.5 Tips on use of manual
We recommend that you read through the entire manual
thoroughly. However, if you cannot spare the time and are
already familiar with piezoelectric force sensors of Kistler,
you may skip to the sections with the information currently
required.
We have tried to organize this manual clearly so that the
required information is easily accessible.
Keep this manual in a safe place where it is readily acces-
si-ble at all times.
If you lose your manual please contact your Kistler distri-
butor for prompt replacement.
Piezoelectric Force Sensors, Ring Force Transducers General
9001C_002-928e-12.20Page 8 Page 99001C_002-928e-12.20
3. General
Piezoelectric force sensors are quartz crystal ring force
transducers. The force to be measured is transferred to
the quartz sensor elements via the cover plate and base
plate of the tightly welded steel housing. The quartz ele-
ments produce an electric charge proportional to the me-
chanical load. A charge amplier generates an electric
voltage from this charge. These signals are displayed, re-
corded or processed in the familiar way.
Thanks to the extremely high resolution of quartz it is pos-
sible to measure a change in force of the order of 1 N
under a pretension of several tons.
Theshape(loadwasher)andtherelativelysmalldimen-
sionsallowexibleapplicationandeasymounting.Stan-
dard accessories for special applications or mounting
conditions are available on the datasheets of the corres-
ponding sensor.
Sensitivity(chargeperunitforce)isaconstantofquartz
as a material. The associated threshold is virtually the
same for all the load washers of different sizes.
This has three unique advantages:
High level of overload protection, very small forces can be
measured with one sensor with a large measuring range
High rigidity; a sensor with a larger measuring range un-
dergoes less deformation
Several sensors can be electrically connected in parallel
toasinglechargeamplier.Theoutputsignalisthenthe
sum of all of acting forces
3.1 Applications
Kistler ring force transducers are very rigid and ideal for
measuring dynamic forces. This very high rigidity has ex-
tremely little effect on the dynamic characteristics of the
object being measured, in which they are mounted.
Depending on the size of the force, quasistatic measu-
re-ment can be performed over several minutes or even
hours(thesignaldriftisonlyabout±50mN/s).However,
truly static measurements over any length of time are not
possible.
On the other hand, after a pause of any length a sensor
undercontinuous static load(forexample, mounted ina
threadedconnection)canbereconnectedtoachargeam-
plierandthechangesinloadthenmeasuredaccurately.
Measurements of dynamic forces (AC mode) are also
possible over any length of time. Kistler load washers
have a virtually unlimited life and are not subject to sensi-
tivity drift caused by aging.
The force to be measured is transferred to the quartz sen-
sor elements via the cover plate and base plate of the
tightly welded steel housing. The quartz elements produce
an electrical charge proportional to the mechanical load.
Thesensitivity(chargeperunitforce,aconstantofquartz
as a material) and hence the threshold is virtually the
same for all of the different sized load washers.
3.2 Sensor design and principle of operation
A piezoelectric ring force transducer consists of one or
two crystal ring washers, an electrode and a housing with
connector(seeFig.1).
The force to be measured must be evenly distributed over
the ring surface. The mechanical compressive stress re-
sults in an electric charge being generated in the quartz
crystal. This charge is proportional to the applied force
and does not depend on the dimensions of the quartz
washers(longitudinalpiezoelectriceffect).
Piezoelectric Force Sensors, Ring Force Transducers Mounting
9001C_002-928e-12.20Page 10 Page 119001C_002-928e-12.20
a)
b)
S
Q = Quartz washers
E = Electrode
G = Housing
S = Connector
F = Force acting on the load washer
Fig. 1: Schematic section through a standard piezo-
electricringforcetransducera)andaSlimline
forcesensorb)
The generated charge is conducted from the electrode
and supplied to the plug connection. The polarity is cho-
sen so that a compression force generates a negative
charge, which is then converted into a positive voltage in
thechargeamplier.Thehousingservesasgroundcon-
nection. Unloading of the load washer produces a positive
charge.
Connecting several force sensors in parallel adds the
chargesoftheindividualsensorandthechargeamplier
measures the total force.
To ensure the forces to be measured are distributed even-
ly over the ring surfaces, the contact surfaces on the ob-
jectbeingmeasuredmustbeasat,rigidandnelyma-
chined as possible.
4. Mounting
If something is not clear or difculties are encoun-
tered when mounting piezo ring force transducers,
please contact the responsible Kistler distributor or,
if appropriate, the manufacturer, for advice. To enable
the query to be handled effectively it is important
to describe the measurement problem and provide
drawings or sketches that make the type of load,
engagement and point of application of the force
evident.
4.1 General aspects of mounting
Kistlerloadwashersmustbemountedbetweentwonely
machined(preferablyground),rigid,parallelsurfaces.This
allows force measurement over a wide frequency range.
TherecommendedsurfaceroughnessisRa=1,6μm.
4.1.1 Pretension and preload
Why to apply a pretension or preload:
Between the always imperfect surfaces inside and out-
side the sensor there are microgaps that act as inter-
posed spring elements. Preloading closes these gaps
to ensure force measurement is in the linear range and
freefromdisturbinginuences.(s.Fig.2)
Pretension eventually allows the measurement of both
compressionandtensionforces(s.Fig.3)
An optimal choice of preload allows to operate the sen-
sor in the range, where it is most robust against ben-
ding moments, which is at 50% of the nominal force of
thesensor.(4.3.1Calculationsrelatedtoengagement
offorce)
Pretension presses the contact surfaces together so
that the high rigidity of the sensor can be fully exploited
Piezoelectric Force Sensors, Ring Force Transducers Mounting
9001C_002-928e-12.20Page 12 Page 139001C_002-928e-12.20
Fig. 2: Linearity of force sensors Fig. 3: Measuring ranges depending on preload
Difference of pretension and preload:
The terms preload and preload force are often used as
synonyms, although they have a crucial difference: A
force is applied to the sensor by both preload and preten-
sion to overcome the nonlinear range of the sensor. How-
ever, when pretensioning a ring force transducer, a screw
is used through the center hole, resulting in a small force
shunt, which is not present with a pure preload. This force
shuntreduces the sensitivityofthe sensorby ≈5…10%,
depending on the layout.
Fig. 4: Pretension and the resulting force shunt through
bolt
How to preload:
When pretensioning, the force must be measured with the
sensoritself,andthechargeampliersettothesensitivity
speciedin thetechnicaldata.Asthepretensioningbolt
forms a force shunt, after being mounted the sensor
must be recalibrated to determine the sensitivity of the
complete measurement setup.
Calibratedsensorscomewithaspecicsensitivityvalue
for preloading.
4.1.2 Sensor in direct path of force
With direct force measurement almost the entire process
force passes through the sensor.
Fig. 5: Measurement in direct path of force
The total force applied (preload force Fv and process
forceFz)shallnotexceedthenominalforceofaringforce
transducer. Otherwise a bigger sensor has to be chosen.
In general, the force shunt effect of the preloading bolt is
neglectedwhenasensorsizehastobedened.Butifcir-
cumstances require it, the effective load on the quartz by
theprocessforceFzcanbereducedbythese≈5…10%
that are absorbed by the bolt. Check the datasheet of the
bolt accordingly.
4.1.3 Sensor in force shunt
Fig. 6: Example of indirect force measurement
If very large forces are to be measured or the sensor
cannot be positioned directly in the path of the force, it is
often mounted in a force shunt. This arrangement allows
the sensor to be used to solve a wide variety of measure-
ment problems. Due to it’s small dimensions, the Slimline
series 913x is very well suited for this purpose.
Piezoelectric Force Sensors, Ring Force Transducers Mounting
9001C_002-928e-12.20Page 14 Page 159001C_002-928e-12.20
4.2 Structural design and force contact
The full measuring range can only be exploited if the
force is evenly distributed. The mounting surfaces
should preferably be ground. Accessories like spherical
washers, force distributing rings, insulating washer and
force distributing caps make mounting easier in many
cases(seewww.kistler.com/force).Atthemaximumallo-
wed load of the particular load washer of whatever size a
surface pressure Gmaxofapproximately150N/mm2ari-
ses.
4.2.1 Examples
The ideal mode of force engagement produces an even
surface pressure on the ring force transducer and is free
from shear forces and moments. Several examples of
how force can be applied most effectively are listed below.
Measurement on rough surfaces
Contactsurfacesmustbeatandrigid.Iftheycannotbe
nely machined, localized overloads and damage to the
surface of the sensor must be avoided by using a force
distributingring(Fig.7).
Fig. 7: Mounting with a force distributing ring Type 95x5
on a rough surface
Measurement of a screw force
When measuring a screw force it is essential to avoid load
casea),asitcausesanoverloadattheinsideedge.To
ensure accurate measurement and exploitation of the full
measuring range, a matching element for introducing the
force must be manufactured.
Thebearingsurfacesontheloadwashermustbenished
by grinding. A good grease applied at the screw thread
and head (such as Kistler Type 1063) must be used to
reduce the friction.
Fig. 8: Measurement of force in a screw connection;
a)ineffectiveintroductionofforce,b)withcon-
structional element
Measurement of force between roughly machined
and/or oblique surfaces
Measurement between rough and/or oblique surfaces
should be avoided if possible (Fig. 9, case a). Machine
the mounting surfaces, preferably by grinding. A force dis-
tri-buting ring or a spherical washer should only be used
asatemporarysolution(Fig.9,caseb).However,under
load a spherical washer will no longer allow compensation
for misalignment.
Fig. 9: Force measurement between roughly machined
andobliquesurfaces,a)ineffectiveintroduction
offorce,b)withforcedistributingringandsphe-
rical washer
Measurement of a point force
A force distributing cap prevents introduction of force at a
point. If the plate is too thin it is deformed into a dish sha-
peandoverloadstheinsideedgeoftheloadwasher(Fig.
10,casea)inasimilarwaytotherstexampledescribed
(Fig.8,casea)).Asshownincaseb),theforcedistribu-
ting cap provides a remedy.
Piezoelectric Force Sensors, Ring Force Transducers Mounting
9001C_002-928e-12.20Page 16 Page 179001C_002-928e-12.20
Fig. 10: Measurementofapointforce;a)ineffective
introductionofpointforce,b)withforcedistribu-
ting cap
Measurement of force on a beam with two load
washers
Thedeectionofabeamsupportedontwoloadwashers
can result in local deformation of the washers (Fig. 11,
casea)).AsimpletrussarrangementasshowninFig.11,
caseb)providesaremedy.
Fig. 11: Measurement of force on a beam with two load
washers;a)ineffectiveapplicationofforce,b)
with simple truss arrangement
4.3 Effect of elasticity conditions on the measurements
With pretensioned connections, attention must be given to
the diversion of force without fail.
Fig.12showsitsinuenceasafunctionoftheelasticity
conditions, by means of stress-strain diagrams.
Ideally, the force shunt via the pretensioning elements is
very small, so that almost the entire force to be measured
is transmitted and measured by the load washer.
If the force shunt is large, it is still basically possible to
perform measurements, provided that the setup is calib-
rated. However, there is a risk that the magnitude of the
forceshuntmaychangeduringoperation(forexampleas
material compression, together with changes in tempera-
tureordeformations),andfalsifyingthemeasurementre-
sult despite calibration.
In all cases in accordance with Fig. 12 recalibration with
the washer mounted and pretensioned is necessary.
Examples
a) Theboltusedforpretensioninghasapproximatelythe
same rigidity as the load washer (with surrounding
elements).Eachofthetwopartstakeshalfoftheex-
ternal force F. The load washer only measures 50% of
theactingforceF(Fu=0.5F)
b) Iftheloadwasher(withsurroundingelements)iscon-
siderablymoreexiblethanthebolt,onlyasmallpro-
portion of the external force is measured (Fu <<F).
This solution should be avoided if possible
c) Iftheloadwasher(withsurroundingelements)iscon-
siderablymorerigidthanthebolt(idealcase),almost
theentireforceismeasured(Fu≈F).Theexactvalue
of the force shunt is determined by the calibration