Joining modules.

The new NCFE Type 2162A electromechanical joining module from Kistler, is designed specifically for applications where low joining forces between 2 and 5 kN are needed. The compact design with a centre distance of only 80 mm allows multiple arrays to be installed in minimum space. The new module is ideal for applications ranging from simple, manually controlled single unit installations to automatic multiple unit applications in a wide range of industries where precision and repeatability are essential.

Unlike pneumatic and hydraulic systems, the Kistler NCFE joining modules are simple to install and can be relocated easily when needed. Total cost of ownership is exceptionally low due to low maintenance and energy consumption leading to rapid cost recovery, often in only a few months.

Installation may be vertical or horizontal using flange mounting or the optional mounting rail adapter for 35 mm cap rail and tapped holes for tool mounting are provided on the plunger. A strain gauge force sensor is integrated into the housing with a side mounted, electronically commutated AC servodrive drive motor with an absolute encoder for the exact positioning. Standard functions such as block pressing, position pressing and force feedback controlled pressing as well as intermediate positioning are supported.

The lower measuring range and compact design enables plant engineers to implement simple but cost-sensitive processes with maximum efficiency. As with all joining modules in the NC series, the NCFE Type 2162A includes an interface for the Kistler maXYmos NC monitoring system making integration into the process environment simply and straightforward.

#Kistler #Pauto 

Brake test problems?

Having problems with your brake test sensors???

All wheeled vehicles rely on brakes to safely stop or slow down when the way ahead is blocked or compromised but none are more reliant on the brakes than vehicles that run on rails; trains and trams. With no option to change direction to avoid danger, vehicles on rails are totally reliant on an efficient braking system.

Kistler’s new, brake force measuring system enables simple and reliable verification of the locomotive and carriage braking system whilst stationary, both in the depot and on the track. The system uses a combination of robust and precise piezoelectric force sensors for brake shoe and disc brakes, signal conditioning, data acquisition and analysis to verify the operation of mechanical and pneumatic brake systems by simultaneously measuring both brake force and air pressure.

The mechanical adaptation meets the specification of UIC and the robust sensors are built to withstand the harsh conditions encountered in the railway environment. All the components are housed in a rugged, custom designed case with battery power for convenient use at base and in the field.

The user-friendly, data acquisition system is pre-configured to transmit the measured data by the built in WiFi connection to a laptop running the supplied dedicated railway brake force analysis and reporting software.

Detection of wear and damage to the pneumatic and mechanical parts of the brake system are monitored and recorded. This data enables engineering and maintenance personnel to extend the maintenance cycle of the brake system and confidently ensure safety and security.

#Kistler #Automotive #Testing 

High and low operating temp. accelerometers

Two new low profile, voltage mode, triaxial accelerometers from Kistler are now available with extended operating temperature ranges; up to +165°C for high temperature and down to –195°C for cryogenic applications both with a measuring range of ±500g.

The three Kistler K-Shear sensitive quartz elements in an IP68 hermetically sealed stainless steel housing, combine long term stability with wide operating frequency range and extremely low sensitivity to thermal transients and transverse acceleration. The charge signals from the three sensing elements are converted internally to low impedance voltage by a Piezotron microelectronic converter.

Because of its low mass of 11g and small size of 15.8mm square by 9.7mm high, the new sensors are especially useful for measuring on small and lightweight structures, where mass loading must be kept at a minimum. It can also be used for drop tests and finds application in a wide variety of vehicle vibration studies, modal analysis, product development and aerospace testing.

The new extended range triax accelerometers are especially suited to demanding applications encountered in the military and aerospace sectors where any error may present a life-threatening situation. Flutter testing, rocket launch pad dynamics, aircraft EMA, ammunition investigations and helicopter rotor reactions are a just few of the applications demanding the capabilities of the new products.

#Kistler #Pauto 

MedTech friction problem solved.

When a dental laboratory commissioned special-purpose machinery manufacturer, Jonas & Redmann, to design and build a highly automated production cell capable of producing and testing five million mixing nozzles per year the company’s 30 years mechanical engineering experience was well up to the task but the short cycle time of 1.5 seconds was a problem when it came to the essential 100% final testing.

The mixing nozzles, used to produce the casting compounds used by dentists, are made of four separate parts and are assembled in the production cell and, like many MedTech products, are disposable, use once items. Final testing, a mission critical part of the production process, had to be based on a friction coefficient test (< 0.5 Nm) on the mixing mechanism of the assembled nozzle. Having worked successfully with Kistler on other projects, Jonas & Redmann looked to the sensor company for a solution.

The solution Kistler proposed used a combination of a type 4502A torque sensor and the maXYmos BL evaluation system to check the torque curve for each individual product. The measurement value produced by the torque sensor is used to generate an OK/NOK signal transmitted directly to the control system so that any product with an out of spec torque curve is automatically rejected. This 100% testing ensures that only perfect products are delivered by the production cell.

One important factor in the successful outcome was the close collaboration of Kistler and the consulting engineers who were executing the project. The two teams quickly devised a test rig to verify the solution which, at the first attempt, confirmed that the transducer produced values for frictional torque that were within the tolerances allowed by the system specifications.

#Kistler #Medical #Automation

Process monitoring for medical apps.

Increased interest from the MedTech sector since the introduction in late 2020 of the new medical compliant versions of Kistler’s ComoNeo cavity pressure monitoring and maXYmos manufacturing process monitoring systems make Stand G26 at Interplas 2021 the ideal opportunity to show the new products to the British plastics industry.

Kistler MaXYmos Med version

ComoNeo 4.1 has several new features needed to comply with the medical market requirements including LDAP Windows authentication and extra logging to store all device changes. The ComoNeoPREDICT, a DoE model based system uses AI and supervised machine learning algorithms based on neural networks to predict the characteristics of injection-moulded parts.

As more injection moulders are providing assembly services to their MedTech customers, the validation of the manufacturing process becomes essential. The Kistler MaXYmos ML, the first process monitoring system to meet the strict FDA and the new European Medical Device Regulations (MDR) for quality assurance in the MedTech sector, simplifies the validation process by delivering 100% confirmation that each step in the manufacturing process has been carried out within the product specification.

The unique combination of Kistler’s ComoNeo 4.1 and MaXYmos ML ensure conformity with both FDA and European MDR whilst delivering higher productivity, zero rejects and accurate costings.

@InterplasUK  #Kistler, #Medical

Compact NCFT joining module.

Kistler has developed a new version of its well proven NCFT joining module in response to customer demand. The stroke length is increased from 100mm to 250 mm whilst reducing the overall length of the unit from 548mm to 482mm. This has been achieved by moving the drive motor from the end of the module to the side. In all other regards, the new compact version retains all of the capability of the original, straight version. 

Both types consist of a robust housing with an integral piezoelectric tension/compression force sensor and an absolute encoder integrated in the drive motor for precise positioning.

The compact mechanism, integral piezoelectric force monitoring in the spindle and two predefined measuring ranges from 0.05 kN to 1.5 kN make both the straight and angular modules ideal for use in assembly and joining processes monitored by force-vs-displacement. The new version delivers complex drive profiles with a maximum speed of 400 mm/s and displacement repeatability of better than 0.01 mm combined with easy selection of the ideal measuring range, high overload factor and modest user spare parts inventory.

Both NCFT Type 2157B servo press modules provide ultra-high precision measurement of extremely small forces directly on the tool holder under actual process conditions, without the need to mount a sensor on the spindle. This eliminates any possibility of the measurement signal being impaired by dynamic characteristics of masses or moving cables. Both versions meet the stringent, cleanroom production environment requirements defined by ISO 14644-1 Class 8 as standard and Class 7 conditions can be met with only minor modification. In addition to medical technology product testing and production, the joining modules are ideally suited to any precision manufacturing applications such as watch and micro-motor assembly as well as automatic production systems and manual work stations.

Needing only an electrical supply and the wireless data connection, make the Kistler NC joining modules easy to install, vertically or horizontally. Compared with pneumatic and hydraulic actuators, the NC joining modules are exceptionally cost-effective for a wide range of applications, in addition to being environmentally friendly.

#Kistler #PAuto 

Combustion engine development.

Since Kistler launched its KiBox in 2009, it has become a market leading measurement system for combustion engine development. Kistler is now launching the next generation, KiBox2, a new and completely redesigned version featuring the latest advances in connectivity, usability and software with the capability to meet the needs of powertrain analysis of internal combustion, electric and hybrid power units. Designed as a modular, extendable platform, KiBox2 opens the way for development engineers to attain unprecedented levels of efficiency in powertrain optimization.

In vehicle powertrain measurement

Automotive design is undergoing a radical transformation: electric and fuel-cell vehicles are gaining ground on global markets but internal combustion engines will continue to play a key part, with plenty of scope for ongoing optimization. To meet the challenges of this new era in the evolution of the automobile, development engineers need measurement technology that is flexible and easy to use. Kistler's response: the all-new KiBox2, a comprehensive powertrain diagnostics system for engine development. Based on an innovative open architecture, the new KiBox2 is a complete solution for electric as well as non-electric powertrains which will help users minimize time to market putting them one step ahead of the competition:

• Versatile in-vehicle and test bench testing, irrespective of electrification level • Verified real-time performance for both closed-loop and in-cycle engine control • State-of-the-art user interface with active user guidance • Maximum connectivity including WLAN, hotspot capability and GPS • Full backward compatibility with the original KiBox • Extendable with software upgrades • Future-proof system architecture based on flexible hardware and software modules

New modular system architecture featuring state-of-the-art technologies

Full connectivity & Usibility

Modularity is a key advantage of the KiBox2, with both hardware and software designed according to the modular principle. The new solution from Kistler also includes the KiBox Cockpit software: an open ecosystem for parametrization, visualization and analysis that ensures seamless connection to third-party devices. The advanced data management functions, included as standard, ensure that the testing efficiency is optimised. The user experience is now enhanced by active-intuitive guidance with voice control and audio feedback to guarantee safe and efficient operation while driving. The list of new benefits include: improved signal conditioning for the crank angle sensor, bidirectional CAN-FD interface and cascading of up to four KiBox2 units.

The key to maximum efficiency in engine development
By integrating measurement and analysis capability for both electric and combustion-based powertrains in the KiBox2, Kistler has developed one of the most versatile and comprehensive powertrain diagnostics systems available on today's market. Outstanding usability, advanced data management features and modular expandability make this solution even more attractive.

An added benefit is that users can enhance their engine development capabilities by using metrics for electric machine efficiency characterization, as well as in-cylinder pressure metrics for “normal” and “abnormal” combustion, including new synthetic fuels. The new KiBox2 is a paradigm shift for propulsion system measurement, providing a complete, highly efficient powertrain diagnostic and optimization solution.

#Kistler #Automotive #Powertrain

Managing the entire measuring chain.

The simple, user-friendly operation and clear representation of the entire measuring chain by KiStudio helps acquire and analyse data quickly and reliably using extensive visualization tools.

KiStudio Lab software package offers an intuitive way of setting up and executing a measurement quickly and easily. Together with the powerful analysis software jBEAM, the user gets a comprehensive package for many test & measurement tasks.

KiStudio Lab is compatible with the Kistler LabAmp 5165A and 5167A. These universal laboratory charge amplifiers provide signal conditioning and data acquisition for the measurement of force, acceleration, pressure, reaction torque or strain using piezoelectric sensors.

jBEAM is a comprehensive post-processing software with extensive analysis functions and the capability of visualization and report generation. jBEAM Basic, included in the starter pack, is sufficient for many basic applications but where more options are needed the Professional version supports the import of multiple measurement file formats common in R&D and testing labs as well as multimedia formats to combine measurement data with images, audio and videos. The extensive analysis functions include arithmetic operations, curve analysis and FFT calculations up to matrix operations, signal filters and statistics. The comprehensive visualization functions allow the inclusion of simple text elements, forms and tables plus multiple types of 2D and 3D graphs. This ensures there is always a suitable format to display measurement data. In addition, the control elements allow the creation of interactive visualizations and reports.

Raw data, centrally stored easily and securely, can be exported and analysed offline in a wide range of formats. If additional measurements are needed at any time in the future, the stored measurement chain set-up may be downloaded and installed enabling further data to be acquired almost instantly. No need to reinvent the wheel!!

The simple, user-friendly operation and clear representation of the entire measuring chain by KiStudio Lab helps acquire and analyse data quickly and reliably using extensive visualization tools. The capability to create reports automatically in a wide range of standard file formats not only saves time but also minimises the risk of errors.

The intuitive software will run on any Windows 10 PC or laptop. The user interface has been developed and designed according to the latest usability criteria, ensuring that it can be intuitively and efficiently operated by both occasional users and experienced measurement technicians and engineers.

#Kistler #PAuto #TandM

Bespoke signal conditioning service.

Where can you go when you need a custom signal conditioning solution? No doubt that there a few specialists that can build the system you need but they will be using components from different suppliers which might cause problems if a fault develops. 

The bespoke design and build service from Kistler uses in-house components and, when necessary, components from trusted suppliers. It is important to realise that Kistler takes responsibility for all the components, not just those with their own brand; if any component fails, Kistler will fix it.

One project recently completed was for a portable test system that can measure 160 channels. This required two portable, shock-absorbent and water-resistant racks each with twenty 8 channel charge amps, a 24 port Ethernet switch with time synchronization, shielded Ethernet cables and a DC power supply. To keep the temperature in the racks within the maximum 60°C operating temperature in an ambient of 21°C, active fan cooling was also required. Add to this, a high spec, custom build computer running specialised software was needed to control both racks.

Not every application will require 160 channels although some may demand even more. The bespoke signal conditioning system service from Kistler delivers exactly what is needed for any application, no more and no less, and with a guarantee that the rig will fully meet the detailed specification.

#Kistler #PAuto #TandM

Data analysis, visualization and report generation.

There is little doubt that the automotive industry leads the world in innovation. Crash tests, road tests, NVH analyses and engine test benches are all applications that create large amounts of data. The Kistler jBEAM software is designed specifically to provide an efficient and easy to use system for the analysis, visualization and report generation of large amounts of data. The jBEAM stand-alone, platform independent, multilingual system delivers better and faster analysis of the data and easy to interpret presentation using extensive visualization tools.

The Kistler JBEAM solution presents a highly flexible system that can be configured to precisely meet the demands of diverse applications. Intelligent data analysis recognizes patterns and identifies relationships with data evaluation tailored to specific measurement needs. System flexibility allows the creation of individual user interfaces and reports with scaling to maintain computing capacities in line with demand and requirements. Networking delivers globally managed measurement data whilst the special MDFS file system guarantees data integrity.

Kistler is well known for manufacturing precision sensors but delivering measurement data with the highest accuracy is only part of the story; data analysis of the same quality is essential to make the data useful. Whatever the reason for data collection, jBEAM interactively analyses the data quickly and efficiently and saves time by automatically creating reports in a wide range of standard file formats.

A complete system from day one but over time, as new features are implemented in response to user feedback and application requirements, jBEAM will evolve to meet the developing needs of the automobile industry.

#Kistler #Automotive #TandM

Capturing very small forces.

The trend toward miniaturization is unstoppable. Medtech devices, semiconductors, electrical components and automotive parts: in almost every industry, products must now combine increasingly compact dimensions with higher performance. And that poses major challenges for manufacturers and suppliers, who have to achieve maximum accuracy when processing these high-precision lightweight parts.

A new, highly sensitive piezoelectric crystal developed by Kistler guarantees extremely precise measuring results. Used in a new Type 9323 press force sensor which is ideal for measuring very small forces in challenging industrial environments and is an excellent solution for calibrating force sensors installed in production machinery.

With a sensitivity of -32 pC/N, the new sensor can accurately measure forces of less than 5 N. The high-precision measuring range of the unique Kistler Type 9323AAA miniature press force sensor cannot be matched by any other commercially available sensor in the world making it the solution of choice for measuring very small forces.

To achieve this Kistler had to develop and grow a new crystal at its Winterthur headquarters, and they are installed in the tried-and-tested sensor cases of the 9323 product family which gives the new sensor many of the same benefits as the established models, including proven insensitivity to lateral load and bending moment influences. 

The new miniature sensor is ideal for use in highly dynamic production processes where high accuracy is absolutely essential.

#Kistler #Medical #PAuto 

First charge amplifier with IO-Link.

A new flexible, miniature charge amplifier with IO-Link, a world first from Kistler, complies with industrial communications networking standard (IEC 61131-9) and combines analogue and digital communication technology to pave the way for Industry 4.0. The new charge amp is ideal for applications over a wide range of industry sectors, including robotics, packaging, food and beverage, as well as OEM’s. Its small size L 38mm x W 25mm x H 31.4mm including the output connections and its low weight of only 30g means that the amplifier can be installed where space is at a premium, such as robotic heads and other moving parts.

The 5028A charge amplifier is the first of its type to use IO-Link technology where analogue output signals from piezoelectric sensors sends digital communications data. The new amp delivers digital data that is resistant to interference from disturbance variables and end-to-end communication all the way through to sensor level. IO-Link technology opens the way to highly reliable, predictive maintenance allowing maintenance tasks to be initiated automatically when data is regularly outside a setpoint range. 

When the IO-Link component is replaced, the new parameters are transferred automatically.

By incorporating a digital interface into the 5028A charge amplifier, Kistler is taking another step towards the fully networked factory in keeping with the goals of Industry 4.0. Users receive reliable data for immediate process evaluation as the raw analogue signal is digitized in the amplifier. The disturbance variables that occur in conventional analogue systems due to inductive or capacitive couplings are avoided and the need for complex and costly individual cabling for analogue and control signals is eliminated. The charge amp is equally suitable for use as an analogue charge amplifier with reset/operate input, it delivers proven performance for controlling fast processes with low latency and jitter. The 5028A charge amplifier is the world's first amplifier for measurement data from piezoelectric sensors with communication based on IO-Link. This device will fit easily into almost any industrial application that calls for small, lightweight components and simple solutions.

As well as its extended functional scope, the 5028A charge amplifier offers customers another decisive benefit;: the interfaces with the upstream sensor as well as the customer's downstream system are compliant with industrial standards. This means that the charge amplifier can be integrated into any existing network that supports IO-Link. This advantage guarantees easy, cost-efficient installation – and users can be sure that data is transmitted reliably and securely. Kistler is thus taking another step towards the harmonization of proprietary connector types according to commonly used standards making the products easier to use. Even on the smallest of Kistler's amplifiers, customers themselves can now adjust the settings in line with their own requirements. This innovation is Kistler's response to an industry-wide trend for more flexible use of components in different systems.

Much valuable space can be saved thanks to the compact dimensions of the 5028A charge amplifier, which can easily be positioned on robot heads or other moving parts. The new device can be used generally in mechanical engineering applications and is also suitable for sectors such as medical technology, because it allows verification of changes to settings at any time. This product's favorable cost-to-benefit ratio underscores the economic advantages of IO-Link technology – an aspect that is also highlighted by the IO-Link Consortium.

#Kestler #PAuto 

Vibrations at very high temperatures.

A new single axis accelerometer for vibration monitoring from Kistler delivers reliable results at temperatures up to 700 degrees Celsius over the long term and up to 1000 degrees for short periods of time. The 8211A sensor is certified to ATEX and IECEX for use in explosion protection making it suitable not only for monitoring purposes, but also for use under extreme conditions in a wide variety of applications.

The 8211A sensor is suitable for many applications with extremely high ambient temperatures, such as testing rocket engines. 

Measuring vibrations inside the combustion chambers of gas turbines, rocket or aircraft engines ambient temperatures are often in the high three-digit range. Under extreme conditions, these measurements must provide exact data as the basis for further developments, for example on instabilities in the combustion process. However, only a few sensors are able to withstand the extreme heat and temperature fluctuations and still deliver reliable measurement data. The new 8211A sensor from Kistler has been designed specifically for such conditions in order to measure vibrations in various extreme industrial environments.

The sensor owes its heat resistance primarily to the PiezoStar crystal at the heart of the accelerometer, which is especially suitable for these applications. Kistler grow the artificial crystal in its own laboratories to eliminate quality fluctuations and supply bottlenecks which are common with natural materials such as tourmaline. Kistler’s artificial crystal is produced to a consistent quality standard and is not subject to variable availability. The robust hardline cable used with the sensor is insulated with magnesium oxide and is equally resistant to heat:
Enduring temperatures of up to 1000 degrees Celsius is not a problem for the new sensor or cable.

The core technology of the 8211A accelerometer is based on the piezoelectric effect: the accelerometer generates an electrical charge that is proportional to the acceleration. In combination with a differential charge amplifier this provides a complete and stable differential measurement chain that is not influenced by environmental factors such as electromagnetic interference.

#Kistler #PAuto

Quality assurance for medical device manufacturers.

The maXYmos TL ML, from Kistler, is the first process monitoring system to meet the strict FDA and MDR regulatory requirements for quality assurance in the medtech sector. The new monitoring system can deliver 100 per cent testing; a critical requirement for manufacturers operating in environments where pharmaceutical goods and medtech equipment are produced.

The new maXYmos TL ML, based on the tried-and-tested maXYmos system, can be easily qualified and validated for integration into existing quality management systems.

Process monitoring systems play an increasingly important part in quality assurance on automated production lines. Medical device manufacturers must demonstrate that their products meet the requirements for safety and quality and provide proof of the reliability and precision of quality assurance monitoring not only throughout their own manufacturing process but also that of their suppliers.

In extreme cases, inadequate quality assurance, during the production of medical devices, can cause injury or even loss of life. Companies that place medical devices on the market are fully liable in the event that their products fail to function accurately and consistently. This is partly why the industry is subject to such strict regulation. Producers of medical devices as well as plant and machinery manufacturers operating in the medtech and pharmaceutical sectors are confronted with huge challenges, especially when it comes to integrating process monitoring systems into automated production and packing processes.


Kistler has developed this new solution on the basis of its maXYmos TL (Top Level) well proven system. Like all the systems in the maXYmos family, maXYmos TL visualizes process profiles and offers an extensive range of interfaces for connecting sensors. The system is integrated directly into the production line to monitor and evaluate the quality of every step in the manufacturing process on the basis of a curve. With the help of evaluation objects (EOs), users can adapt the curve evaluation to the specific monitoring task. For instance, the tolerances defined in the process validation can be used for this purpose. Based on this specification, the system then decides whether each workpiece is good or bad.

The functions integrated in maXYmos TL ML comply with the regulatory requirements for applications in the medtech industry. The system hardware also meets the specific requirements for measurement equipment that apply in the medtech industry, including:

• Designed to accommodate exceptionally small measuring ranges (force-displacement monitoring, torque sensor technology) • Integrated user management compliant with FDA regulatory requirements • Audit trail of all changes to testing processes, with time and user indexing for end-to-end traceability of each individual product • Optional blocking of ports for secure integration into the customer's data structure • Direct printer connection so that test records can be documented as hard copies

The new maXYmos TL ML process monitoring system from Kistler gives producers of medical devices, as well as machinery and plant manufacturers operating in the medtech and pharmaceutical sectors, a much easier solution to the validation of their production processes. With 100 percent inspection of each step in the manufacturing process, the need for mandatory process validation in production can be completely eliminated.

Qualification of the production equipment is the first requirement for proof of the system's safety. For this purpose, Kistler supplies ready-to-use checklists for Installation Qualification (IQ) and Operational Qualification (OQ). An in-plant calibration can then be performed to validate the measurement system at any time – a service that Kistler offers for its customers throughout the world. This also makes requalification of assembly plants much simpler, because the entire measuring chain is calibrated. The key benefit to manufacturers is that they can bring their product developments and innovations to market much more quickly giving them the competitive edge that is such a critical factor in this industry.

The maXYmos TL ML system supports OPC UA, so that it can be easily connected to machine controls and communicate with higher-level control and management systems.

#Kistler #Medical 

Injection moulding process control.

ComoNeo, Kistler’s cavity pressure monitoring and control system, has now been made even more effective with the integration of ComoNeoPREDICT, a DoE (Design of Experiments) model based system that enables injection moulders to achieve zero defect production. The entire injection moulding process can be sustainably optimised to eliminate scrap and pseudo scrap to enhance plant productivity.

With ComoNeoPREDICT, machine settings can now be improved to the point where quality, cycle time and process reliability are all optimised. Based on the cavity pressure curve, it generates reliable statements about each manufactured part in advance.

The quality predictions are based on DoE models that calculate the characteristics of each injection-moulded part. This cutting-edge technology makes use of supervised machine learning algorithms based on neural networks. The first step is to generate a statistical test plan (DoE) which is worked through with ComoNeo on the machine. ComoNeoPREDICT then uses the parameters obtained (such as pressure and temperature curves) and the measured quality characteristics of the part to create a prediction model that serves as a reference for subsequent production runs. If a part is outside of the defined tolerance band limits, it can be separated out automatically. Custom PC software is provided to generate the DoE and the prediction model.

ComoNeoPREDICT adds a range of practical benefits to the ComoNeo system including:

• Accurate scrap separation method from complete quality records • Users acquire know-how from direct monitoring of predicted quality characteristics • Pseudoscrap is minimized • Tolerances and scrap criteria are easily defined • Relevant curve points for calculation are selected automatically • No special knowledge of maths or statistics is needed to operate the software • Ongoing training of models results in continuous improvement • Significant reduction of manual measuring operations in production.

This standardised and documented procedure means that tests and model calculations can be performed regardless of who is operating the system. The transparency of the method gives users a detailed understanding of the whole process. Injection moulders producing precision components for medical technology and other critical high-calibre sectors will value the capability of ComoPREDICT to deliver extensive control of all quality parameters of the moulding process.

 #PAuto #Kistler 

Cavity pressure sensors.

Two new cavity pressure sensors from Kistler have front end diameters of only 1mm, the world’s smallest, and 2.5 mm both of which can be machined up to 0.5 mm to be made flush with the cavity wall contour virtually eliminating any marking of the moulding. Both sizes come with UniSens® uniform sensitivity to simplify installation, option of Titanium Carbo-Nitride (TiCN) coating for use with abrasive media and 2,000 bar pressure range.

The availability of Titanium Carbo-Nitride coating, rather than hard chromium, provides optimum protection against wear, ensuring longer lifetimes. The coating delivers two decisive advantages: exceptional hardness against abrasion, and resistance to corrosion by the action of chemicals making the new sensors ideal for use with glass fiber-reinforced plastics and flame-retardant materials. The front end of the coated versions cannot be machined as this would remove the protective coating. Where front end machining is essential to match the curve of the cavity the uncoated version must be specified.

Both versions have uniform sensitivity to ensure maximum deviation of ± 3% of the nominal sensitivity (2.25 pC/bar). This simplifies installation and interchangeability of sensors, as the nominal sensitivity can be used. All versions with replaceable cable are IP67 protected. Several mounting styles and cable types deliver easy and flexible integration, especially in multi cavity moulds.

The uniform sensitivity provides excellent precision which eliminates the need for sensor detection in the system. The sensitivity of these sensors remains consistently high, so users no longer have to enter values from each sensor data sheet. This also means that replacing the sensors is very straightforward and far easier to handle, especially when multi-cavity moulds are involved. Very tight tolerance ranges and ease of handling will obviously be key advantages for manufacturers of complex high-precision parts, such as high density connectors, automotive components and medical equipment.

The new, direct measuring pressure sensors deliver simple installation due to Unisens® combined with long life in challenging applications and the virtual elimination of marking on surface of the moulding. Used in combination with the Kistler ComoNeo cavity pressure monitoring system, the new sensors add another element in the search for zero rejects in the injection moulding industry.

#Kistler #PAuto 

No rejections!

Zero rejects, the “Holy Grail” of the injection moulding industry, has always been looked upon as an impossible dream. Or, at least, it was until now!

Waldon Ltd, an injection moulder located in the Welsh valleys, began working towards achieving zero rejects when it installed its first Kistler Como Injection cavity pressure monitoring system in 2009 which reduced an internal reject rate of 5% to less than 1%. Since then the company has taken advantage of every Como upgrade as they became available.

The latest addition is ComoNeo with MultiFlow, the next link in the automatic control of the whole moulding process; fully automatic hot runner balancing in real time.

Hot-runner balancing with MultiFlow completely eliminates the need for time-consuming manual optimisation and adjustment of the hot-runner temperatures during set-up and production. The system compensates in real time for variations in the operating environment, such as temperature fluctuations caused by external doors being opened or changes in the external air temperature and humidity, which can increase reject rate, especially at the tight tolerances adopted by Waldon.

The operational benefits of achieving “genuine zero rejects” are considerable. From a business point of view, foremost is the ability to accurately quote for new business by eliminating the need to include a contingency allowance to cover the cost of rejects. This delivers a confidence that the costing is both accurate and achievable resulting in highly competitive pricing even for the most complex mouldings. Add to this a return on investment of around six months it’s no surprise that Waldon is now equipping all new moulds to take advantage of the ComoNeo automatic control of the moulding process.

#Manufacturing #Kistler

Noise, vibration and harshness.

Kistler has launched KiNOVA, a noise, vibration and harshness (NVH) data acquisition and analysis system. The new system provides a consistent level of precision throughout the measuring chain from sensor to analysis; a fully integrated and supported capability which extends from a wide range of sensors and powerful data acquisition hardware and sophisticated analysis software to on-site engineering support.

As legislation pushes for more efficient and environment friendly transportation and customer expectations regarding comfort increase, recent automotive developments has focused strongly on new and more efficient propulsion systems; hybrid and electric motors. The challenge for vehicle and powertrain manufacturers is not only to measure NVH with high accuracy, but also to analyse and interpret data in the most efficient way. To support this approach, the Kistler KiNOVA has been designed specifically to assist NVH engineers in the key phases of powertrain development and refinement no matter if it is a conventional, hybrid or electrical propulsion system.

Starting from the sensor, KiNOVA covers the complete workflow seamlessly - through measuring and analysing by means of the advanced application specific software: Using powerful and convenient application modules, the user can perform specific NVH testing on the powertrain. KiNOVA is compatible with a wide range of Kistler sensors and accelerometers and other third party sensors with IEPE / Voltage signals.

KiNOVA comes in two formats:
KiNOVA Lite Ultra-portable, pocket-size and light-weight with 4 channels of voltage or IEPE inputs and analog inputs configurable for dynamic analysis or tachometer. Remarkable precision and signal conditioning with 24-bit resolution and 100 kHz sampling frequency combined with USB control and power. KiNOVA Capture software package provides data acquisition and signal processing tools comes as standard.The light-weight and USB-powered format makes KiNOVA Lite an ultra-portable device that does not compromise on accurate signal acquisition and processing and
KiNOVA Pro A rugged and solid stackable unit with16 channels of Voltage or IEPE inputs that can be expanded to 32 channels per unit with 24-bit resolution, 100 kHz sampling frequency plus 2 dedicated tachometer channels. USB and Ethernet communications, a programmable standalone function, built-in solid state storage and internal battery deliver a flexible and powerful capability. The standard KiNOVA Acquisition software package provides comprehensive data acquisition and signal processing tools.

Whether it’s conventional, hybrid or pure electric propulsion systems, KiNOVA can make a major contribution in the NVH area by supporting the development of advanced propulsion systems that not only meet legislative regulations but also provide the right sound and comfort experience.

The combination of the new KiNOVA data acquisition and analysis system and Kistler sensors delivers a powerful, new tool for engineers tasked with minimising unexpected noise and vibration under real world driving conditions.

#PAuto #Kistler

Force sensing.

The new piezoelectric 6-component force/moment link, Type 9306A, from Kistler Instruments is equally suited to measuring the forces acting on electric hand tools, rocket engine test benches or robotics.

Force-Moment sensor in wind tunnel

This new sensor delivers precise and direct measurements of three forces and three moments without calculation at very high resolution even under the most demanding operating conditions. The use of large-area quartz discs make for a very rigid sensor with a high natural frequency of 18kHz and low crosstalk of better than ±3.5% for highly dynamic force and moment measurements, especially when very small moments and forces are being measured.

The Type 6306A sensor is 90mm high, 62mm diameter and weighs 1.5kg. Where space is at a premium, the compact Type 9306A31 which is only 45mm high, 83mm diameter and weighs only 540g may be specified

Typical applications include: Robot/Human interaction Wind tunnels Aerospace Medical

The Kistler LabAmp 5167A multi-channel quasistatic and dynamic charge amplifier with analog output and integrated data acquisition provides an ideal signal conditioning capability with the ability to adjust the moment and force measuring ranges independently for each axis. The scalable and configurable high performance system provides channel synchronization, signal filtering, virtual channels and evaluation of individual force signals whilst the integrated data acquisition simplifies the measuring chain and provides added flexibility.

#PAuto #Aeronautics #Robotics #Kistler

Complex powertrain analysis.

The automotive industry is moving fast into an era where electric power is used as the primary power source with hydrocarbon fuels in a supporting role. The use of the “Plug-in Hybrid” concept presents challenges to powertrain designers that demand new technologies to define the parameters of the propulsion systems. Optimising vehicle emissions and fuel efficiency are the main goals without compromising performance and drivability.

The University of Bath and Kistler have co-operated on a project to define how technology can be used to provide an objective and repeatable analysis.

The challenge was to be able to characterize the whole vehicle powertrain performance, such that laboratory conditions and on-road conditions could be accurately matched in real-time. For this, accurate analysis of powertrain inputs, outputs and responses are required, including torque and energy flows for the whole system.

Extensive instrumentation was installed on the BMW i8 test vehicle which is being used by the University as part of a government funded project for defining future vehicle development processes, combining collaborative vehicle modelling with over-the-air, real-time data distribution. The instrumentation included a KiBox (for engine performance metrics and torque), Kistler wheel torque sensors (propulsion torque and braking forces) and instrumented drive-shafts (torque distribution and recuperation).

From the data recorded in real-time and then post-processed, the vehicle propulsion system could be analysed with some surprising observations. In particular, strategies for good tip-in response, involving mechanical energy storage within the powertrain mechanics (via shaft wind-up) could be identified.

Future cooperation between Kistler and the University is planned, and this advanced testing methodology will be increasingly important with the opening of the University’s new £70m Institute for Advanced Automotive Propulsion Systems (IAAPS) in 2021.

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See also: 
• Speeding formula students. (22/2/2017)
• Compact pressure & Temp sensors for Formula Student. (18/8/2017)

#Kistler #Automotive @UniofBath