MAE 3272 - Lecture 4 Notes - Load Cells and LabVIEW

M&AE 3272 - Lecture #4 LabVIEW Intro + Design of Load Cell
24 February 2014
M&AE 3272: Mechanical Property and Performance Laboratory

4th-8thMeasurement Load Weeks Load System: Cell Fabrication and Data Aquisition
Force
Excitation Strain Gage
Load Cell
Signal Conditioning and Processing Elastic Member
Force
Display and Analysis via LabVIEW
M&AE 3272 - Lecture 4
WSachse; 2/2014; 1
Weeks 4-8 Module 2:
M&AE 3272: Mechanical Property and Performance Laboratory
Apply mechanics and strength of materials concepts to design a force-measuring transducer Learn how to mount and use strain gages and strain gage instrumentation to produce a force-measuring system Learn how to write and use data acquisition software (i.e. LabVIEW) Test, Verify and Calibrate your force sensor (Load cell)
WSachse; 2/2014; 2
24 February 2014
Back to us and M&AE 3272:
Were going to learn how to mount strain gages onto an elastic member in order to fabricate a Load cell, or Force transducer.
WSachse; 2/2014; 3
Tasks to do THIS Week, February 24th-28th:
Continue to become familiar with strain gages;

characteristics; mounting procedures, etc.
Take a look at the Supplementary Materials on Blackboard

related to strain gages.
Learn LabVIEW. Complete the LabVIEW Assignment!
This must be uploaded to LabArchives PRIOR to when you will meet in Rhodes 106 to write your vi . in B30 Upson to learn how to mount strain gages.
Sections #405, #406, #407, #408, #410, #412 and #414 meet Sections #401, #402, #403, #404, #409, and
Rhodes 106 to write your vi . #413 go to
Design your Load Cell Todays Lecture!

M&AE 3272 - Lecture 4 WSachse; 2/2014; 4
24 February 2014
Introduction to LabVIEW:
A graphical programming environment which is

used by many in industry and academia to run experiments, collect and process data.
The computer with ancillary input and output

hardware becomes a virtual instrument or vi.
We will use it in Module 2 to collect voltage data,

corresponding to small changes in electrical resistance of strain gages attached to elastic members (load cell), while the load cell is being calibrated and or while it is in use.
We will use it in Module 3 to collect data from

multiple sensors on a dynamical system (bicycle).
LabVIEW Environment Execution Structures Graphical Programming
http://www.ni.com/academic/students/learnlabview/
24 February 2014
Running LabVIEW:
WSachse; 2/2014; 7
LabVIEW Program Example:
(by John Buzzi; 3/1/10)
Function: Generate a noisy DC-level Voltage for Simulation

Slider Input: Set Voltage Level Convert Signal Stream -> 1D Array of Scalars Mean Input of Signal.vi
Simulate Signal (Express.vi) Noise 0.6; fs: 1kHz; 100 pts
Mean
Input Values: Multiplier/Offset
Display Signal Stream via Waveform Chart Slider Level Mean Value
WSachse; 2/2014; 8
24 February 2014
Strain Gage Sensitivity:

Factional Change of Gage Resistance with Strain: R = (1 + 2 ) axial + R Dimensional
piezoresistive
The fractional change of gage resistance per unit strain Strain gage Sensitivity : R R Sgage Sgage 1
axial
Gage Factor Sgage = (1 + 2 ) +
1
axial
When 0.3 : the Gage Factor is given by 1 + 0.6 + (0.4 to 2.0) Metallic conductors 1 + 0.6 + (125 to 175) Semiconductors P type (e. g. Boron) Sgage > 0 N type (e. g. Arsenic) Sgage < 0 > 0 Rg + > 0 [T] Sgage < 0 Rg < 0 [C]
Sgage
Numerical Example : Metal foil gage, 120 ; Sgage 2.0 , then for axial = 1 (i. e. 1 106 in/in) : Rg = Sg Rg
axial
2120106
2.4104 [] = 240 []
WSachse; 2/2014; 9
Wheatstone Bridge Circuit Static Measurements:

Constant voltage (or current) excitation; Resistors R1, R2, R3 and R4 and load resistance RM . Output Voltage: E0 = R1 R3 R2 R4 Ei (R1 + R2))R3 + R4)
At balance : E0 = 0 when R1 R3 = R2 R4 Static Measurements

Constant voltage circuit
24 February 2014
Wheatstone Bridge Circuit Dynamic Measurements:

Dynamic Measurements: R1 R1 + R1; R2 R2 + R2; R3 R3 + R3 and R4 R4 + R4 then . . . E0 = R1 R2 (R1 + R2)2 R1 R2 R3 R4 + R1 R2 R3 R4 Ei + h. o. t.
The omitted higher-order-terms lead to an error given by Error : =

4 i=1
4 i=1
Ri/Ri
Ri/Ri + 2
When R1 = R4 and R2 = R3 = 0 or : R2 = R3 and R1 = R4 = 0 Error equals zero.

Common Strain Gage Wheatstone Bridge Circuits:
Dummy Gage: Temperature Compensation
WSachse; 2/2014; 12
24 February 2014
Calculation of Bridge Output Voltages:
+ - +
Matt Ulinski Notes (2008)
WSachse; 2/2014; 13
Load Cell Design (Week of March 3rd Mar 7th):

Lpadd
Gage Dimensions
Lpad Wpad Lgage Dedge
Lgage Dedge
7/16 5/16 1/16
Wpad
WSachse; 2/2014; 14
24 February 2014
Calculation of Load Cell Voltage Sensitivity:
WSachse; 2/2014; 15
Load Cell Design:

Load Cell Design Bending Beam Configuration S-Beam Load Cells S-Beam load cells get their name from their S shape. SBeam load cells can provide an output if under tension or compression. Applications include tank level, hoppers and truck scales. They provide superior side load rejection. Cost: $250-$400
24 February 2014
Commercial S-Beam Load Cells:
WSachse; 2/2014; 17
S-Beam Load Cell Mechanics Analysis:
Load Cell Diagram
Free Body Diagram
Where are you going to glue your four (4) gages?

24 February 2014
Glue gages at points of maximum stresses!

The maximum stresses (tensile: T(+), and compressive: C(-)) are expected at:
Load, P
C() #1 T(+) #2 C() #3 T(+) C() T(+) C()
Beams
Load, P
C() #1 C() #2 T(+) #3 T(+) C() C() T(+)
Beams
Load, P
T(+) #1 C() T(+) #2 C() #3 T(+) T(+) C() C()
Beams
T(+)
T(+)
(a)
Load, P
(b)
Load, P
C() #1 T(+) T(+) #2 C() #3 C() T(+) T(+) C()
Beams
Load, P
(c)
Load, P
C() #1 T(+) #2 C() #3 C() T(+) C()
Load, P
Beams
(d)
Load, P
(e)
Load, P
WSachse; 2/2014; 19
Shear/Moment Diagrams; Max Stresses/Strains

Load, P
C() #1 T(+) T(+) #2 C() #3 C() T(+) T(+) C()
Beams
Load, P
WSachse; 2/2014; 20
10
24 February 2014
Calculation of Load Cell Sensitivity:
WSachse; 2/2014; 21
Signal Collection and Processing via LabVIEW:
PC NI cDAQ-9172
LabVIEW Display
LabVIEW Software
WSachse; 2/2014; 22
11
24 February 2014
A/D Converter Specifications:

4 Channel, 25 mV/V, 24-Bit Simultaneous Bridge Module NI 9237
4 simultaneously sampled analog inputs 24 bit resolution 50 kS/s max sampling rate 25 mV/V analog inputs
WSachse; 2/2014; 23
Dynamic Range / Resolution of Load Cell:

System uses NI-9205 Analog Input Module:
A/D Converter Resolution: 24 bits = 16,777,216 voltage levels A/D Converter Input Signal Range: +/-25 mV/V Bridge excitation is 2.5 V Maximum Input Voltage: 25 mV/V2.5 V= 62.5 mV Vmax Voltage Resolution: 262.5 mV/16777216 = 7.451E-9 V PADmax = Vmax/Calib_Factor >>> System Maximum Load This will correspond to the Maximum Allowable Load if A/D Converter Controls Dynamic Range. Load Resolution: Smallest theoretically detectable Load Resolution corresponding to one level or . . . PADmin = 7.451E-9/Calib_Factor >>> System Load Resolution
12
24 February 2014
Re: Load Cell System Range and Resolution:

Load Cell Dynamic Range is likely NOT determined by Vmax of ADC System rather by < Yield/F.S. Load Cell Resolution may NOT be determined by the Voltage Resolution of the ADC but rather by other factors.
WSachse; 2/2014; 25
Load Cell: Calibration Sheet

1. 2.
3.
Due: Week of April 7th to 11th

Two weeks after you did the Calibration
4.
5.
WSachse; 2/2014; 26
13
24 February 2014
Tasks to do during the upcoming three Weeks, March 3rd March 21st:
Sections: 401-404; Sections 405-408; 409; and 413 410; 412 and 414 Mar 3rd Mar 7th Build Load Cell in Upson B-30 Finish Building Load Cell in Upson B-30 Build Load Cell in Upson B-30 Finish Building Load Cell in Upson B-30
Mar 10th - Mar 14th
Mar 17th Mar 21st
Test and Calibrate your Load Cell in Upson B-30 (see Schedule)
WSachse; 2/2014; 27
Tasks to do NEXT Week, March 3rd March 7th:
You should have familiarity with LabVIEW. Everyone meet in B30 Upson to fabricate your Load Cell. Come
prepared to show your design to your TA so that you can receive parts.
WSachse; 2/2014; 28
14

MAE 3272 - Lecture 4 Notes - Load Cells and LabVIEW

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MAE 3272 - Lecture 4 Notes - Load Cells and LabVIEW

Uploaded by

Copyright:

Available Formats

M&AE 3272 - Lecture #4 LabVIEW Intro + Design of Load Cell

M&AE 3272: Mechanical Property and Performance Laboratory

Display and Analysis via LabVIEW