Mech 455 Supplement to Laboratory #3

Strain Gauge Installation

Adapted January 2002 from the Pop Can Lab prepared by R. Brougham and G. Mclean December 2000

Introduction:
The proper installation of a strain gauge requires a number of distinct steps. First, the surface must be properly cleaned and polished. After this, the gauge is installed and lead wires are connected. Finally, a protective coating is applied to protect the gauge. It is suggested that you practice with some practice gauges before trying to install the final gauge. This supplement will guide you through the process of installing a strain gauge onto a pop can. Although a pop can is used for illustrative purposes the procedures described are equally applicable to other gauge installations on metals. The installation of a gauge on other surfaces will require the appropriate preparation of these surfaces.

Cleaning procedure for the pop can experiment

The surface where the gauge is to be installed should be cleaned no more than 30 minutes prior to the installation of the gauge. If more time has elapsed, repeat this procedure. 1. Degrease the surface of interest with a small amount of isopropyl alcohol and a Kim Wipe. Take care not to contaminate the cleaned surfaces from this point on. 2. Apply one or two drops of M-prep Conditioner A to the cleaned area and lightly sand with 400 grit or higher emery paper to remove the paint in the gauge area. Sand carefully to prevent damage to the pop can surface. See Figure 1.

Figure 1: Surface with paint removed.

3. Use a Kim Wipe to remove any loose particles from the surface. Continue wiping until no trace of paint can be seen on the Kim Wipe. 4. Wet the exposed area with one or two drops of M-prep Conditioner A and lightly scrub the area with a Kim Wipe. Finish by using a fresh wipe and making a single stroke across the surface.

5. Wet the exposed area with one or two drops of M-prep Neutralizer 5A and lightly scrub the area with a Kim Wipe. Again finish by using a fresh wipe and making a single stroke across the cleaned surface. 6. If required, create a pencil line on the surface to enable proper alignment of the gauge.

Gauge Preparation and Installation:

Strain gauges are shipped clean and ready for installation. NEVER touch a strain gauge. Always use tweezers to handle gauges and prevent contamination of the contact surface. 1. Place the gauge and strain relief terminals bonding side down on a chemically clean surface such as a microscope slide leaving a 1/16 (1.5 mm) gap between them. See Figure 2.
Strain gauge Strain relief Slide

Figure 2: Strain gauge assembly on microscope slide.

2. Align 4 (100 mm) of M-LINE PCT-2A Cellophane tape over the length of the microscope slide and anchor one end of the tape to the slide. Make sure that the gauge is centred in the tape strip. 3. Carefully wipe the tape down over the gauge and terminals. 4. Lift the tape at a shallow angle (< 45) to lift the gauge and terminals off the slide. Be careful to not over-bend the tape and ruin the gauge. See Figure 3.

Figure 3: Removing the gauge and terminals from the slide.

5. Align the gauge in the appropriate location and anchor one side of the tape to the surface. Lightly wipe the tape down to place the gauge and confirm the alignment. Reposition the gauge as necessary. See Figure 4.

Figure 4: Strain gauge position check.

6. Lift the tape from the end opposite the strain relief terminals till the gauge and terminals are clear of the surface, fold the tape under and tack it behind the gauge. The area where the gauge is to be bonded should now be clear. See Figure 5.

Figure 5: Strain gauge assembly positioned for bonding.

7. Apply M-bond catalyst sparingly in a thin and uniform coat: a) Wipe the catalyst brush on the bottle 10 times to remove most of the catalyst. b) Brush the surface with single strokes that cover the entire length of the gauge. Do not lift the brush during a stroke. c) Allow the catalyst to dry for at least one minute. 8. Bond the gauge to the surface (This step must be done within 5 seconds if the gauge is to properly bond to the surface): a) Un-tack the end of the tape farthest from the bonding site. b) Apply a single drop of M-bond 200 Adhesive to the junction of the tape and the surface nearest the bonding site (this junction should be about (13 mm) from the bonding site). c) Rotate the tape toward the bonding site until it forms an angle of 30 to the surface. The gauge will now be directly above the intended site but not in contact with the surface. d) Use a clean gauze sponge to bond the gauge to the surface with a single wipe. Start from the terminal end of the tape and wipe towards the un-tacked end. e) Immediately apply firm thumb pressure to the tape directly over the gauge. If adhesive leaks from the sides of the tape remove the excess without releasing the pressure.

9. Maintain the thumb pressure on the gauge for at least 1 minute. The warmth of your thumb helps set the adhesive. See Figure 6.

Figure 6: Curing the adhesive using pressure from your thumb.

10. Wait two minutes to allow the adhesive to fully set. 11. Remove the tape from the gauge assembly by peeling it back carefully. The gauge assembly will now appear as shown in Figure 7.

Figure 7: Strain gauge bonded to surface.

Lead Wire Attachment:

When attaching lead wire, the most important factor is to prevent overheating of the gauge. This can melt the gauge and render it useless. 1. 2. 3. 4. Mask the strain gauge with drafting tape leaving only the solder tabs exposed. Clean the tip of the soldering iron on the wet sponge pad. Tin the soldering tip with some rosin core solder. Lay the end of the solder across the solder pad and apply the iron tip onto the solder. Apply firm pressure for no more than one second and remove both the solder and the iron simultaneously. 5. You should now have a bright even mound of solder on the pad. Repeat the above procedure until you have a nice even mound of solder on each solder pad and each strain relief terminal. 6. Strip and tin the wires. Bend the ends of the wire such that there will be a small bend between the strain relief and the gauge when the wire is soldered to the gauge. 7. Tape the wire assembly in place using the provided drafting tape. Make sure the wires are in the exact place they will be once they are installed. If you are installing a rosette or multiple gauges, labelling the wires at this point will allow you to identify them once they are soldered into place.

8. Press the soldering iron onto the wire over a pad while feeding a small amount of solder between the iron and the wire. The wire should slide into the melting solder. Allow the connection to cool thoroughly before handling. 9. Repeat for each solder tab and the strain relief terminals. 10. Remove any leftover flux from the solder with a gauze sponge soaked in rosin solvent. Use a dabbing action to prevent damage to the gauge. 11. Check the connections and their resistances. If there are any unexpected resistances or the wire are not solidly attached, re-solder the connections.

Protective Coating:
1. Apply a coating of M-Coat A over the entire gauge and terminal area.