M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

M&AE 3272: Mechanical Property and Performance Laboratory

Weeks 4-8:Module 2:
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)

M&AE 3272 - Lecture 5

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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)

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Load Cell Design:

Materials set 2: Materials set 3: Materials set 4:

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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
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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Commercial S-Beam Load Cells:

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Measurement of Loads/Forces, Static and Dynamic:

OMEGA's DLC101 dynamic load cell is ideal for measuring force transients or dynamic force pulsations in impact or vibration applications. This load cell contains a thin piezoelectric crystal that generates an analog voltage signal in response to an applied dynamic force. The DLC101 has 2 threaded ends, enabling installation of threaded members such as mounting studs, impact caps, and machine elements. Its welded construction encloses and protects the crystals from the environment. SPECIFICATIONS Excitation: 2 mA nominal @ 18 to 30 Vdc, constant current Rated Output: 5V nominal FS Amplitude Linearity: 1% FS (BSFL/0) Resonant Frequency (@ No Load): 75 kHz High Frequency Range: 25 kHz (approx. 1/3 of resonant frequency, no load) Low Frequency Range (-3 dB): 0.08 Hz Stiffness: 11.4 lb/min Overload Recovery: 10 ms for 2x range Maximum Shock/Vibration: 10,000/5000 g (no load) Temperature Range: -75 to 120 C (-100 to 250 F) Temperature Sensitivity Effect: 0.03% FSPF Output Impedance: 100 Bias Voltage: 10V nominal Weight: 43 g (1.5 oz) nominal
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Omega: $ 420.00 DLC101-10 For High Frequency Tension/Compression Force Measurements Ideal for Measuring Impact or Pulsating Forces Frequency Range up to 25 kHz Force Ranges up to 5000 lb Calibration Certificate Supplied Stainless Steel Impact Cap and Mounting Stud Provided
M&AE 3272 - Lecture 5

M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Dynamic Force Sensor - Modeling:

Second-order Mechanical System:
d 2 s (t ) ds (t ) 2 + 2n + n s (t ) = F (t ) 2 dt dt

Natural frequency:
n =
k 1 [rad/s] ; fn = 2 m
k [Hz] m

Damping ratio:

c c = cc 2 km
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M&AE 3272 - Lecture 5

Dynamic Force Sensor Modeling Results:

Time response to step loading:

Magnitude

Phase

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M&AE 3272 - Lecture #5 Load Cell Background and Design

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Measurement of Dynamic Forces:

How can you verify that it works? T-Scan System: Permits time-dependent forces as a function of position over a piezo-resistive sensor array

W FB+T

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Measurement of Occlusal Forces in Teeth:

Sensor Array (2K Sensor elements) T-Scan III Occlusal Analysis System

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Load Cell Design (Week of Feb 25th Mar 1st):

Lpadd

Gage Dimensions
Lpad Wpad Lgage Dedge
Lgage Dedge

7/16 5/16 1/16

W pad

2.5 Volts DC
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S-Beam Load Cell Mechanics Analysis:

Load Cell Diagram

Free Body Diagram

Where are you going to glue your four (4) gages?

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Shear/Moment Diagrams; Max Stresses/Strains

Load, P
C() #1 T(+) T(+) #2 C() #3 C() T(+) T(+) C()
Beams

Load, P

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Load Cell Hook-up and Output:

Load, P
C() #1 T(+) T(+) #2 C() #3 C() T(+) T(+) C()
Beams

Load, P

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Calculation of Bridge Output Voltages:

+ - +

Matt Ulinski Notes (2008)

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Calculation of Load Cell Sensitivity:

7.20

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Wheatstone Bridge Output per Load:

7.20

7.20
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Expected Calibration Measurement Result:

Measured Output Voltage [V]
Non-linear regime

= Sensitivity [V/lb] = Zero

Applied Load [lbs]

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Actual Calibration Measurement Result:

Predicted Sensitivity: 19078 [P/(V/V)]

Load Cell Parts Set #3: 4x1/2x1/4 in Predicted Sensitivity: 19078 [P/(V/V)]
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Load Cell: Testing Schedule (March 17th 21st)

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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Bridge Output Voltage [mV]

Module 2 Deliverable: Load Cell Calibration Data and Curve:

6 Load Cell Calibration

20
Measured Calibration Data Linear Fit: 0.215 [mV/lb]

Linear Fit Line

15

Calibration Data Points

10

3b

Zero

3a
0 0 20 40

Slope: Calibration Constant or 1/Sensitivity

60 80

Applied Load [lbs]

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Load Cell: Calibration Sheet

1. 2.

3.

Due: Week of April 7th to 11th

Two weeks after you did the Calibration
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4.

5.
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M&AE 3272 - Lecture #5 Load Cell Background and Design

3 March 2014

Tasks to do during the next 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 Construct LabVIEW Done vi in 163 Rhodes Construct LabVIEW Done vi in 163 Rhodes Build 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)

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Tasks to do THIS Week, March 3rd - 7th:

Everyone should now have familiarity with LabVIEW. Sections #401, #402, #403, #404, #409, and #413
meet in B30 Upson to fabricate your Load Cell. Come prepared to show your design to your TA so that you can receive parts. Then: Prep. Glue. Wire.

Sections #405, #406, #407, #408, #410 , #412

and #414 can go to the Lab to check out their LabVIEW vi. (Go at times when the Sections above are not session.) Thanks. Enjoy the week!

P.S.: Liquid Mountaineering is a fraud.

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