Calibration machines for force and torque

Gassmann Theiss Messtechnik GmbH

Defining Precision
For over 10 years, GTM has delivered convincing competence and knowhow in force and torque metrology. GTM calibration machines define the national standards for the quantities force and torque world-wide, and GTM calibration devices have found widespread applications in calibration and quality control labs.

It is the flexibility of the medium-sized enterprise in particular which has positive effects for the customer, be it for bespoke product solutions, short delivery times or personal service on site.

The Hierarchy of Metrology

The primary standard machine ... defines the Newton or the Newtonmeter, respectively. In both cases the quantities are compared with combinations of base units: mass, length and time. Preferably, deadweight and lever machines are used for the definition of force. For torque, lever-mass systems are usually applied.

The secondary standard machines ... serve for the calibration of sensors which are used in industrial quality laboratories as working standards. All GTM types are suitable for this purpose even hydraulic systems offer sufficient measuring uncertainties.

The calibration machine ... is used for the calibration of measuring instruments which are used for production testing. GTM offers cost-effective devices with measuring uncertainties that are optimised for the specific task.

The measuring instrument ... verifies the physical parameters as specified for a process. With GTM force and torque transducers as your standard instrument you achieve the level of metrological certainty required for your process control.

The link between the levels of this hierarchy is accomplished by GTM force and torque transfer standards. They allow comparisons of all the various standards and enable traceability of measuring instruments to national standards. GTM transfer standards are characterised by their exceedingly high reproducibility.

Calibration machines with direct mass action (deadweight) - Type DW

For the most precise definition of the physical quantity of force, since mass as the base quantity can be determined with a precision better than 1 x 10-6. Therefore, this type is most suitable for primary standards in national metrology institutes (NMIs) and for secondary standards in accredited calibration labs, if Class 00 is required. The design follows the 3-column steel base frame, carrying a four-column loading frame on top. The force generation is by steel mass disks (deadweights). Additional flexibility in their use can be achieved by application of a binary exchange mass stack instead of the simple sequential stack. In this case, an electromechanical substitute load system is activated during load changes. The test spaces are in accordance with international standards.

Mass stack

Test space 100 kN force standard machine at PTB, Germany

Features
Standard type series from 200 N up to 500 kN capacity Secure load application with patented GTM coupling system Electromechanical substitute loading device Measuring uncertainty 2 x 10-5, traceable to leading NMIs Internal verification of the machine by self-check routine

Design examples
Deadweight machine with

Model

Dimensions HxWxD (mm)

Test space Tension HxW (mm)

Test space Compr. HxW (mm)

Weight (kg)

200 N 500 N 1000 N 2 kN 5 kN 10 kN 20 kN 50 kN 100 kN 200 kN 500 kN

2280x550x550 2540x550x550 2700x630x630 2850x710x710 3380x820x800 3670x1000x1000 4040x1200x1200 4400x1350x1350 5300x1900x2100 6800x2400x2200

50-600x260 50-600x260 50-600x300 50-600x300 50-600x400 50-600x400 50-600x400 50-600x400 150-750x500 150-800x630

10-200x190 10-200x190 10-240x250 10-240x250 10-260x300 10-260x300 10-600x300 10-600x300 10-600x470 10-800x500 10-1200x600

140 220 400 680 1000 2500 4500 7000 13000 42000 75000
sequential stack exchange stack twin sequential stacks

8800x2825x2000 150-1200x800

Calibration machines with lever amplification - Type LA

For larger forces, above 500 kN or so, the installation of direct-loading deadweight machines tends to be financially uneconomic or even impossible for reasons of limited available space. The application of a highly precise lever amplification system even for very high nominal forces enables cost effective calibration machines with measuring uncertainties of 100 ppm. Also, the force range of existing deadweight machines can be increased by adding such a lever system. In the lower force range, such a machine operates with direct mass action (deadweight). A highly precise lever transmission generates the higher forces. The lever support is designed as strain-controlled elastic hinges, which in contrast to the older types (using knife edge bearings) operate completely wear-free and enable accurate amplification. This strain-controlled bearing also serves for the lever control and position monitoring and thereby increases the reliability. An additional advantage is the large combined measuring range of such lever-deadweight machines of up to 2000 : 1. This makes them attractive for capacities as small as 50 kN.

Lever-amplified force standard machine at EIM, Greece

Design examples
Lever-deadweight machines with ...
FEM Simulation: Lever 3-D Design of an operating platform

Features
Standard type series from 50 kN to 2 MN Lever amplification with strain controlled elastic hinges (GTM patent) Electromechanical substitute loading device Measuring uncertainty 2 x 10-5 / 1 x 10-4, traceable to leading NMIs

Model

Dimensions HxWx D (mm)

Test space Tension HxW (mm)

Test space Compr. HxW (mm)

Weight (kg)

sequential stack

exchange stack

50 kN 100 kN 200 kN 500 kN 1000 kN 2000 kN

2100x1500x1010 2580x1700x1050 2800x2000x1200 3300x2360x1480 4100x2820x1850 5800x3100x2230

50-600x450 50-600x500 50-800x580 50-800x580 50-1000x660 50-1000x750

0-600x450 0-600x500 0-800x580 0-800x580 0-1000x660 0-1000x750

1600 2500 6800 13000 20000 33200

Calibration machines with jockey weight and lever - Type JW

The design principle of the strain controlled elastic hinges is used here once more, together with a travelling weight. The lever (symmetric with regards to its fulcrum point) generates tension and compression forces with only one weight in a single test space. This for the first time enables calibrations with alternating loads (when using GTM coupling rods) and continuous calibrations. With up to three separate jockey weights measuring ranges of up to 625 :1 are possible. Since there is no expensive mass stack required, this type of lever machine offers a particularly cost-effective solution amongst calibration machines. A fact that makes it an ideal choice for the production testing of force transducers and load cells.

Test space

Lever bearing Jockey weight machine, GTM DKD Force Calibration Laboratory

Features
Load ranges from 100 N to 100 kN Lever amplification with strain controlled elastic hinges (GTM patent) Continuous loading possible Through-zero calibration of force transducers in one test space Measuring uncertainty 1 x 10-4, traceable to leading NMIs

Design examples

Model

Dimensions HxWxD (mm)

Test space Tension HxW (mm)

Weight (kg)

100 N 200 N 500 N 1000 N 2000 N 5000 N 10 kN 20 kN 50 kN 100 kN

1100x370x1810 1100x370x1810 1100x370x1810 2100x2400x560 2100x2400x560 2100x2400x560 2200x2400x620 2200x2400x620 2200x2400x620 2400x2400x740

20-140x130 20-140x130 20-140x130 20-220x460 20-220x460 20-220x460 80-380x520 80-380x520 80-380x520 320-520x520

150 150 150 580 580 580 950 950 950 1700

Calibration machines with hydraulic force generation and transfer standard - Type HT

Ideally suited as secondary force standard for day-to day calibrations in industrial quality control labs. High forces can be realised by such compact and low-cost machines. Hydraulic force standard machines differ in many essential areas from material test machines of otherwise similar appearance: much lower hydraulic power due to short and slow piston travel, highly precise controllers, and the use of transfer standards optimised to the highest possible reproducibility.

Force calibration with reference transducer

Features
Force ranges from 50 kN to 10 MN Continuous loading possible Measuring uncertainty 2 x 10-4, traceable to leading NMIs
Secondary force standard machine at LBF, Frauenhofer Institut fr Betriebsfestigkeit

Design examples

Load range

Dimensions HxWxD (mm)

Test space tension HxW (mm)

Test space Compr. HxW (mm)

Weight (kg)

50 kN 100 kN 200 kN 500 kN 1000 kN 2000 kN 5000 kN 10000 kN

2200x720x400 2500x800x500 2500x800x500 3150x910x670 3150x910x670 4000x1220x800

50-600x350 200-600x460 200-800x460 270-950x520 270-950x520 400-1200x600

10-600x320 10-600x400 10-600x400 60-740x520 60-740x520 100-800x600 200-1200x680 200-1200x800

600 1100 1200 3400 3500 8800 15000 21000

5200x1515x1200 800-1800x800 6500x1800x1400 800-1800x1000

Torque calibration machines

Definition of torque directly traceable to the base units of mass and length by weight action of calibrated mass disks onto a frictionless supported lever. A welded steel base frame designed for floor mounting carries the lever for torque generation, using strain controlled elastic hinges arranged at right angles at both sides of the lever. Binary mass stacks are coupled at both lever ends via strain-controlled joints. During torque changeovers, a substitute loading device is active to maintain stable torque.

Mass coupling

Lever support

Features
Nominal torque ranges from 20 Nm to 5000 Nm Measuring uncertainty over a range from 0.1 % - 100 %: < 50 ppm Large measuring range up to 1000 : 1, cw and ccw direction Lever support in elastic hinges arranged at 90 Continuous loading possible Clockwise and counter-clockwise operation in a single test space Measuring uncertainty 5 x 10-5, traceable to leading NMIs

Primary torque standard machine, EAM Switzerland

Design examples
Primary torque standard with direct mass action ...

Nominal torque range

Dimensions HxWxD (mm)

Test space (mm) Length/

Weight (kg)

20 Nm 50 Nm 100 Nm 200 Nm 500 Nm 1000 Nm 2000 Nm 5000 Nm

1600x1700x 2300 1600x1700x 2300 1600x1700x 2300 1700x1900x2600 1700x1900x2600 1700x1900x2600 1800x3000x3200 2000x3600x4000

700/400 700/400 700/400 900/500 900/500 900/500 1200/600 1200/600

1050 1250 1500 1500 1600 1800 2500 3800

Top view

GTM torque standard machines a modular system

Primary torque standard machine with one or two mass stacks and double-sided lever for torque generation highly flexible (fine torque spacing) by binary mass stacks fully automatic operation, with measuring uncertainties < 50 ppm measuring uncertainty < 50 ppm

Secondary torque standard machine jockey weights on a double sided lever for torque generation short calibration times with continuous torque loading through-zero testing without gaps and delays measuring uncertainty 100 ppm

Torque calibration machine calibration against reference transducers of the highest precision quickest possible calibration with continuous torque loading measuring uncertainty 400 ppm vertical axis design possible

All GTM torque calibration machines can be upgraded on a modular basis if the demands on measuring uncertainty and ease of operation grow. Thus you remain flexible and can achieve low uncertainties from the beginning on a small budget.

Design examples
Torque calibration machine with ...

... vertical transducer axis

... jockey weight

... manual loading

... reference transducer

Technical advance
Load application Quick and exact increase and decrease of forces is essential for economic and reliable operation of a calibration machine. The patented coupling system developed by GTM is unique in this respect: exact centring of the masses during loading and unloading no stick effects due to statically determined location guides quick coupling of the masses by guided movements metrologic monitoring of force shunts in the mass stack

Strain controlled elastic hinges Are used instead of knife edge lever bearings and eliminate disadvantages like increasing transmission error caused by wear and correspondingly intensive maintenance. In principle, the strain controlled hinges are similar to a bending spring which is mounted between the lever and the machine frame. Strain gauges on both its sides measure bending stresses during the load increases and decreases, which are proportional to the bending moment. Modern servoelectric drives use this input and together with a closed-loop controller adjust the loading crosshead such that the resulting moment is zero. This "controlled" amplification for the first time fulfils a longdemanded requirement, i. e. to monitor the complete amplification mechanism in metrology terms, thereby keeping the measuring uncertainty over long periods in guaranteed small limits.

Strain controlled elastic hinges at right angles Are based on the principle of strain controlled elastic joints and enable the wear-free and frictionless bearing of the lever in GTM torque calibration machines.

Control and data processing With the GTM Force and Torque Manager GTM has created machine-specific control software which due to being PC-based enables simple and easy operation of the calibration machines. Microsoft Windows was chosen as operating software. The whole operation of the machine is activated by mouse and keyboard. Simple clicking on the corresponding buttons and options enters all commands for a measuring series. User data, such as transducer capacity, type etc. are entered via the keyboard. The flexibility of testing is further enhanced by a module which allows the pre-programming of arbitrary test routines. This enables product-specific tests and quick reaction to changing test standards or customer demand. The evaluation of test results is displayed in tables and diagrams. Data exchange through a network or another software tool is possible.

Options
Temperature chambers For testing of transducers at temperatures different to room temperature. The special chamber geometry achieves an even temperature distribution. No condensation on the sensors due to integrated drying device. Temperature ranges from - 20 C to + 40 C.

Magazines For optimum utilisation of your calibration machine. Magazine capacities up to 40 transducers, linear and round designs available, high flexibility due to exchangeable spacer masks.

10

More than just a machine

Comparison measurements We arrange full traceability measurements (intercomparisons) with national standards as specified by you.

Training Reliable results require the right technology and well trained operators. GTM offers training in all aspects of force measurement, both at the GTM lab and on-site.

Maintenance In order to keep your precision machines in good shape over long periods of time, we recommend scheduled maintenance for the whole installation. GTM offers proven routines for this purpose.

defining precision

Gassmann Theiss Messtechnik Philipp-Reis-Strae 6 D-64404 Bickenbach Phone +49 62 57 / 97 20 - 0 Fax +49 62 57 / 97 20 - 77 contact@[Link] [Link] - [Link]