HBMhotline.com. Efficient precision. An ethos of efficiency, a passion for precision. HBM Test and Measurement customer magazine

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1 HBMhotline.com HBM Test and Measurement customer magazine Blazej Maksym / Igor Zh / Dmitry Kalinovsky / Konstantin Shishkin / Lebedev Maksim / wandee007 / Shutterstock.com Image composing: CONTRUST DESIGN Efficient precision An ethos of efficiency, a passion for precision _ A question of stability: testing PCBs _ A well networked data stream the interface is critical _ The electrification of mechanics: Are you already measuring synchronously?

2 In this issue HBM hotline.com HBM transducers are internationally renowned for their custom-made precision demanded by specific applications. This is not a coincidence precision is our passion and efficiency our ethos. > page 4 HBM has improved the PMX460 measuring amplifier module making it more versatile so it ideally suits use in test benches and production systems. > page 13 The French company, GreenMot, uses HBM s GEN2i data recorder to meet the increasingly demanding challenges of measurement technology for testing electric motors. > page 11 Technology trends New products Customer solutions 04 Efficient precision competence on all levels 07 The interface is critical in a wellnetworked data stream 16 More than just shopping: the new HBMshop 18 Consistently making full use of physical possibilities 20 A question of stability 24 The electrification of mechanics: Are you already measuring synchronously? 08 Test benches: Industrial Ethernet-based torque measurement technology 12 Compact and well-protected: CMD600-P 12 Small and very sensitive: the CST/ Frequency input for torque measurements 13 Remote access gives complete production data picture 26 Calculating electrical power in real time 10 Rogue wave encounters 11 Electric motors on the test bench 14 Top-quality steel reliably recording all parameters 14 Press monitoring boosts operating time 15 Quality control for switching devices 15 Smart devices undergo intensive testing 23 Optimum use of resources in MDF production systems Imprint Published by HBM Test and Measurement Im Tiefen See 45 D Darmstadt, Germany info@hbm.com 2

3 HBM hotline.com Editorial Andreas Hüllhorst President HBM Group Dear reader, HBM has stood for competence, precision and reliability in measuring, evaluating and simulating mechanical and electrical quantities for more than 60 years. Based on this experience our engineers achieve extraordinary results again and again, refining them to create superior metrological solutions that meet market needs. The most accurate torque flange in the world that is indispensable for developing today s resource-saving combustion and electric motors is one example. Your needs are our driving force As we strive for the best metrological solutions, our attention is not focused inward. Your needs and applications drive us forward. We know that the only basis for optimizing your products over the entire product lifecycle is accurate and reliable measurement results. This gives a reliable basis for simulation, for reducing the time-tomarket, for consistently meeting performance requirements, and ultimately to reduce overall costs. Our key competences extend from strain gauge manufacturing to sensor design and manufacturing, electronics development and on to software production and worldwide support. That means we can fine tune the various components to each other, thereby optimizing the entire measuring chain so that you can fulfill your mission successfully. Good advice: quickly and efficiently applied If necessary our experienced application specialists can assist you in project planning or through the entire project runtime, from selection to approval, anywhere in the world. And if you already know what you need, you can buy basic metrological components such as sensors, electronics, software and accessories conveniently and economically in the HBMshop. Seven days a week, 24 hours a day. You can always rely on our promise to you, "measure and predict with confidence". Tomorrow and in the future your needs and requirements will be the impetus for our actions. Yours sincerely, Andreas Hüllhorst 3

4 We wanted to make a promise to our customers with our product: quality in series production. We succeeded. Markus Haller, Dipl.-Ing. Product Manager for Torque Transducers, HBM 4

5 HBM hotline.com Technology trends Efficient precision competence on all levels There are many torque and force transducers, yet HBM s products are unique. The HBM brand guarantees reliable measurement results worldwide. This is not a coincidence as our developers across the world are driven by a strong passion for precision. Furthermore, all processes ranging from development through production and calibration are integrated under one roof. This results in competence and a high commitment to quality at all levels. When it comes to reliable results, technology leaders all over the world accept no compromises when choosing their sensors. They rely on torque and force transducers from HBM and with good reason. HBM transducers are renowned for custom-made precision as required in specific applications and, if needed, are available in high volumes. It s always very special, when you hold a torque transducer prototype in your hand, says Markus Haller, Dipl.-Ing. Product Manager for Torque Transducers, I am always thrilled when I see that transducer produced in high volumes some months later. Haller notes, We wanted to make a promise to our customers; precision in series production. We have succeeded. The transducers provide accurate and meaningful measurement results - even for decades in many applications. Furthermore, all process chains at HBM are integrated from development through production and assembly. This approach benefits our customers. Your requirements in view at all times HBM offers more than just products, it provides solutions. Customers can expect more from HBM transducers: more precision and reliability that is optimally adapted to their requirements. All this is thanks to a highly motivated and competent team of developers and some other qualities that make HBM unique: Cutting-edge competence in strain gauge technology: In-house development and production of HBM strain gauges the core of every transducer. This allows for optimum adaptation of strain gauges to the respective transducer spring elements. HBM established its calibration laboratory, the first calibration laboratory in the German Calibration Service (DKD), today DAkkS, in HBM s calibration support is unsurpassed in Germany and Europe. Customers trust in the reliability of the calibration machines for example, the 240 KN dead load machine, the 5 MN calibration machine for force transducers or the 25 knm dead load machine for torque. HBM places great emphasis on service. Our experts are happy to advise you when it comes to selecting the right transducer. Whether in application engineering, maintenance or repair we support you with many available services ensuring that applications are successful. to be continued >> 5

6 Technology trends HBM hotline.com >> continued Technical progress in force sensors is truly enormous and far greater than 20 years ago. Thomas Kleckers, Dipl.-Phys. Ing. Product Manager for Force Transducers, HBM The driving force However, there's more to it than these factors. The actual "secret of success" behind our transducers' special quality is our passion for precision. Our developers have been working with passion, knowhow and experience to ensure continuous progress in torque and force measurement technology for decades - encouraged, again and again, by our long-standing customers' feedback. Kleckers says, I often hear that even tricky tasks, for example, measuring very small forces using force transducers with high nominal (rated) force can be accomplished. HBM supplies the U10M force transducer calibrated for two ranges 200 N and 16 kn for field work. Kleckers adds, Covering this broad range requires high precision during production, particularly regarding thermal properties. At the same time, costs are kept to a minimum. These solutions are impressive and encourage us to develop further. HBM presented its first model T1 torque transducer in 1958 the first force transducer had been launched two years earlier. HBM has been able to score with new innovative advances since then for example, presenting its T12 digital torque transducer in 2006, which is unequaled in terms of precision to this day. Striving for innovation is key to our corporate culture. Every new development, every new product brings us closer to a major goal: increasing efficiency for you, our customers and using state-ofthe-art technology to make your measurement projects a success now and in the future. Our latest developments: the T40B and T40FM digital torque transducers with optional, integrated rotational speed measuring system and reference pulse as well as the TIM-EC interface module. The s-shaped S2M force transducer for measuring static and dynamic tensile and compressive forces is a new addition to our range of force transducers. more 6

7 HBM hotline.com Technology trends The interface is critical in a well-networked data stream titelio / Shutterstock.com Networking of intelligent devices is becoming a major issue in everyday life, particularly in industrial and automation environments. Here, powerful networks ensure additional efficiency and productivity today. Various fieldbus systems are widely used for data transmission. The test and measurement equipment used also needs to meet these requirements making compatible interfaces necessary. In modern production systems, intelligent sensors transmit data in real time. In the process, status information such as temperature, service life or degree of wear are often transmitted in addition to the actual measurement signal. The optimum fieldbus system for data transmission Profibus, DeviceNet, AS-Interface or CANopen depends on the application s requirements. However, Ethernet-based fieldbus systems have increasingly replaced conventional systems in recent years. This is understandable since there are many benefits from EtherCAT, PROFINET, EtherNet/IP and CC-Link: Flexibility through compatibility Test and measurement equipment is increasingly used in production systems and test benches in the industry today. It contributes to increasing efficiency and reducing down time and rejects. Compatible interfaces are needed when test and measurement equipment is integrated with a system. For this reason, HBM provides the most important Ethernet-based fieldbus interfaces for its measuring amplifier systems: High performance Easy wiring thanks to known IT standards Easy integration in and transition to the IT world Reduced costs through use of standard components in the devices Higher system availability thanks to remote maintenance and advanced diagnostic tools EtherCAT PMX Industrial amplifier QuantumX Universal measurement data acquisition system TIM-EC Torque interface module EtherNet/IP more PROFINET HBM features reliable and precise measurement equipment combined with the flexibility of different interfaces. 7

8 New products HBM hotline.com Test benches: Industrial Ethernet-based torque measurement technology Energy efficiency is a hot topic in the automotive industry. Optimizing motors and resistance requires new vehicle designs with increased efficiency resulting from ever more accurate measurements. Consequently, demands on test benches and test and measurement equipment used for determining torque and rotational speed are steadily increasing. Digital torque transducers have long since become standard. The number of fieldbus-based systems has also increased. This comes as no surprise considering that they offer flexible use, provide precise results and allow real-time measurement. HBM's T40B and T40FM digital torque transducers meet the automotive industry's high requirements. In addition to conventional output signals such as frequency and voltage they feature a TMC (Torque Measurement Communication) digital interface on the stator. Moreover, the torque transducers can now be upgraded with the new highly flexible TIM-EC interface module to significantly enhance their performance and field of applications. They can thus be integrated into automation and control concepts using conventional signals and modern Ethernet-based fieldbus technology such as EtherCAT. TIM-EC is an interface module featuring two channels. In addition to the digital torque signal TMC, RS-422 compatible rotational speed signals from series T40 torque transducers can be connected. Users are provided with the following process data and measured values on the EtherCAT bus: Torque Rotational speed Angle of rotation Power Torque and rotational speed signal are also available on the module's backplane bus. This offers extreme flexibility and modularity which is a real advantage particularly for integration into higherlevel control and automation systems. A single transducer can be operated on two separate TIM-EC units connected to each other via 8

9 HBM hotline.com New products Well integrated into fieldbus-based systems: T40FM and T40B torque transducers plus the TIM-EC interface module. the backplane bus. All settings including signal conditioning can be changed independent of each other and without any secondary effects. The control and automation levels can thus operate in an optimal way, responding flexibly to the requirements of the tasks at hand. Thanks to its modularity the system can be upgraded at any time. Fast control based on current values Controlling increasingly efficient and complex motors via a growing number of test bench motor management functions is becoming ever more demanding particularly in terms of flexibility, data throughput and speed. The EtherCAT real-time environment allows highly dynamic, top-quality test bench control. This is possible thanks to low-latency message transmission and the system's very low jitter. The powerful TIM-EC also supports update rates or bus cycle times of up to 20 khz. Direct digital processing and output of the torque signal via the TMC signal on the stator in combination with optimized hardware and signal conditioning in the TIM-EC interface module enables group delays of approximately 100 s. TIM-EC thus enables the quality and stability of the test benchbased control loop to be enhanced. Diagnostics and parameterization In addition to comprehensive diagnostics data via EtherCAT, TIM-EC has an Ethernet TCP/IP service interface. The integrated web server provides clear visualization of diagnostic data for the interface module and the connected torque transducer ("traffic light" presentation). Diagnostics and status information in plain text allow further analyses. For example, users can conveniently retrieve onsite diagnostics data. Fast testing of the entire measuring chain or the TIM-EC is as easy as possible. A modern integrated web server is used for visualization of TIM-EC functions. The interface module can be conveniently connected, tested, analyzed, and parameterized via a standard PC with Ethernet interface. No complex software installation is required. The measurement system can be used in test benches and is also the ideal solution, for example, for testing dual-mass flywheels. In this application scenario, torque (angle) can be quickly and reliably determined using the angular signal. Markus Haller, HBM more 9

10 Customer solutions HBM hotline.com Rogue wave encounters Researchers of Hamburg-Harburg Technical University have simulated, in a spectacular test, the impact of a rogue wave hitting a cruise liner's window. HBM's Genesis HighSpeed system ensured reliable data acquisition during the test. Kevin Renes / G Tipene / Shutterstock.com Spacious windows are increasingly being installed on huge cruise liners to improve passengers experiences with transparency and brightness. However, these features raise questions regarding the ship's design. Wave impact is a particularly critical issue. How should windows be designed to withstand the impact force of large masses of water or even so-called "rogue waves"? Big water balloon test The Institute for Design and Strength of Ships of Hamburg-Harburg Technical University conducted a research project examining questions surrounding the use of large window surfaces. The impact of a wave on a window was simulated as part of an experiment: For the first drop test, the height and amount of water were chosen such that the glass did not suffer damage. The intention of the second drop test, during which 1500 liters of water in a balloon were dropped from 38 m height, was to ensure that the window pane was broken by the water balloon. Split second data acquisition Hamburg-Harburg Technical University opted for HBM's GEN2i mobile data recorder as the data acquisition system to be used. At the moment when the rogue wave hits, a huge volume of measurement data must be read at high resolution. GEN2i was therefore fitted with a bridge amplifier input card with a sampling rate of 1 MS/s. One million data items per second must be reliably saved and rapidly visualized. With the Perception software from GEN2i, live data can be visualized on-screen within seconds using patented StatStream technology. more 10

11 HBM hotline.com Customer solutions Electric motors on the test bench The French company GreenMot specializes in testing thermal engines, hybrid drive systems and energy systems. Testing electric motors represents a new challenge in terms of measurement technology. The fast GEN2i data recorder from HBM has proven to be the optimum solution. Stéphane Londos, Managing Director and founder of GreenMot, has relied on HBM measurement technology for years: "We work in applied research, which is extremely demanding in terms of the quality of measurements. HBM products are an excellent overall match for our metrological requirements regarding measurement uncertainty, repeatability and synchronization of measurements." Measurement technology requirements are especially demanding for testing electric motors. This is due to the high voltages and the high sampling rates that are required. GEN2i is used as a front end for data acquisition. Digitized measured values are transferred via optical Gigabit Ethernet connection to a PC workstation where they are graphically represented, continuously saved and analyzed. The optical connection allows for perfect isolation between the power supply voltage of the motor being measured and the workstation. The Perception software package, developed by HBM especially for applications of this kind, is used for data processing of recorded raw data, including calculation of the effective and reactive power or motor efficiency. New metrological challenges Electric motors are controlled by means of a pulse width modulated voltage of several hundred volts with a basic frequency of 5 to 25 khz. These signals have numerous harmonics, which are very rapid and differ greatly in intensity. To analyze motor power and understand the effects on the power supply on the speed and torque of the motor, they have to be continuously recorded. more Reliable data acquisition with GEN2i "We decided to use the GEN2i system from HBM. It can record highvoltage signals up to 1 kv directly and at sampling rates of up to 2 MS/s, which is more than sufficient for detailed signal analysis, says Stéphane Londos. testing by HBM 11

12 New products HBM hotline.com Compact and well-protected: CMD600-P The CMD600-P charge amplifier can be positioned directly in the machine near the measuring point because it features a compact design and high functionality, together with IP65 degree of protection, making it ideal for use in harsh environments. The risk of damage to the sensor lines and the possibility of interference have been minimized. Connectors that are not needed can also be securely closed off with protective caps. Digital inputs and outputs plus the Ethernet interface allow easy parameterization and monitoring of the device. Integrated peak value detection and limit value monitoring functions enable control functions to be distributed and thus relieve the central control unit. The command set implemented in the CMD600-P facilitates its use in control systems as well as for integration into the system visualization. It can also be used for remote maintenance. Small and very sensitive: the CST/300 The CST/300, a highly sensitive piezoelectric strain transducer, is designed for applications where transducers based on strain gauges reach their limits due to size or low sensitivity. The compact transducer is mounted with a screw and records even slight strains, which are converted into proportional signals. If appropriate calibration is carried out, the CST/300 can also be used to determine the active force. The transducer, which is insensitive to electromagnetic fields, is well suited for applications in machines for cable production, in presses or welding machines. more 12

13 HBM hotline.com New products Frequency input for torque measurements Remote access gives complete production data picture PX460, the new measurement module for PMX optimized for use in test benches The web server from PMX features impressive performance and userfriendly design. The PMX measuring amplifier from HBM is now more flexible to use than ever before. The new PX460 module is ideally suited for use in test benches and production systems. The frequency measurement amplifier can be used to connect up to four torque flanges for simultaneously determining torque or rotational speed. The full dynamics of the world's leading torque transducer from HBM can also be recorded using TMC (Torque Measurement Communication) signals. Data rates of up to 38 khz/channel allow for a measuring bandwidth of up to 6 khz for each signal. All commonly used encoders or linear scales with TTL output can also be connected. The measurement signals of the PX460 can easily be sent for further processing via analog/digital outputs of the PMX in stand-alone applications. The measurement module can also be easily integrated into automation concepts using Ethernet-based real-time fieldbuses such as EtherCat and ProfiNet. The internal calculation channels of the PMX also allow for real-time calculations of various output quantities as well as peak, mean, root mean square and limit values and also PID control. Like the PMX amplifier before it, the software is also setting new standards, specifically in terms of performance and user friendly design. This ensures maximum security for your investment in the future. Users need only an Internet-capable terminal device to use the system. A web browser provides access to all your production data, for service and maintenance or to evaluate processes. The combination of Ethernet technologies and Internet also allow for inexpensive remote maintenance. You can access a test device live at HBM in Darmstadt worldwide at catman Easy/AP, the professional software tool for measurement engineers, also supports the PMX measurement system in versions 3.4 and above. In this way you can parameterize PMX in just seconds using an expandable sensor database. This ensures that measurements can be visualized and recorded quickly during start-up and also for quality control. The free PMX driver package can be used for easy integration into the complete system or machine concept in the future: The package can be integrated into LabVIEW TM * or the user's own software with.net API (C++, C#, VB.NET). *LabVIEW is a registered trademark of National Instruments more 13

14 Customer solutions HBM hotline.com Top-quality steel reliably recording all parameters Press monitoring boosts operating time Paul Broadbent / istockphoto.com Force measurements for steel forming with PMX Long runtimes and precision are needed for industrial presses. Depending on the final product, steel must be available in a special shape, alloy and quality. The quality of the outgoing products, sheet steel, is largely determined in production. Steel of the required thickness is formed in long rolling mills. The important parameters in this forming process are force, temperature and speed. PMX records these parameters to ensure reliable processes and makes them available to system control via real-time-capable fieldbuses. To remain competitive, these plants must be highly automated and require minimal servicing. PMX scores high in this respect with its diagnostic functionalities. Remote maintenance up to the sensor level can also be implemented with the integrated web server, which reduces maintenance costs. Strain gauges are used to record signals directly in the roller bearings. Precise position, dimensioning and assembly are performed with finite elements calculations by HBM. This ensures that the customer receives a custom-made complete solution. Modern industrial production would be unthinkable without presses. The range of products extends from coins to large automobile parts. Presses run at up to 800 strokes per minute. The quality of the workpieces that are produced must always remain consistent. One way to achieve this is by using HBM sensors and PMX press monitoring. PMX measuring chains record pressing forces as they occur with absolutely no interference, either in a direct force flow or in a force shunt measurement. The high, 24 bits resolution of the PMX makes it possible to record very small partial forces. Internal calculation channels analyze the measurement signal in terms of its curve and peak forces. These signals provide valuable information which is forwarded via real-time Ethernet interfaces to the press controller, so that the press parameters can be readjusted. With an automation system concept of this kind, press manufacturers can increase the runtime and quality of their presses while lowering maintenance costs. The concept is becoming increasingly common in retooling, i.e. retrofitting or upgrading presses. successfully in use 14

15 HBM hotline.com Customer solutions Quality control for switching devices Smart devices undergo intensive testing Guryanov Andrey / istockphoto.com Alexander Raths / istockphoto.com The switches, relays and contactors of a switching device must be reliably tested. New touch panels run through extensive test procedures. The task of end-of-line test benches is to guarantee that switching devices can perform reliably over their entire service life. The PMX shows its strengths in this application. Two test tasks have to be handled, both in strict real time. First, the haptics of the switching device have to be recorded. This is done by measuring and monitoring the force-distance signals when the switching device is activated. The electrical function must also be ensured. To do this the signals of the switching contacts are read into the PMX and overlaid with force-distance signals. The switching device does not receive a quality seal unless the two criteria haptics and switching function match. The PMX has 1000 internal parameter sets making it very economical to test as many types of switching devices in as short a time as possible. The PMX and the entire EoL test bench is controlled via ProfiNet, which maximizes speed and minimizes installation time and expense. Modern smartphones and operating units provide fascinating new features and user friendly design. But these devices must pass through an extensive development and testing process before they ever reach consumers. Before testing begins, the scope of the tests is defined. It must meet and go beyond the actual requirements. Small robots equipped with a movement profile and a saved test sequence are used to simulate the different operating procedures and forces that can occur. PMX measures forces of a few Newtons for this application with long term stability and saves the maximum forces. The data is recorded via internal calculation channels and transferred to the test bench control. All measured values are also recorded by PMX via Ethernet with the HBM software catman for quality data storage and later evaluation. Each parameter set includes a separate test program, suitable for the touch panel being tested. more 15

16 Technology trends HBM hotline.com Zudy and Kysa / istockphoto.com More than just shopping: the new HBMshop Fast and convenient shopping, 24/7 that's what the new HBMshop offers you. In addition to purchasing directly through our sales team, our customers can also go to hbm.com/hbmshop for online shopping now. However, the new HBMshop is more than just an online shop, it is a comprehensive information platform. 16

17 HBM hotline.com Technology trends The advantages: All HBM products are available for purchase from the new HBMshop. Select the item you wish to buy, add it to the shopping cart and submit the order buying test and measurement equipment is that easy and convenient. However, many useful functions are available prior to and after the purchasing process. Available 24/7 Comprehensive information platform Time saving Transparent Convenient Cost saving A comprehensive information platform HBMshop is much more than an ordinary online shop. We wish to make your purchase as transparent as possible. You can compare products to find out how well they correspond to your requirements from sensor through software so you choose the right product. Products can also be configured to your specifications. Perhaps you have made a choice, but you are still unsure whether or not to submit the order in this form? No problem. You can save your shopping cart for the next time you log in. Or you can forward all the ordering information to your colleagues to make your purchasing decision easier. We have added this function, for you. Of course, you can also directly request a quote. Once your order is submitted, it can be tracked at any time. Order histories can also be accessed any time. Exclusively for online shoppers HBMshop customers benefit from attractive discounts. Individual prices can be agreed with OEM customers purchasing large quantities. When the price agreement has been stored, it is applied to all product orders from the HBMshop. Do you use e-procurement? HBMshop is easy to integrate into your systems. Please contact us for further assistance. The HBMshop is presently available in Germany, France, Great Britain, Benelux, Austria, Switzerland and the USA. Rollouts in other countries are scheduled for this year. Save time and money with a convenient, fast and transparent purchasing process. It goes without saying that you can always count on competent advice from our sales and service team, also when shopping in our HBMshop. We look forward to your visit to hbm.com/hbmshop 17

18 Technology trends HBM hotline.com Consistently making full use of physical possibilities Globally HBM is today the embodiment of high-precision measurement technology and is represented in all important markets. And for good reason: for more than 60 years, innovative products have been shaping the world of measurement technology. Metrological institutes around the world trust precision amplifiers from HBM. Currently the brand new DMP41 is just about to be released another milestone. Since its founding over 60 years ago, HBM has worked in close cooperation with the German National Metrology Institute (PTB) in Braunschweig and with other institutes, scientists and engineers, always making new tools available which have contributed substantially to perfecting worldwide metrology for measuring force, mass, torque and pressure. But HBM's success story began very modestly at first in That was when engineer Karl Hottinger founded the company Hottinger Messtechnik in Vogtareuth, Bavaria. With ten employees at that time he produced inductive force, displacement and vibration transducers. No wonder then that now legendary KWS amplifiers support this very technology for measuring force, displacement and acceleration. From strain gauges to measuring amplifier Just five years after its founding, the company had gone through such rapid growth that a move to Darmstadt became necessary. In 1962 the company changed its name to Hottinger Baldwin Messtechnik GmbH. HBM was the first company in Europe to recognize the potential of strain gauges (SG) and began to manufacture them. With the triumph of the new technology, the need for accurate SG amplifier technology grew. In 1970 HBM presented the trailblazing KWS/6E-5 amplifier, a powerful multi-channel system. Reliable accuracy: the first DKD calibration laboratory The type DK 37 digital compensator from HBM has marked another milestone in terms of accuracy. The precision of this measuring instrument made it possible in 1977 to open the first calibration laboratory within the German Calibration Service (DKD, now KWST HBM opens the first calibration lab of the German Calibration Service (DKD, now DAkkS). DK37 DMP DK37A DK38 DK38S The history of precision measuring instrum

19 HBM hotline.com Technology trends Precision amplifiers from HBM have been used for decades in force, torque and pressure laboratories, as well as in the manufacturing of load cells. DAkkS), which was accredited at HBM. Types DK 38 and DK 38S6 followed. Even today there are still many DK devices in use around the globe in institutes that pioneered the system for calibration and traceability. DMP: fully exhausting physical possibilities HBM introduced the DMP series in late The DMP39, which was developed in close collaboration with the German National Metrology Institute (PTB) in Braunschweig, was just beginning to fully exhaust the physical possibilities of that strain gauge measurement technology. The device class was subsequently fine tuned continuously in terms of operation and interaction. And finally the successor device, the DMP40, set a standard around the world in primary and secondary laboratories. HBM will soon be marking another milestone with DMP41, the youngest member of the DMP family. The precision amplifier supports simultaneous measurement with multiple channels. It is even more insensitive to interference and can be integrated in various ways into modern laboratory network environments. Metrological institutes will continue to be able to rely on maximum precision in the future. Dr.-Ing. André Schäfer, HBM more Accuracy class ML DMP ML38B DMP D-K ents and calibration services at HBM 19

20 Technology trends HBM hotline.com A question of stability Printed circuit boards of electronic components in automobiles, commercial vehicles or smart phones must withstand a great deal in mobile use. Even slight cracks can cause the entire electronics system to fail. To ensure this does not happen, manufacturers test the mechanical stability of printed circuit boards. Strain gauges from HBM provide exact results. c a b = Strain gauges from HBM 20

21 b HBM hotline.com Technology trends c a Strain values are the only parameters that are reliably predictive in terms of the stress loading of PCBs. Christof Salcher, Product Manager, HBM Cars drive over cobblestone pavement; commercial vehicles make their way around bumpy construction sites. In summer they are exposed to heat; in winter to freezing temperatures. All of this places high requirements on the individual components of products such as printed circuit boards (PCBs). They are the crucial element of electronic modules. Designers need to measure the effect of mechanical loading very precisely during the development of a prototype since vibration and thermal deformations can cause small cracks between the board and the component located on it leading to failure. In this way they can ensure that the PCBs will function properly up to the loading limit and also not undergo any damage in the production process. Cars and commercial vehicles are just one field of application where measuring mechanical loading is useful; trains and laptops are also continuously exposed to vibrations. Basically, there is a risk of breaks and cracks at every connection between the PCB and a component placed on it, explains Christof Salcher, Product Manager at HBM. That can be expensive, for example, when the electronics in an automobile no longer works due to a small crack. Manufacturers are increasingly requiring their suppliers to prove the mechanical stability of PCBs. "Strain values are the only parameters that are reliably predictive in terms of the stress loading of PCBs. They can be measured using strain gauges, which are placed directly on the PCB to do this, continues Salcher. Lead-free but more sensitive However, the requirements for these tests have become more stringent. One factor driving this is the conversion to lead-free soldering. A directive of the European Union (RoHS) prohibits the use of certain hazardous substances in electrical and electronic devices. This includes lead, which was previously used frequently for solder connections between the board and the component. The lead-free solution is more sensitive to mechanical influences and breaks more easily. Another factor that makes tests more stringent is the increasing use of more compact modules such as ball grid arrays (BGA). They allow for more connections than a conventional surface-mounted device (SMD). Contacts on BGAs are quite rigid with mechanical stresses acting on the PCB transferred more forcefully compared to solder connections joining SMDs to the board. to be continued >> 21

22 Technology trends HBM hotline.com >> continued Different standards Different standards have been developed for measurements with strain gauges (SG) to meet these new requirements (e.g. IPC/JE- DEG-9702). They include a description of where, how and by what means measurements are conducted. Many companies have also developed specific test procedures based on their own experience. Loading during later use and factors at work during the production process must be considered. Especially for the production of a new product, the entire process must therefore be accompanied by measurements made in the real production environment, explains Bernd Wolf, Project Engineer at HBM. Strain is measured at places where there are components at risk of being destroyed. HBM provides the complete measurement chain for such applications from strain gauges through to the QuantumX MX1615 amplifier and catman AP software for data acquisition and analysis. The different measurement tasks and their constraints require the use of different strain gauges. HBM offers a wide selection for this purpose. For example, type RY rosettes have three measuring grids that can be adapted to different geometries, dimensions and nominal (rated) resistances. Their temperature responses are adjusted for steel, aluminum or to customer specification. Especially for the launch of a new product, the entire process must therefore be accompanied by measurements made in the real production environment. Bernd Wolf, Project Engineer, HBM Christof Salcher, HBM more 22

23 HBM hotline.com Customer solutions Optimum use of resources in MDF production systems The production systems for wood-based material panels of the Eppinger Dieffenbacher Group are in worldwide demand. Systems for MDF panels and THDF thin panels require special precision to produce top-quality wood fiber board with efficient use of energy and material while protecting the environment. These are the reasons why Dieffenbacher has decided to use HBM s digiclip digital industrial measuring amplifier and load cells in the fiber control of its production systems. Developed for automation: digiclip The digiclip product series of digital industrial amplifiers from HBM is the first choice for all users who would like to measure force, weight, torque or pressure. The modular system for automation in industrial environments can be connected with all strain gauge full bridge transducers. The digiclip is also a perfect match for existing automation systems. That's because digiclip uses the standardized interfaces PROFIBUS DP-V1, CANBUS and DeviceNet. Dieffenbacher's production systems stand for high system competence, efficiency and profitable innovation. An example of this is the latest generation of production systems for MDF panels and THDF thin panels. The combined use of a digiclip amplifier and HBM weighing technology in these systems pays for itself. For example, it allows for freely configurable filters to correct fluctuations in speed that occur due to the irregular nature of the belt. The resulting reliable weight values reduce the use of raw materials in production while at the same time measurably increasing the quality of the final product. Thus the investment in systems pays for itself faster. User-friendly and convenient Users can make all the settings for the device with the free digiclip software on the PC. Even changing the amplifier and making upgrades during ongoing operation are incredibly easy with digiclip. These tasks are accomplished with Plug & Measure and Hot Swapping. There's also a valuable bonus: digiclip supports TEDS, the electronic data sheet in the transducer and detects transducers equipped with TEDS fully automatically. Complicated settings and configurations are eliminated. Even untrained employees can easily start up digiclip. Michael Guckes, HBM more 23

24 Technology trends HBM hotline.com The electrification of mechanics: Are you already measuring synchronously? For testing household appliances, automobile drives, machines, systems or high-voltage components: HBM offers integrated solutions for synchronous recording of mechanical and electrical quantities. This gives users full access to accurate raw data and less complexity in the test setup. MR.LIGHTMAN / istockphoto.com Electromechanical actuators and drives have extended their success to use in numerous applications. Consider the automobile, for example, mechatronic components are playing an ever greater role in areas such as the drive, chassis, comfort and safety. Modern cars are becoming more and more like driven computers with central closing systems, windows, seats, climate, brakes, steering and electrified drives. Today a luxury limousine may contain up to 100 electrical drives. The growing demand for more comfort, reduced CO 2, increased efficiency and safety functions is leading to a rise in electrical and electronic components such as electric motors, sensors and control units. This in turn increases the need for reliably predictive tests with numerous electrical and mechanical signals to optimize these components. Earlier test methods work with a wide range of different measuring instruments such as multimeters and dynamometers. This means they return somewhat inaccurate results that are not synchronized with the mechanical data, which is no longer adequate. The rise of mechatronic components The advance of mechatronic components is by no means limited to the automotive industry. There are numerous examples of applications for electromechanical actuators in machine and plant engineering. Even in aviation many partial systems that were previously hydraulically controlled are now being converted to electrical control. The "electrification of mechanics" is indeed a challenge for testing system components. But in the future it will be essential to record electrical and mechanical signals synchronously and reliably. For example, it is extremely important when optimizing system components to analyze the required or reciprocal mechanical or electrical responses. Synchronous measurement acquisition: HBM s integrated solution You're on the safe side with HBM. Depending on the measurement or test requirement, we offer you a suitable integrated solution for synchronously recording mechanical and electrical measurement data from measurements of low-voltage signals to tests on highvoltage components. 24

25 HBM hotline.com New products Users benefit instead from less complexity in the test setup and more reliable measurement data an indispensable prerequisite for making significant improvements in performance and optimizing development projects. NEW: QuantumX SCM-HV HBM also offers a series of precise transducers for recording mechanical quantities such as torque, force, distance, pressure and weight. Using the Genesis HighSpeed and QuantumX data acquisition systems and corresponding software packages Perception and catman AP, you can synchronously record additional measured quantities such as temperature, vibration and bus signals. All data, including video synchronization, can be saved reliably and reproducibly in commonly used data formats. The QuantumX SCM-HV signal conditioning module enables voltages up to 300 C VAT II to be measured with QuantumX series amplifiers. In this way electrical quantities can be measured on AC or DC machines, electromagnetic actuators or batteries in parallel and synchronously with mechanical quantities. The instrument has already been developed as required by version 3 of the IEC/DIN standard and ensures safe operation in the operating voltage range. HBM solutions for recording electrical and mechanical quantities The traditional solution in typical test environments: the QuantumX universal measurement data acquisition system Recording electrical and mechanical signals synchronously: with QuantumX series amplifier and the new QuantumX SCM-HV signal conditioning module NEW Recording mechanical and electrical signals synchronously and dynamically and calculating power and efficiency: with the T12 torque flange and the Genesis HighSpeed measurement data acquisition system For high-voltage measurement tasks: the ISOBE optical transmission system and the Genesis HighSpeed series data recorder Christof Salcher, HBM more 25

26 New products HBM hotline.com Calculating electrical power in real time The new isolated 1 kv data acquisition card from HBM was introduced recently. This new amplifier card for the Genesis HighSpeed series is specially designed for input voltages. It can be used to measure electrical voltages up to 1000 V at sampling rates of up to 2 MS/s with a high level of measurement accuracy. Now the possibilities of the 1 kv card have been significantly expanded with the introduction of the Perception software version 6.40 making new real-time calculations available for users. In future, card users will be able to perform multiple real-time calculations for each channel. To do this, the new Perception software will create corresponding logical calculation channels. This will make it immediately apparent which channels contain "original raw data" and which are "real-time calculation channels". Software version 6.40 will provide the following real-time calculations for each channel: Root Mean Square (RMS) Minimum Maximum Mean Value Peak to Peak Area Energy 26

27 HBM hotline.com New products > Real-time calculation per channel Effective immediately, users can calculate the root mean square value (RMS) in real time. This is especially useful for measuring electrical quantities such as current and voltage. Now users can also trigger a measurement to these real-time channels for example for the RMS of a current or voltage calculated in real time. Previously it was only possible to trigger instantaneous values of a measured quantity. > Selection of cycle detection for real-time calculations The diagram below shows Cycle-Detect (red curve) in a distorted sinusoidal signal (green curve). "Cycle-Detect" finds the zero passes The new software version also offers two options for defining the time window for the real-time calculations mentioned above. To do this the user precisely defines the required time window. As shown in the example, the calculation can be performed in a time window of one second. > Cycle-Detect in a distorted sinusoidal signal Calculating effective, reactive and apparent power After the RMS value is calculated in real time, the effective, reactive and apparent power can be calculated with Perception software. The effective power for periodic voltage and current curves is defined as the mean value over time of the instantaneous power p(t) during the duration of the period T. The required mean value of the current and voltage over time can now be easily and reliably calculated with the 1 kv card and the recently developed real-time math algorithm. That removes practically all limits for users calculating electrical power. > Selection of cycle detection for real-time calculations The second option is based on an algorithm that has just been developed. This algorithm can be used to find the zero passes of the signal for a channel and to use this as the "Cycle-Detect" for subsequent calculations. That means users are able to calculate the RMS of a current or voltage for each half cycle (or for several) of the signal. Dirk Eberlein, HBM more 27