DIGIFORCE^® 9307HIGH-END X/Y process monitoring and analysis

• Haptic testing of rotary / push button switches including electrical switching edge
• Monitoring of armature forces when actuating electromagnetic valves
• Force / displacement / open circuit voltage monitoring during battery cell assembly

Task

A combination of mechanical X/Y process monitoring, such as force/displacement or torque monitoring, and the synchronous acquisition of electronic events and signal curves places high demands on measurement and evaluation systems. DIGIFORCE^® 9307 offers a convenient and universal solution for automation applications.

For haptic testing of electrical control elements, motor starters and circuit breakers, electromechanical control and regulating valves or battery cell production, DIGIFORCE^® 9307 enables 3-channel synchronous X/Z monitoring to meet the highest requirements.

• 100% testing during series production
• Friction force test (ease of movement) during movement of the steel needle in the cannula
• Two synchronous tests can be performed in one sequence

Task

Venous cannulas are subject to the highest quality requirements during the manufacturing process. In the end-of-line test, the ease of movement of the steel intravenous needle is tested during full movement in the flexible cannula catheter. DIGIFORCE^® 9307 records the force/displacement curves of two test specimens simultaneously and evaluates them. A gripper is applied to the two cannulas and performs a uniform forward/backward movement. Sensitive burster 8510 series bending beam load cells detect the low friction forces, which are evaluated in the DIGIFORCE^® controller. The displacement signal is transferred directly from the actuator unit.

• Force/displacement press-in monitoring with window and envelope curve technology e.g. acquisition of min/max peak values and force average value in a parameterized tolerance range
• Connection via PROFINET and Ethernet UDP supports flexible sequence control and measurement data acquisition
• Up to 128 measuring programs enable high product variance

Task

During the production of vehicle batteries, force/displacement monitoring of the insertion of the individual cell plates/cell blocks into the cell housing takes place. In order to optimise the cycle time, three units are always joined at the same time, whereby the joining force of each individual plate is recorded and evaluated. Recording and validation take place in the DIGIFORCE® 9307 X/Y process controller. Process results are available to both the station controller and the host to be logged via PROFINET and EtherNet UDP.

• Dynamic measurement of force/displacement characteristics with OK/NOK monitoring
• Integration into full automation via universal fieldbus interfaces such as PROFINET
• Up to 128 measurement programs for flexible type management

Task

As an alternative to fixed-contact power rails and busbars, backplanes with spring contacts enable individual testing and replacement of a battery’s cells. Dimensional accuracy and spring characteristics are critical to the quality of such contacts, so 100 % checking has to be carried out on each contact terminal.

Special Features

• OK/NOK testing with high accuracy for force and displacement channels
• Acquisition and transmission of quality-relevant parameters spring rate, hysteresis and contact spring initial height h₀

Lösung

By means of an automatic X/Y positioning unit, each spring contact is positioned under an electrical linear actuator with a 8431/32 strain gage force sensor mounted on the front end, and a test stroke is initiated orthogonally to the spring contact. Depending on the design of the spring contact, a test stroke of typically only < 1 mm compression is performed within the permissible elastic spring deflection. The DIGIFORCE® 9307/9311 process monitoring can record the quality-relevant parameters of initial height h₀, spring rate and hysteresis, and check them for compliance with tolerance specifications. An OK/NOK evaluation and measured values for reporting are made available at various interfaces.

Video Application

• Measuring range 10 N*m with a linearity error of 0.05 % F.S.
• Integral angular position sensor with 2000 increments (maximum resolution 0.045°)
• Zero-maintenance contactless construction
• Analog output or USB version available
• Optionally available as a dual-range sensor

Task

Steering rods, as a safety-related component, must undergo a defined test procedure both in pre-production testing and during the production process. After compression of the bearing, it is tested for low breakaway and friction torques. Torque sensor 8661 with 10 N*m measuring range is used featuring a high-resolution angular position output, which is evaluated by a DIGIFORCE^® 9307. This process step can be used to prevent admissible component tolerances being exceeded.

Precision torque sensor model 8661

• Non-contact transmission
• Torque measurement < 0.05 Nm
• Angle resolution 0.0885 °

DIGIFORCE^® 9307

• Comprehensive process monitoring
• High sampling rate
• Measurement accuracy of up to 0.05 %

Task

The haptic behavior of rotary switches should be measured based on torque/rotation angle. The exact determination of the torque to be applied is an important control variable for a rotary switch in terms of haptic behavior (adjustment force to be applied > proprioceptive perception > tactile perception).  

Specific Requirement

Very low nominal torque due to low operating forces. Fine angle resolution to map the fine detent points of the rotary switch. 

Solution

The Type 8661 torque sensor measures even the smallest torques over a defined angle range in forward and reverse rotation with high precision and reproducibility. Using the Type 8661 torque sensor also reduces the design complexity, as no additional angle sensor is required.
The haptic behavior of the rotary switches is evaluated with the DIGIFORCE^® 9307 based on the torque/rotation angle curve.