Transducer Mounting and Test Setup Configurations
Rick Bono The Modal Shop
Transducer Mounting
Mechanical connection method
Stud mount Adhesive mount Magnetic mount Press-fit friction mount
Test parameter considerations
Frequency range Mass loading
2
Mechanical Mounting: Impact on Frequency Range
Hand Probe +40 Sensitivity Deviation (dB) ~ Ref. 100 Hz +30 +20 +10 0 -10 -20 1.0
Dual Rail Flat Magnet Magnet
Mounting Adhesive Pad Mount
Stud Mount
10
100
1000
10 000
100 000
Log Frequency (Hz)
Stud Mount Transducers
Best frequency response characteristics just like the manufacturers cal labs Apply silicon grease at mating surface Requires surface preparation Proper torque recommended
Adhesive Mounting Supplies
Adhesive Mount Transducers
Cyanoacrylate (superglue)
Instant adhesive; strong, but still removable Gel vs liquid depends upon surface flatness Excellent frequency response characteristics
Adhesive Mount Transducers
Petro wax (bees wax)
Ultra convenient and simple Good for short term testing only Frequency response characteristics highly dependent upon surface prep and amount
Adhesive Mount Transducers
Hot glue
Allows attachment to poorly-mated surfaces Good for short term to mid term testing Frequency response characteristics poor, but generally good enough for modal apps
Adhesive Mount Transducers
Dental cement / fast-cure epoxy
Allows attachment to poorly-mated surfaces Pseudo-permanent attachment for reference transducer at shaker input location Use disposable mounting pad with stud
Magnetic Mount Transducers
Extremely convenient High attraction forces allow for reasonable high frequency characteristics Available in dual-rail style for attachment to curved surfaces
10
Press-fit Mount Transducers
Extremely convenient and efficient Designed specifically for low frequency (<1000 Hz) laboratory modal applications Cable base mounts adhesively, modal sensor mechanically attaches using electrical pins
11
Mounted Accelerometer Frequency Response Calibration
Mounted Accelerometer Frequency Response
300.0 250.0
Cyanoacrylate Sensitivity (mV/g)
200.0
Hot Glue Putty
150.0
Petrowax Stud (handtight w/out grease)
100.0
Stud (w/ grease)
50.0
0.0 0 2000 4000 6000
Frequency (Hz)
8000
10000
12000
12
Mass Loading Considerations
Acquire FRF with a single accelerometer Mount a second accelerometer next to the first and re-acquire FRF Compare for measurable differences
13
Test Setup Considerations
Understand goals/reasons for performing experimental modal analysis
Troubleshooting or failure analysis Finite element model verification Finite element model correction Component substructure / system modeling
14
Test Setup Considerations
Recognize the 4 primary assumptions of experimental modal analysis
Observability Time Invariance (Stationarity) Linearity Maxwells Reciprocity
15
Observability Assumption
Response DOF must have adequate spatial resolution to represent the modes of interest
Graphics from Agilent Application Note 243-3
16
Observability Assumption
First bending beam with seven accelerometer measurement points
17
Observability Assumption
If data acquired only at endpoints bending is not observable
18
Observability Assumption
19
Observability Assumption
Forcing function(s) applied at input location(s) must adequately excite the modes of interest
AVOID NODES!
Graphic from Agilent Application Note 243-3
20
Modally-Tuned Impact Hammers as PreTest Tool for Evaluating Structures...
21
for Optimizing Reference Locations and Ensuring Observability
Good Input Location
Freq Resp 2:1 Freq Resp 2:1 40 dBg/lb [Link] [Link]
Mag (dB)
Bad Input Location
-60 0 Hz 1 kHz
22
for Determining Optimal Frequency Range
Assure adequate spatial resolution to observe: - Important, dominant modes - Necessary modal density
Empty Freq Resp 2:1 40 dBg/lb
Mag (dB)
-60 0 Hz 1.6 kHz
23
for Testing Boundary Conditions
Rule of Thumb: 5-10x separation between rigid body and flexible modes
Graphic from Agilent Application Note 243-3
24
Time Invariance Assumption
Test article (and its boundary conditions) must exhibit stationarity
Parameter estimation algorithms assume consistent global modal properties throughout data set Environmental changes during data acquisition cause shifts in stiffness/damping properties resulting in measurable shifts in resonant frequencies Roving accelerometers to acquire data set results in variable mass loading on test article
25
Time Invariance Assumption
DATA CONSISTENCY DATA CONSISTENCY DATA CONSISTENCY i.e. acquire entire data set simultaneously (single snapshot) or at least as fast as possible
26
Time Invariance Assumption
Test methodology to achieve best data consistency
Simultaneous MIMO/SIMO testing Automated bankswitching Manual bankswitching Roving accelerometers Impact testing
27
Benefits of Bank-Switching
Simultaneous, 288 ch No. of Test Configurations 1 2 3 4 Total Time Allotted
Roving, 112 ch No. of Test Configurations 1 2 3 4 Total Time Allotted PreSetup Time 3 hrs Acquisition Time 6 hrs 17 min 6 hrs 17 min 6 hrs 17 min 6 hrs 17 min 28 hrs 8 min Cost Estimate 40%
PreSetup Time 9 hrs
Acquisition Time 5 min 5 min 5 min 5 min
Cost Estimate 100%
9 hrs 20 min
Bank-switch, 288 to 112 ch No. of Test Configurations 1 2 3 4 Total Time Allotted PreSetup Time 9 hrs Acquisition Time 17 min 17 min 17 min 17 min 10 hrs 8 min Cost Estimate 60%
28
Bank-Switching Example
Inputs: 2 vertical, 1 lateral, 1 skewed
29
Bank-Switching Example
Response points: 17 patch panels, each bank of 16 accelerometers
30
Bank-Switching Example
Bank-switch patches of data (3 x 96 ch) into smaller data acquisition system
31
Modular Cabling / Patch Panel System for Clean Setup
Eases setup troubleshooting Eliminates messy rats nest of cables Economical multi-conductor cabling
32
Time Invariance Assumption
Roving accelerometers results in inconsistent global resonant frequencies due to variable mass loading on test structure
Graphic from Agilent Application Note 243-3
33
Linearity Assumption
Input and output characteristics remain proportional within measurement range Confirm using precisely controlled inputs from shaker(s) across a range force levels Impact testing technique poorly suited when dealing with nonlinear test structures
34
Electrodynamic Modal Shakers as Excitation Source for MIMO
Allows best control of input forcing function to optimize frequency content and signal-tonoise ratio Through-hole armature greatly simplifies setup attachment to test structure
35
Through-Hole Armature Eases Setup
Traditional shakers with tapped armature connection leave little tolerance since setup has tapped connection at both ends
36
Reciprocity Assumption
Maxwells Theory of Reciprocity states that FRF matrix is symmetric FRF between input A and output B is the same as output A and input B Confirm using multiple shaker locations and impedance heads for driving point measurement
37
Impedance Heads for Verifying Reciprocity Assumption
Accelerometer built into preload stud of force transducer
Freq Resp 2:1 Freq Resp 2:1 30 dBg/lb
Mag (dB)
-70 0 Hz 500 Hz
38
Other Pre-Test Considerations
Free Boundary Conditions
Shock Cord Foam Rubber Air Suspension
39
Other Pre-Test Considerations
Fixed Boundary Conditions Realistic Boundary Conditions Match Impedance(s) at Boundaries Mass Loaded Boundary Conditions
40
Other Pre-Test Considerations
Transducer selection
Single axis vs triaxial package Sensitivity, measurement range & resolution Frequency range & mass
41
Transducer Electronic Data Sheet (TEDS, IEEE 1451.4)
Identifies transducer (type, serial number, location) Stores calibration data Automates book keeping, reducing errors
To ICP Supply
TEDS Memory
4ma -5 V
Uses reverse bias scheme to access digital memory
42
Other Transducer Setup Considerations
Use PDA scanner with bar-coded TEDS transducers to ease bookkeeping
43
Final Channel Setup Definition
Combine Data From Geometry, PDA, and TEDS Complete Test Set-up Information Defined in Universal Files
Virtual Channel Table (1807) Channel Table (1808) Parameter Calibration Geometry (15)
Model / Serial No. Direction Node No. Meas. Ch. Geometry Stored In TEDS X X Stored In PDA X X X X X X Stored On Host (PC)
44
Thank you for your time.
45