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Latest Kistler maXYmos BL keeps quality and costs under control

18 February 2013

The latest version of the Kistler maXYmos BL offers fast data transmission via serial Ethernet/IP and USB interfaces as well as ±10 V input. Fast data transmission also enables documentation of process data for traceability down to the individual part.

The new maXYmos PC software allows direct transfer of the test record from the maXYmos BL to the PC and offers many functions for visualizing, measuring and analyzing measurement curves and process values as well as for evaluating the process capability.

The functional modern case design, equally suitable for desktop, wall or panel mounting, clear menus and practical functions add up to an easy to use monitor. The high-contrast, colour, touch screen display, together with a sophisticated, context sensitive menu that shows only what is needed for a particular function allows smooth operation of the maXYmos BL.  The built-in functions enable many standard XY monitoring tasks to be set-up easily and quickly.

The maXYmos BL records and interrelates all of the measurands supplied by force or torque sensors on the Y-channel and potentiometric displacement or rotation angle sensors on the X-channel. It uses evaluation objects such as BOX, LINE and ENVELOPE to analyze sections of the recorded measurement curves. This allows the maXYmos BL to monitor and evaluate the quality of a product or production step.

For example, force versus displacement or time in press-fit processes, and torque versus rotation angle or time in screw tightening processes may be monitored. The quality of an individual manufacturing step, assembly or entire product can be determined on the basis of the measurement curves.

The earlier in the production chain such monitoring is started, the more certain it is that the finished product will subsequently pass final inspection. Out of specification items detected can be diverted for rework at an early stage, rather than being scrapped after a whole series of further costly manufacturing operations have been wasted.

The large built-in memory allows nearly continuous monitoring of the curve plus storage of 16 measurement programs for 16 different types of part, each with four evaluation objects.

Automatic trend tracking, which can be activated for the band of the envelope curve, tracks the set point limits, for example with progressive tool wear, and matches the evaluation function to the actual process situation. The internal curve memory and the ability to display stored families of curves simplifies fault analysis.

To simplify product changeover, up to 16 measurement programs for 16 different types of part, with up to 8 000 pairs of XY values per curve, can be stored in non-volatile memory with password protection The maXYmos BL provides functions that allow many standard XY monitoring tasks to be set-up easily and quickly.

The envelope curve evaluation is standard to further enhance the performance of this versatile and compact monitor.  During setup, the band of the envelope curve automatically wraps around the outside contour of a previously measured bundle of curves evaluated as “Good”.

The latest version of the Kistler maXYmos BL process monitoring and product testing system can be used as the basis of a complete XY measuring chain costing less than £2,000, including sensors, providing a cost-effective method of monitoring a wide range of manufacturing processes, especially joining, assembly, and product testing.  Monitoring the relationship between force and distance provides an accurate evaluation of any variation in a production process or product performance compared with a known optimum.

Expanded torque measuring system
Meanwhile, Kistler has added three new measuring ranges to its KiTorq torque measuring system. The new ranges of 100, 200, and 5,000Nm have been added to the existing ranges of 500, 1,000, 2,000 or 3,000Nm measuring ranges. All are available with an accuracy class of 0.05% of range. These additional products complete the portfolio for test benches for internal combustion engines, electric motors, transmissions and drive trains.

Rotors of different sizes can be combined with same ringless stator, which is particularly easy to install and allows different items to be tested without the complete reconstruction of the test stand. The ringless stator design speeds up the installation, protects against damage during assembly operations and facilitates visual observation during the test process.

A single, intelligent stator can be used with any KiTorq rotor of the same speed rating and will automatically recognise the rotor measuring range.  This minimises hardware investment as one stator may be used with rotors of differing ranges for different applications.

Installation is simplified by the contactless, digital telemetry that does not require an antenna ring.  The lack of an antenna ring has not reduced the precision of the sensor which has an excellent signal bandwidth of 10 kHz and accuracy of better than 0.05%. A speed measurement of 60 pulses per revolution is integrated in the standard system.

The stator is now available with Profibus, Profinet CANopen and Ethernet interfaces in addition to the analog / frequency, USB and RS-232 interfaces which allow analogue and digital signal outputs to be fully scalable. When needed, the rotor's original measuring range may be overridden to allow the full output signal to be available over a defined range. A second, freely selectable measuring range may also be defined at each output.

The solid measuring flange is extremely robust and has been tested to EN 60068-2-27 for mechanical shock, EN 60068-2-6 for triaxial vibration loading and EN 61326-1 for interference immunity. The KiTorq system is supplied as standard with SensorTool configuration and diagnostic software and calibration certificates.

Several calibration options are available for the configurable output signals of the KiTorq system and when replacing an individual rotor or stator, the notional calibration values can be calculated to avoid the need to have the unit recalibrated by the manufacturer.


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