Customer Solutions

Developing a Data Acquisition System for Force Measurements in Grind-Hardening Process

Author(s):

Prof.Dr. M Almakky, Alexandria University; Eng. M. Abd Elwahab, Alexandria University

Industry:

Machines/Mechanics

Product:

Data Acquisition, LabVIEW

The Challenge:

Developing a complete data acquisition system for online monitoring of the cutting forces in a grind-hardening process using an available Kistler dynamometer and developing the software using NI-DAQ system.

The Solution:

Using NI LabVIEW software, data acquistion hardware, a scew terminal, a chage amplifier, and a force dynamometer to build the required data acquisiton system.

We developed two different data acquisition systems for online measuremtn of force components and temperature during a grind-hardening process. We developed the DAQ system using NI LabVIEW software, based on graphical-programming technology.

We achieved high programming efficiency, high performance, and cost saving using NI LabVIEW software and DAQ hardware to build the grind-hardening control and monitoing system. It is now possible to monitor, control, and log data from a dynamometer using a common PC.

With LabVIEW, we desiged the entire system setup uing a single PC to control and monitor the process. The system is made of a Kistler dynamometer type 9257 A connected to a charge amplifier type 5803 A, which is connected to a screw terminal. The output signal is logged using a DAQ card.

The signals obtained from the dynamometer are converted into voltage, then transferred to the charge amplifier by efficiently using shielded wiring. This secures data transfer between the DAQ board and the PC. Then, the data is automatically saved for further analysis. Using this system, we can read data continuously or call any collected data. Using this system, we achieved high sampling rates and instantaneous data logging and monitoring capabilites with no delay. We can also adapt this system to any other dynamometers after the calibration stage.

During the grind-hardening process, the workpiece is mounted on the Kistler dynamometer, which is mounted on the magnetic table of the surface.

During the process, the data acquisiton system collects and converts the dynamometer signals to determine the tangential force values.

The workpiece is mounted over the dynamometer duing the grind-hardening process. This represents the tangential force cahnge.

Results and Benefits
The grind hardening force signals are instantaneously sent to Microsoft Excel or used for further analysis.
We obtained the following mesturment spectrums during the grind-hardening experimnets a different feed speeds:

· Feed Speed (Vf = 0.45 m/min.)
· Feed Speed (Vf = 0.32 m/min.)
· Feed Speed (Vf = 0.16 m/min.)

The benefits of using such system are the cost saving, high efficiency, and flexibility.

For more information, contact:
Prof. Dr. M. Y. Al-Makky
Coordinator of Machining Division,
Production Engineering Department,
Faculty of Engineering, Alex.University
21544 Alexandria, Egypt
Tel.: +20101536078
Fax: (+203)5921853
E-mail: almakky@intouch.com