This document discusses the optimization of capacitive gauges in terms of testing and manufacturing procedures. It describes work done at CERN to optimize capacitive gauges, including validating a new testing machine with better accuracy and precision, implementing an ISO calibration standard, and exploring alternative manufacturing methods to reduce hysteresis and zero drift. The optimized gauges showed promising results with uncertainties meeting accuracy class 0.5 according to ISO 7500-1 and decreased combined uncertainty compared to baseline models, though further improvements are still needed. The internship provided valuable engineering experience for the author's career.
This presentation addresses the changes and trends in key standards; factors that influence results and solutions; and increasing lab efficiency and throughput in regards to melt flow, heat deflection temperature (HDT), & impact testing.
If you order or are involved with product testing or specifying, this presentation by Element Materials Technology Senior Metallurgical Engineer & Engineering Manager Dr. John Tartaglia, this presentation will answer many standards questions, including:
- What's the difference between various types of ASTM standards, e.g., test methods, specifications, practices, terminology, and guides?
- How often are ASTM and SAE test methods and other standards revised?
- What are some guidelines for citing open specifications and test methods in industrial part prints and contractual documents?
- What are some key similarities and difference between between the standards published by various organizations, e.g., SAE, ASTM, AMS, JIS, DIN, EN, ISO, etc.?
Melt Flow Index Tester, Melt Flow Index Tester Manufacturers and Suppliers In...Presto Group
Looking for Melt Flow Index Tester manufacturers, Melt Flow Index Tester suppliers, Melt Flow Index Tester producers, Melt Flow Index Tester exporters, Melt Flow Index Tester wholesalers, Melt Flow Index Tester production centers ? Browse PrestoGroup.com for all your testing instruments needs. For more information visit- http://www.prestogroup.com/plastic-testing-instruments/melt-flow-index-deluxe
Polyfilms and laminates testing instrumentsPacorr Testing
Poly Films & Laminates Testing Instruments - Pacorr offers a wide range of highly accurate Poly Films & Laminates Testing Instruments that help the industries in testing the quality of their products. Call now for price: +91 8882149230
This presentation addresses the changes and trends in key standards; factors that influence results and solutions; and increasing lab efficiency and throughput in regards to melt flow, heat deflection temperature (HDT), & impact testing.
If you order or are involved with product testing or specifying, this presentation by Element Materials Technology Senior Metallurgical Engineer & Engineering Manager Dr. John Tartaglia, this presentation will answer many standards questions, including:
- What's the difference between various types of ASTM standards, e.g., test methods, specifications, practices, terminology, and guides?
- How often are ASTM and SAE test methods and other standards revised?
- What are some guidelines for citing open specifications and test methods in industrial part prints and contractual documents?
- What are some key similarities and difference between between the standards published by various organizations, e.g., SAE, ASTM, AMS, JIS, DIN, EN, ISO, etc.?
Melt Flow Index Tester, Melt Flow Index Tester Manufacturers and Suppliers In...Presto Group
Looking for Melt Flow Index Tester manufacturers, Melt Flow Index Tester suppliers, Melt Flow Index Tester producers, Melt Flow Index Tester exporters, Melt Flow Index Tester wholesalers, Melt Flow Index Tester production centers ? Browse PrestoGroup.com for all your testing instruments needs. For more information visit- http://www.prestogroup.com/plastic-testing-instruments/melt-flow-index-deluxe
Polyfilms and laminates testing instrumentsPacorr Testing
Poly Films & Laminates Testing Instruments - Pacorr offers a wide range of highly accurate Poly Films & Laminates Testing Instruments that help the industries in testing the quality of their products. Call now for price: +91 8882149230
Bottles (PET & Glass) Testing Instruments - Pacorr offers a wide range of highly accurate Bottles (PET & Glass) Testing Instruments that help the industries in testing the quality of their products. Call now for price: +91 8882149230
The energy required to heat and cool outdoor air and infiltration air is a significant fraction of thermal loads. This project has developed diagnostic procedures to identify air leaks and methods to calculate the savings from air sealing large commercial and institutional buildings. Envelope air sealing could significantly reduce large building energy consumption, but no systematic research has identified the most cost-effective strategies for Minnesota buildings.
This is one slide set in a multi part series on the BGA rework process. In this section the BGA cleaning and inspection process is explained. Get more information on www.solder.net or to see or multitude of soldering process videos.
3P Engineering, an innovative Italian SME, design, develop and produce testing solutuion for manufacturing industry.
Here an overview of our test benches developed for our international customers.
Some of them follow international reccomendation ISO/IEC, others are customized to answer to specific request of the customer.
XRF Advancements Improve Detection of Trace Silicon in Carbon Steel in On-Lin...Olympus IMS
Carbon steels with low-Si (< 0.10 %) content can corrode at an accelerated rate when exposed to sulfidation corrosion conditions. Detecting silicon content in carbon steel via X-ray fluorescence (XRF) and optical emission spectroscopy (OES) has been performed in recent years, though typically during downtime under ambient temperatures.
Recent advancements in handheld X-ray Fluorescence (XRF) to quantify levels of silicon (Si) in carbon steel as it pertains to API RP 939-C’s avoiding sulfidation corrosion failures in oil refineries will be discussed. The utility of handheld XRF is explained in practical terms that apply directly to industrial material testing and specifically the surface and environmental variables that affect in situ trace Si testing in high temperatures.
Recent developments are identified and their impact as related directly to this application. Dramatically improved hardware and software bring a new level of speed, improved accuracy and precision to the detection of silicon at concentrations below 0.10 wt % in carbon steel process piping systems and components up to 900F. Specifically, better detector/signal processing (1.5X higher count rate, resolution <145 eV) produces improved sensitivity and allows reduced test times in high temperature environments. Additionally the heat sink, standoff and fan design of current instruments mitigate the effects of heat on the instrument.
Bottles (PET & Glass) Testing Instruments - Pacorr offers a wide range of highly accurate Bottles (PET & Glass) Testing Instruments that help the industries in testing the quality of their products. Call now for price: +91 8882149230
The energy required to heat and cool outdoor air and infiltration air is a significant fraction of thermal loads. This project has developed diagnostic procedures to identify air leaks and methods to calculate the savings from air sealing large commercial and institutional buildings. Envelope air sealing could significantly reduce large building energy consumption, but no systematic research has identified the most cost-effective strategies for Minnesota buildings.
This is one slide set in a multi part series on the BGA rework process. In this section the BGA cleaning and inspection process is explained. Get more information on www.solder.net or to see or multitude of soldering process videos.
3P Engineering, an innovative Italian SME, design, develop and produce testing solutuion for manufacturing industry.
Here an overview of our test benches developed for our international customers.
Some of them follow international reccomendation ISO/IEC, others are customized to answer to specific request of the customer.
XRF Advancements Improve Detection of Trace Silicon in Carbon Steel in On-Lin...Olympus IMS
Carbon steels with low-Si (< 0.10 %) content can corrode at an accelerated rate when exposed to sulfidation corrosion conditions. Detecting silicon content in carbon steel via X-ray fluorescence (XRF) and optical emission spectroscopy (OES) has been performed in recent years, though typically during downtime under ambient temperatures.
Recent advancements in handheld X-ray Fluorescence (XRF) to quantify levels of silicon (Si) in carbon steel as it pertains to API RP 939-C’s avoiding sulfidation corrosion failures in oil refineries will be discussed. The utility of handheld XRF is explained in practical terms that apply directly to industrial material testing and specifically the surface and environmental variables that affect in situ trace Si testing in high temperatures.
Recent developments are identified and their impact as related directly to this application. Dramatically improved hardware and software bring a new level of speed, improved accuracy and precision to the detection of silicon at concentrations below 0.10 wt % in carbon steel process piping systems and components up to 900F. Specifically, better detector/signal processing (1.5X higher count rate, resolution <145 eV) produces improved sensitivity and allows reduced test times in high temperature environments. Additionally the heat sink, standoff and fan design of current instruments mitigate the effects of heat on the instrument.
Aplication of on line data analytics to a continuous process polybetene unitEmerson Exchange
This Emerson Exchange, 2013 presentation summarizes the 2013 field trail results achieved by applying on-line continuous data analytics to Lubrizol’s continuous polybutene process. Continuous data analytics may be used to provide an on-line prediction of quality parameters, and enable on-line detection of fault conditions. Information is provided on improvements made in the model used for quality parameter prediction, and how the field trail platform was integrated into the process unit. Presenters Qiwei Li, production engineer, Efren Hernandez and Robert Wojewodka, Lubrizol Corp., and Terry Blevins, principal technologist at Emerson, won best in conference in the process optimization track for this presentation.
Tailor welding blanks generally used for making doors of an automobile get crack along welding line. This leads to rejection and Wrong body production. Its analysis & countermeasure shared in sides.
Then … Now … and Tomorrow. This presentation discusses how meters, loads, and communications have changed over the years and why it is important today. Standards Changes are reviewed as well as new definitions.
Inspired by the energy saving potential of window shades, our idea is to develop a smart energy window with sustainable features. The product which is to be developed, consists of Motorised
mechanism to control the motion of Shades, thereby reducing heat gain during day time. It consists of an automatic shade closing feature which adapts to the climatic condition without
any human intervention. It has a manual over ride features with smart phone control which
reduces the human need to operate the Window shades physically. The main focus of our product is the design of Window shades with sustainable materials that can be recycled. The materials are selected based on the thermal
resistivity factor that reduces the absorption of heat. This contributes to the reduction in heat raps in the building and hence the use of Air conditioning equipments.
2. Optimization of the capacitive gauges in terms
of testing and manufacturing procedures
17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
2
Mechanical Measurements Laboratory – Technological
Educational Institute of Piraeus
Konstantinos Velissaridis
3. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
3
Engineering Department
Mechanical & Materials Engineering Group
Mechanical Measurements Laboratory
Displacement
Transducers
Load-Tensile
Sensors
Vibration
Sensors
Strain gauges –
Optical /Resistive
Thermal Probes Calibration Tools
Properties measured : Force , stress, strain, displacement, vibrations, temperature, etc...
Environmental conditions : Magnetic fields, cryogenic temperatures, radiation
Introduction → MML
Static and Dynamic
Acquisition Systems
Post-Processing
and Analysis
Engineering Reports /
Conclusions
Preparation of the
Instrumentation
4. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
4
Introduction → CERN Internship
Projects assigned
Technical student in MML
Experimental
Stress
Analysis
LHC Diodes
Fresca 2
Sample Holder
Vibration
Measurements
ALICE Power
Converters
Experimental
modal analysis
Instrumentation of
magnet
prototypes
11 Tesla Fresca 2
Capacitive
gauges
optimization
Testing
sensors
R&D
sensors
EDMS
1263617
EDMS
1266838
EDMS
1275022
EDMS
1281142
EDMS
1246113
EDMS
1221318
EDMS
1318324
EDMS
1304901
5. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
5
Optimization plan
Testing
Set up
assessment
ISO Standard
Calibration
Mechanical
integration
EDMS Documentation – Bachelor thesis
New machine
validation
Manufacturing
Plastification of
the steel foils
Connection
alternatives
Implementation
of new ideas
My activities
Comparison with
baseline model
6. d0
Compression
forces Fc
17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
6
Introduction → Working principals
Based on the capacitance effect and the
principles of the elasticity of materials
𝑆𝑖𝑔𝑛𝑎𝑙 =
2 + 𝜔2
∗ 𝐶 𝑇 𝐹
2
∗ 𝑅2
4 + 𝜔2 ∗ 𝐶 𝑇 𝐹
2
∗ 𝑅2
−
2 + 𝜔2
∗ 𝐶 𝑇 𝐹=0
2
∗ 𝑅2
4 + 𝜔2 ∗ 𝐶 𝑇 𝐹=0
2
∗ 𝑅2
7. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
7
Introduction → Why capacitive gauges?
Load range: 0 to 200 MPa
Surface: According to applications
Thickness : 0.5 mm
Conditions: Cryogenic and magnetic field
Accuracy: < 5%
Others: Synchronized measurements with strain
gauges
Integrated surface
Average contact
stress measuring
Local uniaxial or
biaxial stress
monitoring
8. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
8
Optimization plan
Testing
Set up
assessment
ISO Standard
Calibration
Mechanical
integration
New machine
validation
Manufacturing
Plastification of
the steel foils
Connection
alternatives
Implementation
of new ideas
My activities
Comparison with
baseline model
EDMS Documentation – Bachelor thesis
9. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
9
Optimization → Machine Validation
• 400 KN
• Automatic control
• Insensitivity parasitic forces
• 200 KN
• Manual control
• High deformations
Hydraulic
Press
Load
Capacity
Control
Mechanical
Effects
Zwick Z400E
10. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
10
Optimization → Machine Validation
Conclusion
• Better accuracy and precision
• Homogenously distributed pressure
-500
-450
-400
-350
-300
-250
-200
-150
-100
-50
0
0 10 20 30 40 50
Signal(mV/V)
Force (KN)
Lab_Press
Z400E
x10-4
EDMS:1110695
11. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
11
Optimization plan
Testing
Set up
assessment
ISO Standard
Calibration
Mechanical
integration
New machine
validation
Manufacturing
Plastification of
the steel foils
Connection
alternatives
Implementation
of new ideas
My activities
Comparison with
baseline model
EDMS Documentation – Bachelor thesis
12. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
12
Optimization → ISO Calibration
Force ref
Resolution
Reproducibility
Repeatability
Zero Drift
Creep
Interpolation
Combined standard
uncertainty
𝒖 𝒄 =
𝒊=𝟏
𝟕
𝒖𝒊
𝟐
Experimental
Uncertainty
Assessment
13. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
13
Optimization → ISO Calibration
Force ref
Resolution
Reproducibility
Repeatability
Zero Drift
Creep
Interpolation
Combined standard
uncertainty
𝒖 𝒄 =
𝒊=𝟏
𝟕
𝒖𝒊
𝟐
Accuracy
Class 0.5
ISO 7500-1
14. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
14
Optimization → ISO Calibration
Force ref
Resolution
Reproducibility
Repeatability
Zero Drift
Creep
Interpolation
Combined standard
uncertainty
𝒖 𝒄 =
𝒊=𝟏
𝟕
𝒖𝒊
𝟐
0
0.02
0.04
0.06
0.08
0.1
0.12
0 50 100 150 200 250 300 350 400
Signal(mV/V)
Force Ref (KN)
15. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
15
Optimization → ISO Calibration
Force ref
Resolution
Reproducibility
Repeatability
Zero Drift
Creep
Interpolation
Combined standard
uncertainty
𝒖 𝒄 =
𝒊=𝟏
𝟕
𝒖𝒊
𝟐
Zero
Drift
16. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
16
Optimization → ISO Calibration
Force ref
Resolution
Reproducibility
Repeatability
Zero Drift
Creep
Interpolation
Combined standard
uncertainty
𝒖 𝒄 =
𝒊=𝟏
𝟕
𝒖𝒊
𝟐
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0 100 200 300 400
Signal(mV/V)
Force Ref (KN)
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 100 200 300 400
Signal(mV/V)
Force Ref (KN)
3rd degree
1st degree
17. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
17
Optimization → ISO Calibration
18. 0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
18
Optimization → Uncertainty contribution
Room
Temperature
Cryogenic
Temperature
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Contribution
Interpolation
Zero Drift
Creep
Resolution
Repeatability
Reproducibility
Force Ref
19. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
19
Optimization plan
Testing
Set up
assessment
ISO Standard
Calibration
Mechanical
integration
New machine
validation
Manufacturing
Plastification of
the steel foils
Connection
alternatives
Implementation
of new ideas
My activities
Comparison with
baseline model
EDMS Documentation – Bachelor thesis
20. Plot Legend
17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
20
Optimization → Manufacturing
Bonding: Two components adhesive
Application: Manual
Quantity: Random
Layer thickness: Uncontrollable
Energy dissipation → Hysteresis Glue plastification → Zero driftQuantity → Linearity
0
10
20
30
40
50
60
70
80
90
100
0 0.02 0.04 0.06 0.08 0.1 0.12
StressApplied(MPa)
Signal (mV/V)
Impact of the glue thickness
21. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
21
Optimization → Manufacturing
I. Initial signal step
↓
Lack of vacuum
II. Zero drift
↓
Atmospheric pressure
-0.35
-0.3
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0 20 40 60 80 100 120 140 160 180 200
Signal(mV/V)
Force Ref (KN)
First results No Glue Glue
22. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
22
Optimization → Manufacturing
Continuous improvement of the model
Pros
• Simplified, faster and easier
manufacturing.
• Almost non existing hysteresis.
• Decreased thickness.
Cons
• Increased inactive surface.
• Vacuum + Hermetical sealing.
• Acceptable results but not matching
the best made baseline models.
Glue free model
Baseline model
-0.35
-0.28
-0.21
-0.14
-0.07
0
0 50 100 150 200
-0.35
-0.28
-0.21
-0.14
-0.07
0
0 50 100 150 200
-0.35
-0.28
-0.21
-0.14
-0.07
0
0 50 100 150 200
Signal(mV/V)
Stress (MPa)
23. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
23
Optimization → Manufacturing
0
2
4
6
8
10
12
0 20 40 60 80 100 120 140 160 180 200
CombinedRelativeUncertainty(%)
Stress (MPa)
Gauges' uncertainty comparison
New - RT
New - Cryo
Baseline - RT
Baseline - Cryo
24. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
24
Conclusions of my internship
• New machine integrated and validated
• ISO standard calibration procedure
implemented
• Promising new model with great potentials
Capacitive
gauges
• A great introduction to my engineering career
• Perfect learning experience
• Completion of my bachelor’s thesis and my
bachelor’s studies
Professional
• Traveling abroad for the first time
• Meeting and exchanging ideas with new
people
• Having the most memorable year of my life
Personal
25. 17/12/2013
Optimization of the capacitive gauges in
terms of testing and manufacturing
procedures
25
Special thanks to my Professor K. Nikas and my MML colleagues!
Thank you all for your attention!
Questions?