ME56 Instrumentation & Control Eng.

2012

The 2nd Semester S.Y.2011-

Lab : Strain Measurement System

Thursday, Dec.1

Objectives
In this lab, you will 1. 2. 3. know the technique and application of strain measurement using electrical resistance gauges. understand how the strain gauge output is processed. calibrate the electric resistance strain gauge by comparing the mechanical strain

Background reading

Practical Strain gauge Measurement section (Pages E-45 ~ E-72)on the book The pressure strain and force Handbook published by Omega Engineering company

A. Strain Gauge Strain gauges are used in structural(or mechanical) engineering to evaluate stresses in elements of a structure. This involves several considerations which must always be questioned whenever the technique is applied. They are: 1. That the relationship between gauge strain and change of resistance is known. It is by definition the gauge factor GF, where, GF= (dR/R) / However in high class work where the direction of the principal strain is not known, it may be necessary to make allowance for the cross-sensitivity of the gauge; that is, there is a second order change of resistance duet to strain perpendicular to the long axis of the gauge. Also it is normal to measure the gauge factor of a few gauge from each manufactured batch, and assume this factor applies to the batch. That the relationship between surface strain and stress of the structural element is known. It is termed the modulus of elasticity E in the linear elastic stress range of the material, which permits a simple calculation of stress from =E = (E/GF) (dR/R) If the structural element is made from a non-linear elastic material, for example concrete under immediate loading, then a mathematical stress-strain law or a graph may be used to derive stress from strain. In more difficult situations where plasticity is involved, a stress strain graph to at least the recorded strain would be needed for the first loading. That the gauge follows surface strain perfectly. A successful gluing technique is needed to satisfy this condition. Through degreasing, a thin uniform film of adhesive, and compatibility of all the materials in contact are essential. There is no substitute for experience. That there are no indeterminate reasons for change of resistance in the gauge circuit. It does not include change of temperature as this is a factor normally taken into account by using a dummy or reverse active gauge in the balancing arm of the bridge circuit. It is more likely to arise from the variable resistance of joints or plugs and sockets in the gauge circuit, or by moisture reducing the earth leakage resistance of parts of the circuit so that the zero balance drifts. That the strain gauge meter is accurate.

2.

3.

4.

5.

Lab : Strain Measurement System

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ME56 Instrumentation & Control Eng. The 2nd Semester S.Y.20112012 Having gone through the check list, it can be claimed that the use of electrical resistance strain gauges (ERSG) presents a powerful tool for the designer in the many situations where mathematical models are highly complex or loadings arc not known. The present range of experiments provides a survey of the uses and possibilities. This experiment introduces the technique and application of strain measurement using electrical resistance gauges. Firstly there is a simple calibration beam which will permit the gauge factor to be checked B. Wheatstone Bridge The HAC20 Unit accepts inputs from quarter, half or full bridge strain gauge circuits like shown the below. These connection would be found in the most of strain measurement system depending on the applications.
Quarter-Bridge Configuration

Rl R1 + Rl

R g()

F
R g(dummy)

Vout

R2 Rl

= - 4Vr/GF(1+2Vr) (1+ Rl/Rg)

Half-Bridge Configuration for Bending

Rl R1 + Rl

Rg (+)

F
Rg (-)

Vout

R2 Rl

= - 2Vr/GF (1+ Rl/Rg)

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ME56 Instrumentation & Control Eng. 2012

Full-Bridge Configuration for Bending

The 2nd Semester S.Y.2011-

Rg(-)

R g(+)

F
R g(+)

Vout

F
R g(-)

F
= - Vr/GF

Where,

Vr = [(Vout/Vin)strained (Vout/Vin)unstrained]
Dummy or compression

+ve excitation C

Red T

+ve excitation Yellow Positive signal

Yellow

Signal

3 2 T 4

For balancing (tare) 0V Tension

Negative Green signal 0V

Blue (b) Full bridge connector

(a) Quarter and half bridge connector

HAC20 Unit connector

Materials required
1set HST2/10 Strain Measurement System Bench and Accessory Page 3/8

Lab : Strain Measurement System

ME56 Instrumentation & Control Eng. 2012 1 HAC20 Digital Strain Meter Unit 1 DMM 1 Calipers 1 HST.14A specimen 1 HST.14B specimen 1 HST.14C specimen 1 HST.14D specimen

The 2nd Semester S.Y.2011-

Procedure
As a general rule the color code for the gauge leads is blue and yellow for a tension gauge and red and yellow for a compression gauge but there are exception to this rule.

Part 1. Preliminary Measurement and familiarizing the HAC20 Unit

1. 2. 3. 4. Measure Rl, Measure Rg, the length of lead wire. What is accuracy of dial gauge and Calipers? Check the Excitation voltage for sensor provided by HAC20 Unit. Practice how to operate the HAC20 Unit

Part 2. Gauge Factor and Bridge factor.

1. Set up the simply supported beam HST14a as shown in the figure below on knife edges at 200 mm span with a load hanger on each overhanging end and a dial gauge at mid span to measure the upward deflection or the beam.

300mm

200mm

2. Measure the beam section. (b, h) 3. Connect the single gauge (c) (Red and Yellow leads on the socket 4 and 3) 4. One of the gauges (Red -Yellow or Blue Yellow leads on the socket 1 and 2) on the cantilever HSTl4b as a "dummy" temperature compensation gauge in the form of a quarter bridge circuit to the interface of a lead A to the meter. Keep strictly to the color coding when connecting the gauge (c) to ensure that the red lead is connected to the correct outer socket numbered 4 and the yellow lead to socket number 3. This will produce a +ve reading for tension. The dummy gauge leads are to be connected to the sockets numbered 1 and 2. Lab : Strain Measurement System Page 4/8

ME56 Instrumentation & Control Eng. The 2nd Semester S.Y.20112012 5. Power On the HAC20 meter and connect the sockets into the each channel. 6. Set the gauge factor on the meter to the value marked on beam HST14a. the gauge factor is provided by manufacturer of the strain gauge. The strain gauge factor for the strain gauge used in this experiment is 2.12.
400 b h

Gauge c
100 100 100

Gauge a
100

Beam cross section Gauge b

30 45

P P P

7. Set the number of active gauges to one 8. Set zero the "tare" reading on the meter. 9. Add equal increments or 5 N load to each hanger simultaneously up to a maximum not exceeding 40 N, and record the strain readings(ERSG), Analog Output and dial gauge reading for each increment following Table 1. Carry on recording readings as the load is decreased by equal increments of 10N. Table 1 Calibration Beam Load at Each End (N) 0 5 10 15 20 25 30 35 40 30 ERSG Strain () 0 Analog Output (V) Mechanical Strain Deflection (mm) 0

Dial Gauge Reading (0.01 mm) 0

Strain ()

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ME56 Instrumentation & Control Eng. 2012 20 10 0

The 2nd Semester S.Y.2011-

10. Now change the single gauge (c) for gauge (a) but keeping the "dummy" gauge of HST14b. 11. Set zero the meter 12. And record the gauge readings following the table 2 Table 2 Calibration Beam Load at Each End (N) 0 20 40 13. 14. 15. 16. ERSG Strain () Analog Output (V) 0 Mechanical Strain Dial Gauge Deflection Reading (0.01 mm) (mm) 0 0

Strain ()

Next change the single gauge to gauge (b) which is on the underside of the beam. connect the blue lead to socket 4. Set zero the meter And record the gauge readings following the table3

17. Finally rearrange the whole set up to use gauges (a) and (b) to form the half bridge circuit taking care to follow the color coding at the interface (blue lead to socket 1 and red lead to socket 4 and the yellow leads to 2 and 3). 18. Change the meter setting to two active "gauges, which will introduce a divide by two function. 19. Set zero the tare reading. 20. Take readings for a set of load increments of 10 N up to 40 N following the table4. Table 3 Calibration Beam Load at Each End (N) 0 20 40 ERSG Strain () Analog Output (V) 0 Mechanical Strain Dial Gauge Deflection Reading (0.01 mm) (mm) 0 0

Strain ()

Table 4 Calibration Beam Load at Each End (N) ERSG Strain () Analog Output (V) Mechanical Strain Dial Gauge Deflection Reading (0.01 mm) (mm)

Strain ()

Lab : Strain Measurement System

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ME56 Instrumentation & Control Eng. 2012 0 0 10 20 30 40

The 2nd Semester S.Y.20110 0

Results and Discussion

1. Draw the strain gauge measurement block diagram including sensor, signal conditioning and signal presentation. 2. Plot the strain readings against load for the simply supported beam using MS EXCEL program and draw the best fit straight line through the points. 600 500 400 300 200 100 0 -100 ERSO Strain 10 20 Mechanical Strain 30 40 Applied Load (N) Strain ()

3. Calculate Hysteresis error of this strain measurement system from the collected data on the Table1 and discuss it. 4. Calculate the linearity of this strain measurement system. And discuss it. 5. Note whether the three gauges give similar readings when used with the inactive dummy, and the effect or the final arrangement. Calculate the Mechanical strain from the dial gauge deflection using the geometrical expression and fill the calculated values on the column on each table.

= 8h / L2
where = deflection h = half the depth of the beam L = span of the beam

This, being independent of material properties, gives true strain and hence can be used to verify the quoted gauge factor. It is possible to calculate the surface stress of the beam from =M/Z

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ME56 Instrumentation & Control Eng. The 2nd Semester S.Y.20112012 and this could be compared with the stress obtained using an assumed value of the modulus of elasticity (say 205 x 103 N/mm2) in the expression = E. 7. Plot an error analysis graph of all the results in from Table 1 up to Table 4. This is done by calculating the mechanical strain from the dial gauge deflection values to use as abscissa, and plotting the corresponding ordinates given by mechanical strain minus electrical strain reading. For the reversed active arrangement it may be necessary to halve the apparent electrical strain.

9. The results of Part 2 provide data for assessing the variability or readings from strain gauges, 40 and the magnitude of errors. Calculate the likely percentage error in reading and in F.S, and comment on the probable sources of inaccuracies. 30

Error Analysis

20 Conclusion 10 0 -10 -20 -30

200 Lab : Strain Measurement System 0 Table1 Table3

Mechanical Strain Electrical strain

400 Table2 Table4

600

800 Page 8/8 Mechanical strain