Applications

Measuring and
analyzing pressure,
force and acceleration
2 www.kistler.com
measure.
analyze.
innovate.
Kistler in Brief
Kistler Instrumente AG enjoys a world-
wide reputation as a leading supplier of
measurement technology. Kistler
sensors use the piezoelectric effect,
piezoresistive or capacitive, to measure
pressure, force and acceleration.
Our aim
The top priority at Kistler is to satisfy
the needs and requirements of our
customers. This includes developing
leading-edge products and helping our
customers to obtain optimum results
from their application.
Our philosophy
Our success is based on innovative
technologies, precise knowledge of the
market and a comprehensive range of
services.
measure. analyze. innovate.
measure.
Our core strength is the use of sensors
to measure physical magnitudes.
analyze.
The magnitudes measured have no
intrinsic significance. It is only through
analysis and evaluation of the measure-
ments that a process can be under-
stood. To this end, we supply our
customers with all the necessary hard-
ware and software.
innovate.
The information obtained in this way
constitutes the basis for innovative
products and serves to open up new
horizons.
Successful research
Over the years, Kistler's heavy invest-
ment in research and development has
generated a number of revolutionary
innovations:
the world's first commercial quartz
sensor
the patented two-wire constant
current technology constituting the
basis for today's sensors with
integrated microelectronic circuitry
the first high-temperature pressure
sensors (up to 350C, polystable
quartz slice)
the first three-component force
measuring sensors.
These innovations resulted in solutions
to numerous measuring problems for
the first time.
Comprehensive services
Kistler also supplies a comprehensive
range of services, including technical
advice for all applications, calibration
and repair services, as well as regular
training.
Kistler today
Established in Wintherthur (Switzer-
land) in 1959, Kistler currently employs
650 staff worldwide, around 15% of
whom are engaged in research and
development.
In addition to its headquarters in Swit-
zerland, Kistler is represented in over
50 countries and has group companies
in Austria, Denmark, Finland, France,
Germany, Italy, Norway, the Nether-
lands, Sweden, the United Kingdom,
Japan, the USA, the Peoples Republic
of China, India, Korea, Singapore and
Taiwan.
Products Pressure 4
Force 5
Acceleration 6
Electronics and Software 7
Applications Engines 8
Research and Development,
Cylinder Pressure Monitoring
Vehicles 12
Suspension, Safety,
Tires, Road and Traffic
Manufacturing 16
Research,
Process Monitoring,
Product testing
Plastics processing 20
Injection Molding,
Extrusion
Biomechanics 24
Gait Analysis, Balance,
Performance
Acceleration Applications 26
Automotive/Transportation,
Aerospace and Military,
Condition Monitoring
Other Applications 28
Chemicals/Pharmaceuticals,
Explosives,
Pneumatics and Hydraulics,
Conveyances and Transport
Tailor-made 30
System Solutions
Service to Order 34
3 www.kistler.com
Contents
4
Pressure
In piezoelectric pressure sensors, the
pressure acts on the surface of a dia-
phragm which converts it into a pro-
portional force. This force is transmit-
ted to a crystal, giving rise to an electric
charge on the opposing surfaces.
In piezoresistive sensors, the pressure
is converted into an electrical signal
by the elastic bending of a diaphragm
made of monocrystalline silicon.
A Wheatstone bridge consisting of
semiconductor resistances diffused in
the diaphragm is thereby detuned in
proportion to the pressure.
With both types of sensors, the output
signal (the electric charge measured in
pC or the voltage) is exactly propor-
tional to the pressure applied. Piezo-
electric sensors can be used to make
only quasi-static and not static measure-
ments. On the other hand, they are
ideal for the precise measurement of
fast processes, such as combustion
Kistler sensors measure
pressures accurately and
precisely over a wide range,
even under extreme
environmental conditions.
6041A
ThermoComp

,
water-cooled pressure
sensor with measuring
range 0 ... 250 bar.
pressure in an engine. Piezoresistive
sensors, on the other hand, are perfect
for measuring static pressures.
Typical applications
Dynamic measurement of cylinder
pressure and fuel injection pressure in
the development of internal combus-
tion engines
Continuous monitoring of cylinder
pressure in large diesel engines
Measuring explosive pressures in the
development of air bags
Regulating cavity pressure in injection
molding so as to maximize molding
quality and minimize scrap
www.kistler.com
5 www.kistler.com
Force
Single and multi-component
force sensors
With Kistler quartz sensors, forces
can be measured both directly and
indirectly. With direct measurement,
the sensor is placed directly in the path
of the force, which results in high
accuracy, irrespective of the point of
application of the force. Where the
sensor cannot be placed directly in the
path of the force, indirect measure-
ment is used, with a large part of the
force being passed through a shunt.
Where the force acts in only one direc-
tion, it can be measured with a single-
component force sensor. Forces acting
on various axes require the use of
multi-component sensors.
Typical applications
Quality assurance in manufacturing
and assembly
Monitoring of presses
Measuring cutting forces in
metal-cutting machining
Biomechanics
Product testing
Material testing
Dynamic weighing of moving vehicles
Wheel force measurement
Forces move masses
Kistler sensors detect forces
with infinite resolution and
are extremely rugged.
When subjected to a mechanical load,
quartz produces an electrical charge in
direct proportion to the force acting
on it. In other words, the quartz acts
both as a spring element and as a
transducer. The force to be measured
generates the signal directly. The out-
put signal of a piezo crystal is exactly
linear and free from hysteresis, as well
as offering a wide measuring range. As
quartz is highly rigid, the measuring
deflection is very small, generally wit-
hin a few micrometers. Thanks to their
high natural frequency, quartz sensors
are excellent for measuring ultra-fast
high frequency processes in the micro-
second range.
9333
Press Force Sensor
with measuring range
up to 120 kN.
6 www.kistler.com
Acceleration
It is necessary to determine the
torsional behavior of vehicle bodies,
the stability of machine anchorings,
the vibrational behavior of the suppor-
ting structure of roller coasters.
For dynamic applications, Kistler has
been making use of piezoelectric
sensors for many years. These sensors
are highly reliable and they can be used
to measure frequencies over a very
wide range, from minimal amplitudes
in the g range to enormous shocks
measuring thousands of g. To measure
static or low frequency acceleration,
micro machined silicon sensors are the
technology of choice. Their measuring
principle is based on a change in
capacitance of the measuring element
in proportion to acceleration.
Typical applications
Monitoring the vibration of rotational
machines such as pumps and turbines
Modal analysis in vehicle and aircraft
development
Measuring shock in car crash testing
Seismic measurements in tunnel
construction
Machine tool monitoring
General vibration measurement in the
laboratory
The same Kistler sensor can
be used to detect changes
in velocity from moderate to
lightning speeds.
Kistler sensors provide valuable
information in countless applications.
For example:
The vibration signal generated by
turbines or engines provides valuable
information on the condition of
various moving parts.
The dynamic behavior of aircraft
wings needs to be tested and
checked.
The bogies of high-speed trains have
to be kept in position.
8795A
K-Shear

triaxial ac-
celerometer with a
measuring range of
50 g
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Electronics and Software
Typical applications
Measuring instruments for research
laboratories
Automation components for OEM
Measuring instruments and control
devices for production
Measuring magnitudes is
the first task. Analyzing the
results is the next.
Kistler products help to give
us completely new insights.
5015A
Universal charge
meter with a measur-
ing range from
2 to 2 200 000 pC.
Even ultra-precise measurements do
not in themselves constitute useful
information. This is only achieved with
the analysis and evaluation of the data.
Kistler's electronic instruments and
software products specifically designed
for the various applications provide you
with valuable support and new know-
ledge.
While our instruments deliver high
performance, they are simple to operate.
We offer you support, as necessary,
with the installation and maintenance
of measuring systems throughout their
service life.
8 www.kistler.com
Accurate knowledge and
analysis of combustion
chamber pressures are
essential for the develop-
ment of modern internal
combustion engines.
For over 40 years, Kistler has been the
innovator and market leader in engine
measuring technology. Our pioneering
achievements include the development
of the worlds first M10 and M8 water-
cooled sensors, as well as the miniature
pressure sensor with M5 thread. Our
precision sensors provide indications and
measurements of cylinder pressures,
injection pressures as well as intake and
exhaust pressures.
Thanks to the extreme miniaturization
of its piezoelectric sensors, Kistler is
also able to offer new measuring spark
plugs and measuring glow plugs, which
allow pressures to be measured with-
out need for additional cylinder head
bores.
For signal conditioning, Kistler supplies
high precision measuring amplifiers for
use in the laboratory and on the test
bed. The latest generation amplifiers
allow the construction of modular and
computer-controlled systems.
Piezoelectric sensors are ideal for
measuring combustion pressure, where
the advantages of wide temperature
range, small dimensions, high measu-
ring dynamics and long service life are
of high importance.
Piezoresistive sensors are used for
measuring injection pressures as well as
for intake and exhaust measurements;
they allow both static and dynamic
measurements. These sensors measure
pressure with a resistance bridge
diffused in silicon.
Kistler In Practice:
Engines
9 www.kistler.com
Water-cooled sensor
6041A, 6061B
Standard sensor for
precision measure-
ments, low thermal
shock error, M8 and
M10 mounting
thread.
Miniature pressure
sensor 6052B1
Small, accurate,
uncooled sensor for
extremely confined
spaces. Front sealing
with M5 thread.
Measuring spark
plug 6117B
No indicating bore
necessary, virtually
front flush sensor
mounting. Available
for all standard heat
values and with M14
thread.
Miniature pressure
sensor 6001
Small, accurate,
uncooled pressure
sensor for universal
applications, shoulder-
sealing with 5.55 mm
front diameter.
Miniature pressure-
probe 6055BB,
6057A
Extremely small
(4 mm diameter)
uncooled pressure
sensor. Mainly used
in glow plug adapters.
Combustion
Application
As cylinder pressure measurement has
to cope with very rapid dynamic pro-
cesses associated with high loads, the
sensor must exhibit good thermal
shock behavior and knock resistance,
as well as excellent linearity.
The piezoelectric principle has proved a
worldwide success in precision cylinder
pressure measurement. Uncooled or
water-cooled sensors are mounted in a
separate indicating bore in the engine.
Measuring spark plugs or glow plug
adapters are also used for pressure
measurements on production engines.
Use/purpose
To improve efficiency
To reduce fuel consumption
To reduce exhaust emissions
To increase knock resistance
To improve performance
To improve cold starting behavior
Gas exchange
Application
Low-pressure indication for intake and
exhaust measurements is an important
part of engine measurement technology,
the main tool for this purpose being
static and dynamic measuring piezo-
resistive pressure sensors. Kistler offers
a wide range of water-cooled and
vibration-damped adapters. Switching
adapters which incorporate atmospheric
pressure are also available for use with
piezoresistive sensors.
Use/purpose
To optimize volumetric efficiency
To optimize and analyze gas
exchanges
To obtain absolute cylinder pressure
measurements during the gas
exchange cycle
To optimize the intake manifold
To optimize valve control times
Rugged pressure
sensor 6125B
Uncooled pressure
sensor, ground-
insulated, front flush
mounting, shoulder-
sealing, front 6.2 mm
diameter.
Research and Development
Kistler pressure sensors, along with
computer-controlled simulation tools,
play a key role in the development
of modern, high-performance, low-
emission combustion engines. For
example, the development of new
methods of combustion, such as direct
injection in diesel engines, would have
been impossible without the precise
recording of the pressure curve in the
cylinder. Meanwhile, low-pressure
indication has become established as
an essential tool in the optimization
of the gas exchange elements (e.g.
intake manifold, exhaust system and
valve control).
10 www.kistler.com
Injection
Application
As the injection process has a consider-
able influence on the fuel mixture,
injection pressures and timing must be
optimized in order to match the engine.
Piezoresistive high-pressure sensors
with measuring ranges up to 5000 bar
are used for this purpose. In addition,
Kistler supplies easily mounted clamp
adapters for simple measurement taken
directly at the injection line.
Use/purpose
To improve efficiency
To improve particle emission in
diesel engines
To improve mixture formation
To improve combustion
To improve exhaust emissions
To optimize injection nozzles
Knock detection
Application
Knocking superimposes strong vibra-
tions on the cylinder pressure curve;
this can lead to engine damage within
a short time. However, to obtain high
performance and low fuel consump-
tion, the engine has to be operated as
close as possible to the knock limit. To
calibrate knock control in the electronic
engine management system, it is essen-
tial to have reliable measurements of
the onset of knocking, particularly at
high speeds. The sensor characteristics
required here are stability and high
resonance frequency.
Use/purpose
To optimize the electronic engine
management system
To improve engine performance
To reduce exhaust emissions
To prevent engine damage
To match the electronic engine
management system to different
types of fuel
7013C, 7613C
Sensor with low
thermal shock error
and very long service
life. Suitable for use
in industrial condi-
tions (dirt, humidity
etc).
Crank angle encoder
2613B
System for measuring
the crank angle of the
crankshaft for crank-
shaft-synchronous
cylinder pressure
measurements up to
20 000 1/min.
Glow plug adapter
6535Q
No indicator bore
necessary, customer-
specific design,
M8/M10 thread.
High-pressure sensor
4067
Standard piezoresistive
sensor for measuring
injection pressures up
to 5 000 bar,
M10 thread.
6013CA, 6613CA
Rugged sensor with
M10 thread for con-
tinuous monitoring
and control of gas
engines. Integrated
charge amplifier with
range switching.
11 www.kistler.com
Gas engines
Application
To minimize emissions and maximize
efficiency in the operation of gas
engines, the combustion curve must be
optimized for each individual cylinder.
The best way of doing this is by regula-
ting the cylinder pressure. To this end,
Kistler has developed a continuous
operation sensor specifically designed
for the control of gas engines. Its excel-
lent long-term stability and low short-
term drift make it suitable for difficult
measuring tasks.
Use/purpose
To detect/control knock
To detect faults
To limit peak pressure
To calculate the performance of
individual cylinders
Diesel engines
Application
Kistler has developed the extra long-
life 6613 for continuous cylinder pres-
sure monitoring. This rugged sensor is
particularly suitable for large engines.
The 6613 is primarily suitable for ma-
nufacturers of evaluation systems.
For startup and maintenance, Kistler
offers handy and easy to operate
measuring instruments and software.
Use/purpose
To reduce fuel consumption
To optimize maintenance intervals
To detect damage at an early stage
Cylinder Pressure Monitoring
Cylinder pressure monitoring is the key
to the efficient operation of large diesel
engines and gas engines. It allows faults
and wear to be detected and corrected
at an early stage. Kistler offers the right
sensor for every application, from
simple peak pressure measurement to
the more demanding online monitoring.
6302A, 6352A
Small, rugged measu-
ring probe for conti-
nuous monitoring of
gas and diesel engi-
nes. Available with
charge output or in-
tegrated amplifier.
6229A, 6729A
For measurements on
diesel engine injection
systems and for use
in hydraulic test beds
on large engines.
Integral impedance
converter.
2515A
Handheld peak-pressure
measuring instrument
for slow and medium-
fast running diesel
engines. Memory for 20
recordings and PC soft-
ware for evaluating the
cylinder pressure curve.
12 www.kistler.com
To improve vehicle safety,
it is essential to understand
the critical processes invol-
ved. By measuring pressure,
force and acceleration,
Kistler sensors create the
basis for improvements.
Nowadays in motor vehicle engineering,
improvements are possible only with
accurate measurement of the critical
parameters. Kistler offers the automo-
tive industry a broad spectrum of
sensors for the measurement of force,
strain, torque, pressure and acceleration.
These are used in the development of
vehicles and tires, as well as in crash
testing and in restraint systems.
Kistler sensors supply the data needed
for constant improvements in safety,
whether on the active side (tires,
suspension, braking systems) or the
passive side (crash systems, driving
comfort, road load monitoring).
Chassis/Suspension
The safety of a vehicle is highly depen-
dent on the design of chassis and sus-
pension. Unsprung masses, i.e. wheels
and wheel suspension, have a great
influence on vehicle handling. Develop-
ment engineers strive for a compromise
which best combines good handling,
high cornering speeds and passenger
comfort.
In 1981, Kistler introduced the first
rotating wheel dynamometers into
the market. Equipped with quartz
sensors, for the first time they enabled
measurements to be made on vehicles
at speeds up to 200 km/h. However,
as these first dynamometers were much
heavier than a standard wheel, they
affected the vehicle's handling charac-
teristics. Today, Kistler's six-component
measuring wheels only add about three
kilograms to the weight of the vehicle.
Yet, thanks to ultra-lightweight cons-
truction using high strength alloys, they
are sturdy enough to measure forces
and frequencies far exceeding the nor-
mal operating range of a passenger car.
Kistler's rotating wheel dynamometers
also help development engineers to im-
prove ABS and traction control systems,
when quartz and silicon sensors simul-
taneously detect the pressure in the
braking and hydraulic systems and in
the control valves.
RoaDyn

P106
9294A
1-component measuring wheel for heavy pas-
senger vehicles, light commercial vehicles and
SUVs. For measuring drive and braking mo-
ments. The signals are transmitted by wireless.
Kistler In Practice:
Vehicles
Hub
Rim
Measuring
wheel
Hub adapter
Rim
adapter
13 www.kistler.com
Dynamics
Application
The Kistler measuring wheel illustrated
below on Page 12 represents the cur-
rent state of the art, with a single sen-
sor making it possible to carry out dri-
ve, braking and coasting tests as well
as statutory acceptance tests. The sen-
sor is screwed to an aluminium produc-
tion rim and can be fitted easily to any
car in the shortest possible time. The
data measured are transmitted by wire-
less to a receiver and control unit.
Use/purpose
Even at the lowest torques, the Kistler
single-component measuring wheel
provides the highest resolution without
having to compromise its rugged de-
sign.
Strength
Application
No matter how sophisticated the
methods of calculation, the operational
strength of car components and entire
vehicles needs to be constantly tested
on the test bed. The data recorded on
the test track can be introduced on the
test bed in a compressed form and
used to load components until they fail.
Use/purpose
Kistler sensors and measuring wheels
enable accurate monitoring of all forces
introduced. Thanks to their rugged
construction, piezoelectric sensors are
particularly suitable for use under these
extreme conditions.
Comfort
Application
The bogies of high-speed trains are
complex electromechanical systems
which need to absorb the loads gene-
rated by high-speed motion and, at the
same time, to ensure the safety and
comfort of passengers. Multi-axis
accelerometers sensors are built into
these bogies to measure vibration and
forces acting on the railcars in different
terrains and to draw the appropriate
conclusions. Continuous monitoring
of vibration also enables changes to be
detected and remedied immediately
without having to wait through normal
servicing intervals.
Use/purpose
To maintain a constant high speed
through curves and over difficult
terrain, thus reducing journey times
and helping the railroad to compete
with other forms of transport. To in-
crease passenger safety and comfort
by stabilizing the railcar. To minimize
rolling stock breakdowns, downtimes
and wear, thus making rail travel more
reliable and extending the service life
of the equipment.
RoaDyn

S625
9266A1
6-component strain gage measuring wheel for
passenger vehicles, light weight carbon fiber
design.
RoaDyn

V6HT
9274A
6-component strain gage measuring wheel for
medium and large trucks. For measuring all for-
ces and moments acting on the wheel.
Accelerometers
Single axis and multi-axis sensors provide
reliable measurements from 0 Hz to 20 kHz.
14 www.kistler.com
Tires
Tires the legs of the car have an
enormous influence not only on safety
but also on efficiency and comfort.
For the development of new tires and
the improvement of existing ones,
manufacturers the world over rely on
Kistler's Fixed Wheel Dynamometers.
The high rigidity of the quartz dynamo-
meter allows accurate force and torque
measurements to be taken over a range
of several hundred hertz. The data
obtained provides information on the
interaction between tyres and road.
There is a choice between two standard
versions: one for car tires with forces
typically up to 30 kN and a version for
trucks with forces up to 70 kN.
Application
Over a hundred of Kistler's fixed wheel
dynamometers have been sold. They
are used by almost every manufacturer
of tire test beds, as well as by univer-
sities and research laboratories engaged
in fundamental research testing.
Use/purpose
Tire data characteristics such as roll
resistance, slip angle, directional sta-
bility, noise and damping provide ma-
nufacturers with information which is
vital for the continued improvement of
their products.
Crash barrier, Ford Motor Co.
Crash barrier with swiveling facility,
equipped with 3-component sensors.
SmartCrash

barrier Audi AG
World innovation with integrated electronics
and digital preprocessing.
Vehicles
Safety
Passive safety defines the behavior of
a vehicle in the event of any impact,
whether from the front, side or rear.
Vehicles are designed with the utmost
care using powerful CAD tools, but,
when it comes to safety, nothing can
be left to chance. Only crash testing
under the most realistic conditions
possible can provide the information
needed.
For over 25 years, car manufacturers
such as Audi, Ford, Volvo, Daimler-
Chrysler and BMW have relied on Kist-
ler force measuring plates. And with
good reason! The characteristics of
piezoelectric measuring instruments are
perfectly suited to the requirements of
crash-test measurement. Their sensitivity
is independent of the center of pressure
and, despite the wide measuring range,
the resolution is large enough to detect
even small changes in force. Customers
also appreciate the way that Kistler
tailors every measuring device to their
own individual requirements. For
example, to equip the Volvo safety
center, Kistler has just developed corner
segments for offset crash tests which
are capable of measuring forces of up
to 1.5 MN in two directions simul-
taneously.
Crash
Application
Kistler's modular measuring system
permits a flexible response to all
customer requirements. Each segment
consists of a baseplate with several for-
ce measuring plates and a charge am-
plifier module. The segments forming
the crash barrier come from the factory
fully wired so that the system can be
rapidly installed on the anchor plate.
The charge amplifiers, which are con-
trolled via a common bus, feed the
measurands as analog signals to be
recorded on the computer.
Use/purpose
The rugged construction of Kistler
crash barriers guarantees reliable
measurements even after thousands
of tests.
Vehicle components
Application
Kistler sensors can be used in dummies
and restraining devices (safety belts,
airbags) as well as in helmet testing.
RoaDyn

P530
9295A
This measuring hub measures forces and mo-
ments acting on the tires.
15 www.kistler.com
Road surfaces
Application
Kistler Lineas force sensors can be
incorporated into all standard road sur-
faces. The elastic properties of Lineas
sensors and their response to abrasion
correspond largely to those of the road
surface itself. This is important because
the quality of a WIM system equally
depends on how well the sensor charac-
teristics conform to those of the road-
wear characteristics.
Use/purpose
Road surfaces and substructures need
to be protected against overloaded
and badly loaded vehicles
Repairs are not only costly but also
result in traffic congestion
The recording and elimination
of overloaded or wrongly loaded
vehicles results in a long term
improvement in traffic safety
Weight measurement
Application
In tire research, dynamic measurement
of wheel load distribution is an impor-
tant means of assessing force and
pressure distribution within the tread
contact. It is also important in road
building research to investigate the
factors involved in serious damage to
the road surface.
Modulas sensors are indispensable for
road surface management systems and
for research into related phenomena
such as cracking and rutting.
Use/purpose
Collecting statistical data (number of
vehicles, classification, loading etc.)
Protection against overload (pre-
selection, overload monitoring, bridge
and building protection)
Road tolls
Road surface research (cracking and
rutting)
Road surface management systems
Road and Traffic
Kistler measuring technology not only
contributes to the active and passive
safety of vehicles but also helps to pro-
tect roads against overloaded vehicles.
Overall weight is not the sole factor.
Damage to road surfaces and substruc-
ture comes mainly from excessive wheel
and axle loads, stress is increasing to
the fourth power of the wheel load.
The Kistler WIM (Weigh in Motion)
system allows axle loads to be deter-
mined as vehicles drive past. Thanks
to WIM, overloaded vehicles can be
taken off the road promptly, thereby
preserving the road surface, avoiding
expensive maintenance work and traffic
congestion and increasing road safety.
Lineas

9195C
Only worldwide WIM sensor which can be
contour shaped after installation.
Modulas
9197A5
32-channel quartz sensor.
Charge amplifiers
5153A
9/18-channel charge
amplifier for Lineas
sensors.
Charge amplfiers
5151A
32-channel charge
amplifier for Modulas
sensor.
16 www.kistler.com
PLC
F
Kistler In Practice:
Manufacturing
Recorded data permits
repeatability, thus allowing
the quality of manufactured
products to be increased and
documented.
Precision and accurate process moni-
toring are of great importance in
industrial production. Sensors permit
processes to be measured by recording
the forces, torques, strains and vibra-
tions in machinery and tools. When
this data is analyzed and recorded,
the manufacturing processes become
repeatable, thus allowing product
quality to be monitored, documented
and improved.
Kistler piezoelectric sensors offer various
technical advantages. As well as having
a wide measuring range which makes
them highly resistant to overload, they
are ideal for recording rapid processes
and have a practically unlimited service
life.
To obtain optimum results, the
measuring system must be designed to
fit the application. This includes the
sensor, cable, charge amplifier and the
appropriate indicating and evaluation
instruments. Kistler measuring techno-
logy permits measurement, monitoring
and control of a whole range of manu-
facturing processes.
1-component Press
Force Sensor 9343
Ready to install force
sensor, three calibra-
ted measuring ranges
for 100, 10 and 1 %.
Charge meter
5015A
Flexible configuration.
The measurands (force,
pressure, etc.) are
shown in the display.
Highly sensitive force
sensor 9205
Measurement of the
smallest tensile and
compression forces
0 50 N.
1-component load
washer 9021A
Universally applicable
for maximum forces
from 7.5 to 1 200 kN.
Control Monitor
CoMo View

5863A2
Web server for pro-
duction monitoring of
manufacturing pro-
cesses.
Miniature force sen-
sor 9211A
Extremely compact
design, only 6 mm
diameter.
Analog signal [V/mm]
Displacement sensor
Control signals
Charge amplifier,
Control monitor
Machine
control
Force sensor L
w
Electrical
charge [pC/N] Analog signal [V/N]
17 www.kistler.com
Primary Forming
Application
The correct proportion of force and
pressure is crucially important in forming
a shapeless substance into a solid body
(e.g. pressing powder into tablets,
pellets, sinter tools, or die-casting
metals under pressure). Kistler's flexible
and reliable measuring technology
serves to optimize the shape, density
and strength of the manufactured parts.
Use/purpose
To achieve minimum tolerances
Re-forming
Application
Whether coining, rolling, deep drawing,
forging, punching or pressing of metal
parts: Kistler force measurement sensors
permit prompt detection of errors, for
example defective parts or non-con-
forming materials arising from varying
press forces.
Use/purpose
Kistler measuring technology detects
errors in dimensions, material charac-
teristics and the positioning of fed-in
parts
Machines and tools are protected
against overload by online monitoring
of the process forces
1 or 3-component
force sensor 9602
Integrated electronic
circuitry, manual
measuring range
switching 1:5.
HighSens strain sen-
sor 9232A
Measurement of
forces at machine
surfaces,
highly sensitive.
Industrial charge am-
plifier ICAM, 5073A
1, 2, 3 or 4 channels,
rugged case rated at
IP65.
Longitudinal measu-
ring pin 9243A
Measurement of
forces and strain in
structures, mounting
in M10 thread.
SlimLine force sensor
9133B
Compact design,
with integrated cable
for mounting in
structures.
VarioComp force
sensor 9601A
Number of measuring
axes, cable or
connector variations
as requested by the
customer.
18 www.kistler.com
Assembly and Joining
Application
In longitudinal presswork, clinching or
bonding (i.e. in the permanent joining
of parts), the consistency of large scale
production is best monitored by
measuring the force applied, using
piezoelectric sensors positioned directly
in the force flux. Alternatively, the qua-
lity can be monitored indirectly by
strain measurement.
Metal Cutting Machining
Application
The aim of metal-cutting machining
(i.e. turning, milling, grinding or boring)
is to achieve processes which are as
fully automatic and reliable as possible.
One to three-component force measur-
ing sensors are fitted in the base plate
of a turret-type tool head. They
measure the machining force which
supplies the necessary information on
cutting, feed and passive forces. At the
same time, they protect machine tools
against overload or tool collisions and
prevent unnecessary wear.
Use/purpose
Kistler measuring technology
optimizes the machining process,
making it safer and more efficient
Typical areas of application:
Force measurement during the
crimping of cable ends ensures
fault-free electrical connection.
Automated systems carry out
assembly operations with force and
torque monitoring, thereby guaran-
teeing consistently high quality of
the mass-produced products.
Measurement of the electrode
clamping force in spot welding
optimizes the welded joint, e.g.
in vehicle body construction.
Screw tightening with torque-con-
trolled assembly operations,
thereby ensuring the fault-free
manufacture and documentation of
safety components such as airbags
or steering columns.
Measurement of force-proportional
strain on structures of wobble riveting
machines ensures high strength
joining of components.
Use/purpose
The joining process can be docu-
mented
Conforming and non-conforming
parts are detected objectively
Constant monitoring of the condition
of the machine
Control Monitor
5859A
CoMo II-S for process
monitoring of a force-
displacement curve
during manufacture.
19 www.kistler.com
Product Testing
Testing machines
Application
High quality products require qualified
test methods. Kistler's wide product
range enables optimum measurement
solutions in the widest variety of
testing systems. Kistler equipment
measures tensile forces in material
testing machines, records impact forces
and accelerations in crash test systems,
or analyzes forces and vibration on
vehicle test beds.
Use/purpose
These measurements are ultra-precise,
the compact and enormously rigid
construction of Kistler force sensors
allowing highly dynamic processes to
be recorded.
Switches and connectors
Applications
Quantity production of connectors,
springs or contact elements requires
reliable error detection. End products
of the highest quality can be produced
by means of a test interval in full or
in the form of random sampling to
record the force or torque function.
Use/purpose
Safety components (e.g. the plug
connections of airbag systems) need to
be absolutely reliable. Equally, contact
elements (relays) need to function
reliably even after thousands of cycles.
It is thanks to Kistler spring-force
measuring technology that millions of
PC users can rely on their mouse to
keep clicking without fail.
3-component force
sensor 9067B
Compact design, for
force measurement in
the X, Y and Z axes.
3-component quartz
force link 9377B
Preloaded and
calibrated, for
measuring tensile and
compression forces.
Reaction torque sen-
sor 9349A
Torque measurement
of 1 ... 1000 Nm,
2 calibrated measuring
ranges of 100, 10 %.
2-comp. dynamome-
ter 9125A
Cutting force measu-
rement on a rotating
tool, up to
max. 25 000 1/min.
3-comp. dynamome-
ter 9257B
Force measurement
with high resolution,
high natural frequency,
splash-proof IP67.
Multichannel charge
amplifier 5070A
For 4 8 indepen-
dent measuring chan-
nels, remote control-
lable via IEEE-488 or
RS-232C.
20 www.kistler.com
Kistler In Practice:
Plastics Processing
Injection Molding
In injection molding, the processes in
the mold determine the characteristics
of the finished product. There is no
way of observing or precisely calculating
these processes. Mold cavity pressure is
the only quantity to describe the entire
process from the injection phase,
through the compression and holding
pressure phase, to the residual cooling
time. Mold cavity pressure correlates
with all the characteristics of the molded
part, such as dimensions, burs, sink
marks, blowholes, shrinkage, distortion,
weight and morphology.
Optimum molding characteristics are
achieved when the mold cavity pressure
exhibits a constant gradient during the
injection phase. At the moment of
volumetric filling, a switch must be made
from the speed-regulated injection
phase to the pressure-regulated holding-
pressure phase. At this point in time,
the pressure in the mold is marked by
a characteristic kink in the curve. The
subsequent compression phase is
followed by the holding-pressure phase
in which the volume contraction is
equalized. At the time of ejection from
the mold, the pressure must have fallen
to the ambient pressure. Kistler puts
these scientific findings to good use
in developing systems for process opti-
mization, monitoring and control.
Kistler products are used to
monitor and control proces-
ses on the basis of pressure
and temperature measure-
ment, thus permitting an
increase in both quality and
productivity.
To optimize, monitor and control
processes, pressure and temperature
curves must be accurately measured
and evaluated. In this regard, the dyna-
mics of the sensors and the recording
location are of critical importance.
Kistler sensors are applied precisely
where the products are manufactured,
i.e. in the mold, while miniaturization
allows them to be used in complex com-
ponents.
High precision electronic circuitry is
needed to condition and evaluate the
sensor signals, and for this reason many
OEMs use Kistler charge amplifiers. In
addition to amplification of the signals,
these amplifiers are increasingly
employed to carry out more complex
control operations.
Kistler system technology optimizes,
monitors and controls processes on
the basis of pressure and temperature
measurements. This minimizes waste,
improves quality, reduces cycle times,
shortens set-up times and, in short,
brings about a considerable increase
in productivity. In cooperation with
research organizations, Kistler is
constantly engaged in developing new
methods to increase the efficiency of
plastics processing operations.
Pressure sensor
6157B
Mold cavity pressure
sensor with
4 mm diameter,
for extremely high
mold temperature.
Pressure sensor
6159A
Mold cavity pressure
sensor with
2.5 mm diameter,
for extremely high
mold temperature.
21 www.kistler.com
Nozzle pressure measurement
Application
Sensors in the nozzle or screw ante-
chamber enable the melt pressure and
melt temperature to be recorded. The
injection work can be calculated from
the integral of the melt pressure over
the screw travel. This result provides
information on the viscosity of the ma-
terial. With hydraulic injection molding
machines, the melt pressure is used as
an optional control variable alongside
the hydraulic pressure. This achieves
reproducible process control. In
machines with an electric drive, the melt
pressure is the only suitable control
variable.
Use/purpose
Monitoring of material fluctuations
(viscosity)
Optional control variable with
hydraulic machines to increase
reproducibility
Control variable in electrical machines
Tie-bar strain measurement
Application
High closing forces are especially im-
portant in injection molding machines
used for manufacturing large molded
parts. Here, the loading on the tie bars
needs to be known in order to prevent
expensive breakdowns. Kistler longitu-
dinal measuring pins screwed into the
center of the tie bar expand in propor-
tion to the closing forces, thus serving
to measure the strain. This measuring
principle can be used to control closing
forces in all machine sizes.
Use/purpose
Monitoring and control of the closing
force
Protection of the tie bar against
overload
Mold protection
Detection of structural faults in molds
(squareness, rigidity)
Mold cavity pressure
Application
Direct measurement
Direct measurement in the cavity is
the preferred option for recording mold
cavity pressure as it is highly accurate
and has advantages in processes invol-
ving large quantities. Since the plastic
melt is in direct contact with the sensor,
there is no need for pins or transmission
media. Moreover, the front of most
sensors can be adapted to the surface
of the cavity so that no impressions are
left on the molded part.
Use/purpose
Extremely precise measurement
Melt temperatures up to 450C
Free positioning in the cavity
Absolutely rigid mounting
Application
Indirect measurement
With indirect measurement, the pressure
in the cavity is transmitted via an ejector
pin to a force sensor. The cavity pressu-
re can be calculated by means of
the diameter of the pin and the force
measured. This option is used when
there is no space available to install a di-
rect-measuring sensor.
Use/purpose
Used for small spaces
Used only for process optimization
No need to dismantle when changing
mold inserts
Pressure sensor
6183AE
Mold cavity pressure
sensor with single-wire
technology, particularly
for multiple tools, front
diameter of 1 mm.
Pressure temperature
sensor 6190A
Combined mold
cavity pressure and
contact temperature
sensor, 4 mm
diameter.
Force sensor
9211A
For indirect measure-
ment of the mold
cavity pressure via an
ejector pin, 6 mm
diameter.
Melt pressure sensor
4085A
Combined nozzle
pressure and
temperature sensor
with
1
/
2
thread.
Measuring tongue
9221A
For indirect measure-
ment of the mold
cavity pressure via
an ejector pin.
Time
The change in volume on cooling of the melt is
compensated by additional holding pressure.
Gate sealing
Atmospheric pressure
Start of shrinkage (until
ambient temperature
is reached).
Cavity is volu-
metrically filled
Melt reaches sensor position
Injection start
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100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
0 2 4 6 8 10 12
Time Min
Cycle No.: 7
Mean
Max
Cavity 1
Cavity 2
Cavity 3
Cavity 4
xt OnLine
0
Plastics
Processing
Measuring amplifier
Application
Amplifiers convert the signals from
sensors into voltages and currents, their
circuitry needing to meet the highest
accuracy requirements. Rugged charge
amplifiers now exist which are capable
not only of coping with signal conver-
sion under severe production conditions
but can also carry out control tasks.
A further development of the industrial
charge amplifier comes equipped with
a special fuzzy-logic chip, which detects
the volumetric filling of the cavity and
automatically switches the molding
machine from the injection pressure to
the holding pressure phase. This reduces
the setting-up time and leads to higher
reproducibility of the process. Molded
part characteristics are kept within a
narrow tolerance band and scrap is
considerably reduced.
Signal conditioners are used in applica-
tion technology as well as research and
development. They allow the recording
of up to 32 variables from the injection
molding process and can be adapted to
any measuring task.
Use/purpose: Charge amplifier
Ultra accurate
Built for industrial applications
SMARTAmp:
Shortens the set-up phase
Achieves high process consistency
Use/purpose: Signal conditioner
High flexibility for laboratory systems
Recording of the most diverse
quantities
Process monitoring and
analysis
Application
The continuous monitoring of mold
cavity pressure allows all process fluc-
tuations to be detected. Thus, changes
in the characteristics of the molded part
due for example to fluctuations in
viscosity or machine wear can be
detected and corrected directly, so that
scrap is minimized. In addition to pro-
cess monitoring, with many injection-
specific functions, the DataFlow soft-
ware facilitates documentation of the
produc-tion process, enabling manufac-
turers to meet this important obligation
to their customers.
Process analysis represents an important
step in process optimization. Optimum
molded part qualities are achieved only
when the cavity pressure curve matches
the ideal curve. Kistler systems allow
simple analysis and thus appropriate
and rapid optimization of the injection
molding process.
Use/purpose
Automatically detects material and
process fluctuations
Automatically documents the produc-
tion process
Simplifies optimization
Process control
Application
Process control systems automatically
detect changes in the process and in
the quality of the molded part, as well
as automatically correcting the machine
adjustment parameters. Thus, optimum
quality is guaranteed at all times and
without manual intervention. Over the
long term, these systems minimize
costs and maximize productivity. Kistler
applies only state-of-the-art technology
to achieve these aims. The SMARTAmp
charge amplifier uses fuzzy logic to
analyze cavity pressure for fully auto-
matic optimization of the switch point
from injection to holding pressure in
the production process.
Use/purpose
Fully automatic compensation of
process and material fluctuations
Minimization of scrap rates
Maximum productivity
Charge amplifier
5049A
Industrial charge
amplifier with fuzzy
logic for volumetric
switching.
Signal conditioner
2859A
Modular signal
conditioning system
for industrial use.
DataFlow
2805A
System for process
monitoring,
documentation and
analysis.
Charge amplifier
5039A
Industrial charge
amplifier.
Signal conditioner
2853A
Modular laboratory
system for signal
conditioning.
23 www.kistler.com
Melt pressure measurement
Application
Kistler's piezoresistive sensors are used
to measure the pressure and tempera-
ture of the melt. They have a rugged
diaphragm, which measures the
pressure directly without a coupling
agent and transfers it to the measuring
element. In consequence, these sensors
are particularly suitable for abrasive
media, for foodstuffs and for the manu-
facture of compounds for finished parts
which come into contact with food-
stuffs. The separate or integral signal
amplifiers, which come with analog or
digital compensation, are readily incor-
porated into machine control systems.
Use/purpose
Rugged, long-life technology
Suitable for use in the food industry
For use in the manufacture of
compounds approved for contact
with foodstuffs
Both digital and analog signals
Compatible with existing systems and
equipment
Innovative solutions at the forefront
of technology
Compounding
Application
In contrast to compounding on a
kneader, extrusion-mixed compounds
are manufactured continuously. Both
thermoplastic and elastomer compounds
are manufactured on such systems,
which are used in both injection molding
and the extrusion of end products.
Pressure and temperature monitoring
in the individual loading areas provide
specific information on the homo-
genization process and the loading of
the compounds.
Extrusion
The dynamic pressure at the extruder
head is the significant quantity which
provides information on the condition
of the melt. The melt pressure deter-
mines the quality of the end product
with regard to its dimensions, its filling
and its warping in the cooling or vulca-
nizing process. By integrating pressure
measuring sensors in the machine
control system, considerably higher
efficiency is achieved by reducing
start-up waste and scrap.
Melt pressure sensor
4090B, 4091B
100 to 2 000 bar,
with rugged
diaphragm and
various amplifiers to
form a complete
measuring system.
Digital compensating
amplifier 4620A
Digital compensation
for maximum
accuracy. Analog
and digital output
for pressure and
temperature.
Melt pressure sensor
4096A, 4097A
200 to 2 000 bar with
integrated amplifier,
rugged diaphragm
and analog output,
optionally with
temperature
measurement.
24 www.kistler.com
High performance force plate
9281C
Multicomponent force plate with a wide
range of applications and excellent measuring
dynamics, 400 x 600 mm.
Kistler In Practice:
Biomechanics
Kistler force plates are used
to supply precise information
on the magnitude and
behavior of the forces acting
on the body, whether to
improve physical performance
or for medical diagnosis.
Biomechanics is a relatively new science;
it describes the processes involved in
the movements of living beings. Such
movements depend on the application
of forces and, as these are often invisible
to the naked eye, orthopedists, athletes
and their trainers, shoe manufacturers,
ergonomists, neurologists and many
other specialists, all rely on data supplied
by Kistler force plates. The equipment
provides them with precise information
on the magnitude and behavior of the
forces acting on the body, whether to
improve performance or for medical
diagnosis.
Human beings may have started to
walk upright over a million years ago
but it is only since 1969 that it has
been possible to measure and analyze
gait accurately and reliably. In that
year, Kistler brought out the first force
plates to become available on the
market. This pioneering achievement
in measuring technology now forms
part of the standard equipment of
specialists in biomechanics all over the
world.
Kistler force plates enable forces acting
between foot and ground to be recor-
ded accurately and in real time during
walking, standing, running, jumping
and sliding. The Bioware

software
developed by Kistler processes the
signals and supplies information on the
resulting force and its direction, the
center of pressure, the frictional forces
and the torques, as well as performance
and energy.
Kistler force plates are used in three
main areas:
Gait analysis in orthopedics, prosthetics
and rehabilitation
Measurement and analysis of perfor-
mance and stresses in sport, in
ergonomics and in the development
of shoes and floor coverings
Measurement and analysis of balance
(posturography) in neurology,
psychology and pharmacology,
as well as orthopedics
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Force
Speed
Height of jump
Performance
3
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30
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1
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0,3
0,2
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25 www.kistler.com
Gait Analysis
Application
Accurate, quantifiable information is
what is needed for the reliable diagnosis
of human gait and that is exactly what
Kistler force plates provide. They detect
the slightest variations and asymmetries
in force behavior and so are able to
provide the specialist with valuable
additional information.
Use/purpose
Accurate, quantifiable information
for research, diagnosis and therapy
Easy to install and use
Balance
Application
We control our balance with tiny,
completely unconscious movements,
minimal changes in forces or shifts in
the center of pressure determining
safety and stability. It is only patients
with impaired balance who come to
realize what a complex task it is to
stand upright and walk. Thanks to their
highly sensitive piezoelectric sensors,
Kistler force plates are particularly
suitable for measurements in this
domain.
Use/purpose
Detecting and quantifying various
pathologies in neurology and
orthopaedics
Examining the effectiveness of
medication
Performance
Application
The level of performance in top class
sport is enormous. Winning requires
not just talent and a bit of luck but,
above all, optimum preparation
through intensive training. Force,
stamina, coordination the limits are
being extended all the time. The
difference between winning and losing
is constantly diminishing and so, too,
is the difference between health and
injury.
Whether in training or in competition,
athletes can use Kistler force plates to
reach their physical limits in a controlled
manner. The equipment permits
targeted, monitored training and show
the athletes how they are progressing.
The Kistler Quattro Jump force plate
is used routinely in performance
diagnosis. It quantifies explosive force
and stamina by means of standardized
jumps irrespective of the type of sport.
Use/purpose
To optimize training programs in
preparation for competition
To adjust the intensity of training
after an injury
Benchmarking
To make selections and compare
performances within the team
High performance force plate
9287B
Multicomponent force plate; its large
dimensions make it particularly suitable for
sports research, 600 x 900 mm.
Slimline force plate
9286B
Flat, mobile 3-component force plate,
particularly suitable for gait and balance
analysis. Modular system allowing very simple
assembly, 400 x 600 mm.
Quattro Jump force plate system
9290A
One-component force plate with software for
sports performance diagnosis, 900 x 900 mm.
www.kistler.com 26
Kistler In Practice:
Acceleration
Accelerometers are used in
every avenue of the dynamic
test environment and Kistler
has developed families of
products covering this
expansive range of applica-
tions.
From ultra low movement encountered
in wafer fabrication technology to
shock spectra reconstruction experien-
ced in pyrotechnic separation event
studies, and everywhere between, an
optimal sensor solution is available. Sta-
tic events are captured with the K-Be-
am static and low frequency product
offerings. Very high frequency activity
is routinely measured using any of
several miniature piezoelectric single
axis or triaxial types. Many sensing
technologies including piezoceramic,
natural quartz and variable capacitance
approaches have been extensively ex-
plored and are employed as needed to
accommodate the demands of the ap-
plications.
27 www.kistler.com
Condition Monitoring
Application
Kistler accelerometers are used in a
wide variety of condition monitoring
applications, such as damage detection
and predictive maintenance. It is impor-
tant to detect equipment malfunction
before expensive catastrophic failure or
safety issues occur. Other condition
monitoring applications include tilt/
angle sensing, bearing/rotating machi-
nery diagnostics, shipping recorders for
packaging industry, elevator and active
control, robotics, sports/medical, civil
engineering structures including bridge/
dam/buildings and roads. Accelero-
meters used in this category include
K-Shear piezoelectric and K-Beam
capacitive accelerometers.
Use/purpose
robust and hermetically-sealed to
guarantee reliable measurement
high sensitivity to ensure reliable
signals
ground-isolated to prevent ground
loops
Aerospace and Military
Application
Very demanding applications are
encountered in the military and aero-
space industry where any error may
present a life-threatening situation.
This category also covers a tremendous
range of applications and nearly all
accelerometer product offerings have
been used in these important investiga-
tions. Flutter testing, rocket launch pad
dynamics, aircraft EMA, ammunition
investigations, helicopter rotor reactions,
etc. are a few of the common measure-
ments performed.
Use/purpose
high sensitivity to ensure reliable
signals
ruggedly built to guarantee long
service life
hermetically sealed to withstand
the toughest environments
Automotive/Transportation
Application
Ride quality has been receiving tremen-
dous attention in recent years. New
vehicle designs are presenting less noise
to the occupants and the subtle details
of the intricacies of road/tire interac-
tion, bump & jar response, and the
overall feel of the ride are important
to every customer. The K-Beam family
covers the low to mid frequency range
of many investigations and the many
piezoelectric offerings extend into the
higher frequency areas of interest.
Use/purpose
light in mass to generate minimum
extra load
high sensitivity to ensure reliable
signals
ruggedly built to guarantee long
service life
K-Beam

8310A
Capacitive sensor for
low frequencies.
Piezotron

acoustic
emission sensor
8152B
Rugged sensor for
acoustic emissions
up to 900 kHz.
K-Beam

8393A
Triaxial sensor for low
frequencies.
K-Shear

8794A
Universal triaxial
sensor for up
to 500 g.
Impulse force
hammer 9722A
To analyze the
dynamic behavior of
mechanical structures.
K-Shear

8702B
Universal acceleration
sensor for up
to 500 g.
www.kistler.com 28
Chemicals/Pharmaceuticals
Application
Typical areas of application for Kistler
pressure transmitters in the chemical
and pharmaceutical industries include:
autoclaves, off-shore installations, high-
pressure/high-temperature applications,
plastics production plant (see also pp.
2023), as well as in processing plant
for paints, varnishes and adhesives.
Use/purpose
Explosion-proof sensors
Rugged construction
Field bus connection
Food
Application
Kistler's piezoresistive pressure-measur-
ing sensors are used in dispensing and
filling systems, in flushing and cleaning
systems, in homogenizers and sterilizers,
in food extrusion and in countless other
sectors of the food industry.
Use/purpose
High repeatability
High density
Food and Drug Administration
approval
Kistler In Practice:
Other Applications
Kistler sensors are used to
monitor a whole range of
equipment and instruments.
They are distinguished by
high resolution and overload
resistance and OEMs can
rely on them completely.
In addition to many applications in
piezoelectric technology, Kistler has
developed piezoresistive and capacitive
pressure sensors for a whole range of
uses. Kistler pressure measuring
technology is universally successful in
many areas: in mechanical engineering,
in instrumentation, in the chemical
industry, in research, in transport, in the
energy sector, in medicine and in the
food industry. Other typical areas of
application include heating/air condi-
tioning/ventilation, the textile industry,
packaging, printing, oil and gas supplies
and construction.
29 www.kistler.com
Expolsives
Application
Kistler's front-sealing high-pressure
sensors are regarded as state-of-the-art
worldwide. They are used, for example,
in the development of airbag ignition
caps or in weapons technology for
testing and development purposes.
Type 6215, for example, is the NATO
standard for acceptance testing of
ammunition.
Use/purpose
High repeatability of measurands
thanks to very low mounting
sensitivity
Very good linearity over the entire
measuring range
Long service life as a result of front
sealing and optimized diaphragm
design
Insensitivity to contamination
Pneumatics and Hydraulics
Application
Kistler sensors and transmitters cover
pressures from 0.2 to 3000 bar and a
temperature range from 40 to 300C.
The sensors in the accuracy classes
0.05 to 2% FS and are highly compa-
tible with most standard media.
Piezoresistive silicon and ceramic sen-
sors are used for the rather lower pres-
sures in pneumatics. Typical applications
include train braking systems, control
systems, closure systems, safety bar-
riers, compressors, transmission control
systems, etc.
The sensors used in hydraulics have to
meet stringent requirements long
service life, frequent load changes and
impacts reaching into the overload
range. Kistler's piezoresistive silicon
sensors are able to meet these require-
ments, thanks to a fully welded cons-
truction and an integrated deflector.
Typical applications include hydraulic
units, mechanical engineering, injection
molding machines, hydraulic elevators,
etc.
Use/purpose
Large selection
Optimum cost-efficiency
Extremely long service life
Conveyances and Transport
Application
Kistler sensors are used to increase
the safety and comfort of railroads and
cableways, measuring for example
braking pressure and braking force.
Other applications include vibration
measurement, derailment detection,
acceleration measurement in tilting
trains, clamping force monitoring on
endless ropeways, etc.
Use/purpose
Special force-measuring sensors for
periodical testing of block brakes and
disk brakes
Derailment prevention through
detection of the excessive vibration
generated when wheels leave the rail
Clamping-force measurement for
coupled chair and cable car lifts (a
legal requirement in many countries)
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High-pressure sensor
4065A
Sensor for static
and dynamic
measurement
up to 1000 bar.
High-pressure sensor
6229A
Rugged, dynamic
sensor for measure-
ments in injection
systems.
Pressure sensor
Ceramet
Suitable for OEM
applications.
OEM pressure sensor
RES15A
The small diameter
and high temperature
application of this
sensor make it ideal
for down hole
applications.
Measuring brake
shoe
Comes with two
special force-measuring
elements for testing
rolling stock braking
systems.
Pressure transmitter
RAG 25
Rugged hydraulic
transmitter.
30 www.kistler.com
Kistler In Practice:
Tailor-made System Solutions
Kistler designs specific
system solutions tailor-made
to customer requirements.
Where standard components
do not provide the best
solution to a problem, Kistler
also develops customized
products.
Sensors are the key components for
modern equipment and systems. How-
ever, measuring technology covers far
more than just sensors. Producing a
measuring system for individual tasks
also requires customized signal process-
ing and evaluation, plus the relevant
interfaces.
The mechatronic approach i.e. an
interdisciplinary approach drawing
together mechanical engineering,
electronics and information technology
helps to see ideas and problems from
different aspects, and thus to develop
new measuring solutions. This is how
Kistler goes about producing customized
measuring systems.
In this regard, we distinguish between
Systems assembled from standard
components and
Solutions which we tailor to customer
requirements.
Systems comprising standard
components
The selection of the right sensors and,
in particular, their installation are just as
important as their accuracy and quality.
We advise our customers on the evalua-
tion, design and commissioning of the
desired measuring system, relying on
our wide and comprehensive range of
sensors, along with our modular elec-
tronic systems for signal conditioning
and software for measurement analysis.
Accurate analysis of the process
variables is crucial for integrated quality
monitoring during the production
process. Extensive measurements are
frequently taken in advance, thus
making it possible to determine quality-
relevant quantities and to define their
evaluation. We provide test engineers
and hire equipment to our customers
to conduct such preliminary testing.
Force measurement during skiing
Two identical dynamometers, installed between
binding and ski, measure the forces and mo-
ments which are transferred by the skier to the
ski.
Force measurement in a wind tunnel
Six-component balance for wing models
constructed using standard three-component
force sensors.
31 www.kistler.com
Instrument for detecting cavitation in
vacuum pumps
Cavitation is an abnormal flow process
in liquid pumps caused by sudden con-
densation of vapor during compression.
This process generates noise and soo-
ner or later will result in destruction of
the pump.
Kistler's Type 4672 cavitation detector,
which was developed in close coopera-
tion with a well-known manufacturer
of vacuum systems for the chemical
industry, is used to detect cavitation in
liquid ring vacuum pumps. Detection is
achieved by the evaluation of a dyna-
mic component superimposed on the
pressure signal using a special vector
algorithm. The piezoresistive trans-
mitter (Type 4285AE1VO166), used
to measure the pressure, is mounted
directly in the pump suction nozzle.
Since cavitation varies from one pump
to the next, the instrument was deve-
loped in such a way that the pump-
specific cavitation point can simply be
programmed in.
Standard components individually
tailored to customer requirements
Many components from our wide range
can be tailored exactly to customer
requirements by simple adjustments
or adaptations. Hence, we are able to
respond quickly and easily to any
individual measuring requirements by
using standard components.
Crash force measurement
In this aircraft landing gear system, the reaction
forces from the landing gear are measured with
a special three-component force plate.
Machining process monitoring
Multi-component load washers measure the
machining forces at the tool spindle, thus
permitting safe and reliable process monitoring.
Cavitation detector
4672
Pressure transmitter and evaluation unit with
visual display of the cavitation condition.
32 www.kistler.com
Tailor-made
System Solutions
Development of tailor-made
systems
Kistler has experienced engineers on
hand for the definition, development
and production of customized solutions.
They develop tailored systems for
applications in research, development
or production where an optimum solu-
tion cannot be obtained with the use
of standard components. If produced
in sufficient quantity, these application-
specific measuring systems can offer
an advantageous cost/benefit ratio.
Areas of application cover conventional
mechanical and system engineering, as
well as materials processing, automation
and the automotive industry.
Crash barrier with
corner sensors
Kistler also offers op-
timum solutions for
challenging applicati-
ons.
33 www.kistler.com
Measuring system for
avalanche research in Davos
Scientists at the Federal Institute for
Snow and Avalanche Research in
Davos (Switzerland) wanted to record
the course of avalanches as they race
downhill and to measure the forces
exerted when they impact with ob-
stacles. For this purpose, a test zone
measuring more than 2.5 km was
established in the Vallee de la Sionne
in collaboration with Mettler & Fuchs.
Various structures were erected in the
middle of the avalanche path, including
various masts, a steel wall and a gallery
roof. These structures were equipped
with Kistler sensors for measuring
forces and velocities. The object is to
use the data from field tests to check
the validity of the theoretical guidelines
and to calibrate and improve the com-
puter programs used to calculate dry
snow and dense flow avalanches.
Scientists from France, Spain and Austria
are already using this spectacular system
for their own experiments.
Study into muscular
atrophy
Patients who are bedridden for a lengthy
period suffer considerable muscular
atrophy. This problem is even more
pronounced in astronauts who spend
a long time in weightless conditions.
The Zurich Polytechnic laboratory for
biomechanics directed by Professor
Stssi has investigated these conditions
in a large project. The Torque Velocity
Dynamometer (TVD) was developed in
a very short time in collaboration with
the European Space Agency (ESA),
Kistler and other partners. This com-
pact high-performance instrument for
training and measuring enabled astro-
nauts to carry out a selective analysis
of the atrophy of various muscles in
weightless conditions. Once again,
Kistler sensors displayed their enormous
loading capacity in the most confined
space. The results of the study should
help, on the one hand, to reduce
muscular atrophy in bedridden patients
and, on the other hand, to allow longer
manned space flights.
Measuring vibration
forces
The main drive system of satellite
launch vehicles produces heavy vibration
during the launch phase. To ensure
that the satellite remains undamaged
while being transported into space,
pre-flight simulations are carried out on
the satellite or its individual components.
Vibration tests are of particular impor-
tance. The components are tested for
their suitability on a vibrating table. If
a component vibrates at its natural
frequency, there is a danger that it will
be destroyed. The standard procedure
today is to monitor and check vibration
forces with accelerometer in combina-
tion with a 3-component force-measur-
ing device, in order to measure the
reaction forces on the component
simultaneously.
To this end, a large number of 3-com-
ponent force-sensors are mounted on
the test object or special dynamometers
are employed as well. If the component
vibrates at its natural frequency during
the vibration test, vibration forces in-
crease rapidly. These forces are limited
by damping (notching) individual
frequency ranges of the stimulation.
This procedure is generally referred to
as force limited vibration testing.
Wheel bearing forces
Special version for measuring forces at wheel
bearings of street cars, locomotives and trams.
TVD (Torque Velocity Dynamometer)
TVD with foot HIF (human interface) for
measuring muscular atrophy.
Measurement of vibration forces
Space satellites and their components are
subjected to vibration testing. Vibration forces
are measured with a special multi-component
dynamometer. The force measurement
monitors the vibration process.
34 www.kistler.com
Kistler Service to Order
Customer satisfaction is our
top priority. For this reason,
we offer you a comprehensive
range of services. If we can
be of assistance, please do
not hesitate to talk to us.
35 www.kistler.com
Technical advice
Experienced specialists from every area
of application are at the disposal of our
customers. More particularly, Kistler
consultancy services include the identi-
fication and definition of the measure-
ment task, the development of the
solution, the selection of the appropriate
measuring system and the planning of
the installation.
Test equipment
Kistler provides its customers with ren-
tal equipment to help solve specific ap-
plication problems.
Repair service
In the event of the failure of a measuring
system, Kistler specialists help to keep
downtimes of machinery or production
lines to a minimum.
Calibration
Kistler offers a calibration service for
the periodic testing of measuring accu-
racy. If necessary, this service can be
carried out on site. Kistler keeps a com-
prehensive record to show which
sensors have been calibrated, as well
as when and how. Kistler also has a
whole series of instruments for
equipping calibration laboratories.
Information
In order to keep customers constantly
aware of the latest information, Kistler
passes on its specialist knowledge at
exhibitions, trade fairs, conferences,
symposia and seminars. Communications
in the form of data sheets, brochures,
reprints, operating instructions and
application descriptions are also avail-
able to our customers in printed or
electronic form.
Training
Kistler trains its engineers thoroughly
at its own training center so that their
knowledge corresponds to the latest
state of the art. Kistler also holds regular
seminars for customers on special
subject areas.
Testing and rental equipment
To ensure that problems are solved quickly in
special cases, our customers can use Kistler
testing and rental equipment.
Calibration
Our calibration service (SCS) is available to cu-
stomers for the periodic testing of measuring
accuracy.
Training
Regular training ensures that Kistler engineers
are always familiar with the current state of
technology.
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Austria
Kistler GmbH
Lembckgasse 49f
AT-1230 Wien
Tel. +43 1 867 48 67 0
Fax +43 1 867 48 67 17
sales.at@kistler.com
Italy
Kistler Italia s.r.l.
Via Ruggero di Lauria, 12/B
IT-20149 Milano
Tel. +39 02 481 27 51
Fax +39 02 481 28 21
sales.it@kistler.com
United Kingdom
Kistler Instruments Ltd.
Alresford House, Mill Lane
Alton, Hampshire GU34 2QJ
Tel. +44 1420 54 44 77
Fax +44 1420 54 44 74
sales.uk@kistler.com
Korea, Republic of
Kistler Korea Co., Ltd.
Gyeonggi Venture Anyang
Technical College Center 801
572-5, Anyang-Dong, Manan-Gu,
Anyang-City, Gyeonggi-Do, Korea, 430-731
Tel. +82 31 465 6013
Fax +82 31 441 6015
sales.kr@kistler.com
Singapore
Kistler Instruments (Pte) Ltd.
50 Bukit Batok Street 23
#04-06 Midview Building
Singapore 659578
Tel. +65 6316 7331
Fax +65 6316 7332
sales.sg@kistler.com
Taiwan
Kistler Representative Office in Taiwan
Room 9, 8F, No. 6, Lane 180
Sec. 6, Mincyuan E. Road
Taipei 114
Tel. +886 2 7721 2121
Fax +886 2 7721 2112
sales.tw@kistler.com
Thailand
Kistler Instruments (Thailand) Co., Ltd.
662/43-46 Rama III Road
Bangpongpang, Yannawa
Bangkok 10120, Thailand
Tel. +66 2293 0221
Fax +66 2293 0223
sales.th@kistler.com
Europe
Germany
Kistler Instrumente GmbH
Daimlerstrasse 6
DE-73760 Ostfildern
Tel. +49 711 34 07 0
Fax +49 711 34 07 159
info.de@kistler.com
France
Kistler France
ZA de Courtabuf 1
15, avenue du Hoggar
FR-91953 Les Ulis cedex
Tel. +33 1 69 18 81 81
Fax +33 1 69 18 81 89
info.fr@kistler.com
Switzerland/Liechtenstein
Kistler Instrumente AG
Verkauf Schweiz
Eulachstr. 22
CH-8408 Winterthur
Tel. +41 52 224 12 32
Fax +41 52 224 14 21
sales.ch@kistler.com
Asia
Japan
Kistler Japan Co., Ltd.
MT Building
2-7-5, Shibadaimon
Minato-ku, Tokyo 105-0012
Tel. +81 3 35 78 02 71
Fax +81 3 35 78 02 78
sales.jp@kistler.com
China, Peoples Republic of
Kistler China Ltd.
Room 925, Yuan Chen Xin Building
No. 12 E1, Yuminlu Road Deshengmenwai
Beijing 100029
Tel. +86 10 8225 2163
Fax +86 10 8225 2124
sales.cn@kistler.com
India
Kistler Instruments (Pte) Ltd.
India Liaison Office
2B Century Plaza
560/562 Anna Salai
Teynampet, Chennai 600 018
Tel. +91 44 4213 2089
Fax +91 44 4213 2331
sales.in@kistler.com
Kistler worldwide
Denmark/Finland/Norway/Sweden
Kistler Nordic AB
Aminogatan 34
SE-431 53 Mlndal
Tel. +46 31 871 566
Fax +46 31 871 597
info.se@kistler.com
Netherlands
Kistler B.V. Nederland
Leeghwaterstraat 25
NL-2811 DT Reeuwijk
Tel. +31 182 304 444
Fax +31 182 304 777
sales.nl@kistler.com
America
USA/Canada/Mexico
Kistler Instrument Corp.
75 John Glenn Drive
Amherst, NY 14228-2171
Tel. +1 716 691 5100
Fax +1 716 691 5226
sales.us@kistler.com
Other countries
Kistler Instrumente AG
Export Sales
Eulachstr. 22
CH-8408 Winterthur
Tel. +41 52 224 11 11
Fax +41 52 224 15 49
sales.export@kistler.com
Headquarters
Switzerland
Kistler Instrumente AG
Eulachstrasse 22, CH-8408 Winterthur
Tel. +41 52 224 11 11
Fax +41 52 224 14 14
info@kistler.com
www.kistler.com