Volume

1

 


Famu-fsu

College of Engineering

Inclinometer testing procedures

&

Prototype Assembly/ Testing Guide

Famu-fsu College of engineering

Inclinometer Testing Procedures & Prototype Assembly/Testing Guide

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ã FAMU-FSU College of Engineering

2525 Pottsdamer Street • Mechanical Engineering Department

Phone 850.410.6335 • Fax 850.410.6337

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


Table of Contents

 

Inclinometer Testing

1.1       Experimental Apparatus. 4

1.1.1        Test Mount Assembly. 4

1.1.2        Accelerometer 6

1.1.3        DYNAM Program and Mechanical Pendulum.. 6

1.1.4        Multi-meter 7

1.1.5        Breakout Box. 7

1.1.6        Power Supply. 7

1.1.7        Magnet Control 7

1.2       Experimental Setup. 8

1.2.1        Accelerometer 8

1.2.2        Mechanical Pendulum.. 8

1.3       Experimental Procedure. 9

1.3.1        Accelerometer 9

1.3.1.1     Zero Field Testing. 9

1.3.1.2     Magnetic Field Testing. 9

1.3.2        Mechanical Pendulum.. 10

1.3.2.1     Zero Field Testing. 10

1.3.2.2     Magnetic Field Testing. 10

Prototype

2.1       Assembly Procedure. 11

2.2       Experimental Apparatus. 17

2.2.1        Detector 17

2.2.2        Laser 17

2.2.3        Prototype. 17

2.3       Experimental Setup and Procedure. 18

APPENDIX

3.0       Appendix 1: Prototype Parts. 19

 

 

Section 1.1

Experimental Apparatus

Inclinometer Testing

1.1      Experimental Apparatus

1.1.1      Test Mount Assembly

Figure 1‑1: Test Mount Assembly

Bottom Plate
 

Top Plate
 

Mounting

Platform
 

Spring
 

Nylon Tubing
 

Micrometer
 

 

Figure 1-1 displays the test mount, which was constructed using aluminum 6061.  The test mount works on the geometric principle of relating distance to angle measurements.  The micrometer, which is mounted to the top of the device, is connected to a nylon tube.  This nylon tube is connected to the mounting plate, which is supported by a spring.  The inclination angles are regulated using the micrometer.  Changing the reading on the micrometer changes the angle of the mounting plate.  Table 1-1 displays the relationship between the micrometer reading and the plate inclination angle.

Table 1‑1: Micrometer Reading - Inclination Angle Relationship

Degree

Micrometer Reading

3.0°

2.81

2.5°

2.67

2.0°

2.54

1.5°

2.40

1.0°

2.27

0.5°

2.13

0.0°

2.00

-0.5°

1.87

-1.0°

1.73

-1.5°

1.60

-2.0°

1.47

-2.5°

1.34

-3.0°

1.21

 

On the top of the test mount, a probe head containing a Deuteronics 19-pin connector is mounted opposite of the micrometer.  This 19-pin connector connects the mounting 6-pin male connector, which connects to the female pin connector of the inclinometer, to the breakout box.   

Section 1.1

Experimental Apparatus

1.1.2      Accelerometer

The Crossbow CXTA01 accelerometer is a single and dual axis analog tilt sensor, which has a design based on a silicon micro-machined capacitive inclination sensor element.  The CXRA01 tilt sensor has a DC response to measure inclination relative to gravity.  The CXTA01 has a 5-pin connection (see Figure 1-2).  The pin numbers and functions can be seen in Table 1-2 below.

 

 

 

 

 


                                                                       

 

 

 

Table 1‑2: Accelerometer Pin Connection Reference Table

Pin

Color

Function

1

Red

Power

2

Black

Ground

3

White

Pitch

4

Yellow

Roll

5

Green

Temperature


1.1.3      DYNAM Program and Mechanical Pendulum

The DYNAM software was developed for calculating and displaying static and dynamic inclinations and profiles using Microsoft Windows.  The DYNAM software is part of the components of the digitized ZEROTRONIC family developed by WYLER AG, which offers higher accuracy.  The system is fully digitized and allows the transmission of signals over long distances without loss of accuracy.  All the sensors and instruments of the ZEROTRONIC family can be operated with the DYNAM software.

 

 The pendulum itself is a ZEROTRONIC sensor, whose measuring principle is based on the changing of the capacity of a capacitor and the pendulum.  The measured change in capacity is directly influenced by the change of the inclination of the pendulum.  The capacity change is the signal that is primarily used for the angle to be measured. 

Section 1.1

Experimental Apparatus

1.1.4      Multi-meter

The multi-meter used was the TENMA True RMS Digital Multi-meter 72-410A has an accuracy of 0.001V.  The maximum power through the device is 10W.

1.1.5      Breakout Box

The breakout box was designed and constructed by the staff at the National High Magnetic Field Laboratory.  It has 18-pin connections and a ground, which correspond to the Deuteronics 19-pin connector.

1.1.6      Power Supply

The power supply used was a Harrison 6253A Dual DC Power Supply.  It has a voltage range of 0-20V and an amperage range of 0-3A.

1.1.7      Magnet Control

The program used to control the magnet was LabView 6i: PS Control.  This program allows the magnetic field produced by the magnet to be controlled by the user.

 

Section 1.2

Experimental Setup

1.2      Experimental Setup

1.2.1      Accelerometer

                                                                                                           

                                                                       

 

                                                                             

Figure 1-3: Accelerometer Orientation on Mounting Plate
 
 

 

 


  1. Screw accelerometer onto mounting plate (see Figure 1-3)
  2. Connect accelerometer to mounting 6-pin connection
  3. Connect breakout box to Deuteronics 19-pin connector
  4. Place mount into magnet bore
  5. Connect PIN 1 (see Table 1-2) from breakout box to +12V on power supply
  6. Connect PIN 2  (see Table 1-2) from breakout box to –12V on power supply
  7. Connect PIN 2 (see Table 1-2) from breakout box to GROUND on multi-meter
  8. Connect PIN 3 (see Table 1-2) from breakout box to INPUT on multi-meter

 

*Warning!! All data collection materials must be beyond the 10 Gauss line.

1.2.2      Mechanical Pendulum

  1. Screw or tape pendulum onto mounting plate vertically
  2. Connect pendulum to transceiver/converter
  3. Connect power cord to transceiver/converter
  4. Connect PC to transceiver/converter using extended USB port connector
  5. Place mount into magnet bore
  6. Turn on PC
  7. Open DYNAM Program

*Warning!! Be sure to connect sensor and power supply to the corresponding ports.

*Warning!! All data collection materials must be beyond the 10 Gauss line.

 

Section 1.3

Experimental Procedure

 

1.3      Experimental Procedure

1.3.1      Accelerometer

1.3.1.1  Zero Field Testing

  1. Turn on power supply to 12V
  2. Turn on multi-meter
  3. Adjust micrometer to read 3° (see Table 1-1)
  4. Record multi-meter voltage reading
  5. Adjust micrometer to read 2.5° (see Table 1-1)
  6. Record multi-meter voltage reading
  7. Repeat Steps 5-6 for micrometer readings of 2° to -3° (see Table 1-1) in 0.5° increments
  8. Repeat Steps 1-7 for three trials

1.3.1.2  Magnetic Field Testing

  1. Turn on power supply to 12V
  2. Turn on multi-meter
  3. Set PS Control level to 0T
  4. Adjust micrometer to read 3° (see Table 1-1)
  5. Record multi-meter voltage reading
  6. Set PS Control level to 1T
  7. Record multi-meter voltage reading
  8. Repeat Steps 6-7 for PS Control levels of 2-10T in increments of 1T
  9. Set PS Control level to 0T
  10. Repeat Steps 3-8 for micrometer readings of 2.5° to -3° (see Table 1-1) in 0.5° increments
  11. Repeat Steps 1-10 for three trials

 

*Warning!! Do NOT adjust micrometer reading in magnetic field greater than 0T.

*Warning!! Remove all credit cards, cellular phones, jewelry, etc. before testing: these items may be damaged in magnetic field.

Section 1.3

Experimental Procedure

 

1.3.2      Mechanical Pendulum

1.3.2.1  Zero Field Testing

  1. Adjust micrometer reading to 0° (see Table 1-1)
  2. Select OFF-SET/RELATIVE button on WYPANEL
  3. Select “Start” from “Button” menu
  4. Select MEAS A&R DATA_001 button on WYPANEL
  5. Record absolute and relative zero angle measurements
  6. Adjust micrometer reading to 3° (see Table 1-1)
  7. Record absolute and relative zero angle measurements
  8. Adjust micrometer reading to 2.5° (see Table 1-1)
  9. Record absolute and relative zero angle measurements
  10. Repeat Steps 8-9 for micrometer readings of 2° to -3° in 0.5° increments
  11. Repeat Steps 1-10 for three trials

 

1.3.2.2  Magnetic Field Testing

  1. Set PS Control level to 0T
  2. Adjust micrometer reading to 0° (see Table 1-1)
  3. Select OFF-SET/RELATIVE button on WYPANEL
  4. Select “Start” from “Button” menu
  5. Select MEAS A&R DATA_001 button on WYPANEL
  6. Record absolute and relative zero angle measurements
  7. Adjust micrometer reading to 3° (see Table 1-1)
  8. Record absolute and relative zero angle measurements
  9. Repeat Step 8 for PS Control levels of 1-10T
  10. Set PS Control level to 0T
  11. Repeat Steps 7-10 for micrometer readings of 2.5° to -3° in 0.5° increments
  12. Repeat Steps 1-11 for three trials

 

*Warning!! Do NOT adjust micrometer reading in magnetic field greater than 0T.

*Warning!! Remove all credit cards, cellular phones, jewelry, etc. before testing: these items may be damaged in magnetic field

Section 2.1

Prototype Assembly

Prototype

2.1      Assembly Procedure

 

Parts Needed:  Solid shaft, larger diameter hollow shaft, 2 identical pin holes, 2 identical deep groove ball bearings, 2 long stems, 1 short stem, 2 mirrors, pendulum ball, Hollow cylindrical shell

           

These are detailed instructions to assemble the prototype from its parts.

 

Hole 1
 

Shaft 1
 

Hole 2
 

Figure 2‑1: Shaft 1

  1. Shaft 1 will connect to the pendulum stem and the mirror stem.  There are two holes drilled perpendicular to the length through the center of the circle.  These two holes are for the pendulum stem and the mirror stem.  These components will be added in later steps. 
  2. Shaft 1 should be press fit into the inside diameter of the bearings. The side with hole 2 should be inserted into the bearing.

 

Section 2.1

Prototype Assembly

Hole 3
 

Shaft 2
 

Slot 1
 

Figure 2‑2: Shaft 2

 

  1. Shaft 2 is hollow.  This shaft will be press fit around the outer diameter of the bearing.  This will allow for some space between the shaft 1 and shaft 2.
  2. There are slots cut in this shaft.  Slot 1 should be lined up with hole 2 on shaft 1.

 

Figure 2‑3: Completed Pendulum Stem

Section 2.1

Prototype Assembly

  1. The pendulum stem is a part that will go in one of the holes of the small diameter shaft.  There is a pin hole connected to the top. 

 

 

Rectangular Stem
 
 


                 

Figure 2‑4: a.) Pin Hole; b.) Exploded View of Pin Hole Assembly

 

  1. The rectangular part of the pin hole will fit into the slit cut in the stem.  Make sure the screw holes are aligned. 
  2. Once these holes are aligned, screw the part in to secure it from movement.
  3. This part should now look like Figure 3-4 above, but with now pendulum ball attached.

Figure 2‑5: Completed Pin Hole Assembly

  1. This piece should now be inserted into hole 1 in shaft 1. 
  2. This stem should be inserted into the hole until the desired lengths are reached.
  3. When the desired length is reached, the set screw should be tightened so the stem will not be able to have sliding motion. 

Section 2.1

Prototype Assembly

  1. On the other end of the stem is screw thread.  This will be screwed into the hole in the pendulum ball.  This should be screwed in as tightly as possible.
  2. The assembly should now look like Figure 3-5 below.

 

Figure 2‑6: Partial Assembly to Step 13

 

  1. Pin hole 2 will be attached with the same procedure as the pendulum shaft pin hole.
  2. This stem will then screw into the hole on the top of the large diameter shaft.  It should be screwed in as tightly as possible. 
  3. It is also important to make sure that it is not turned once it is set.  This could cause errors in data.
  4. The face of pin hole 2 should be parallel with the face of pin hole 1

 

 

Section 2.1

Prototype Assembly

Mirror Stem
 

Pin Hole 2
 

Figure 2‑7: Completed Assembly without Outer Casing

  1. The mirror stem will be inserted into hole 2 on shaft 1. 
  2. The top portion of this stem should already be bent to a 45° angle. It may have the mirror already attached.  The bottom part should still be straight to insert it into the hole. 
  3. Insert the stem into the hole until the desired length. 
  4. Once it is the desired length the bottom portion should be bent to 45° also
  5. A mirror should then be attached to this 45° bend.
  6. The assembly should look like figure 5 above
  7. Readjust the length if it changed any. 
  8. Use a set screw to secure the position

 

Outer Casing
 

Figure 2‑8: Finished Assembly

Section 2.1

Prototype Assembly

  1. The outer casing is the part that will connect with the device in the magnet bore.  It will experience the same rotation as the device.  This is a hollow cylinder that has a solid disc at one end.  It is all one rigid body. 
  2. This solid disc will attach to the bearing.  The bearing will be press fitted into the circular indentation on the inside surface.  This will allow for independent rotation of the large diameter shaft and the small diameter shaft.

 

Section 2.2

Experimental Apparatus

2.2      Experimental Apparatus

2.2.1      Detector

The Metrologic Laser-Power meter was used to measure laser intensity.  This is the major factor in the precision of the readings.  This device has a range of 20 microwatts to 20 mW.  This device may also be replaced in experiment. If it is replaced by a power meter that allows smaller readings, more precise readings may be taken.

 

2.2.2      Laser

Laser diode control unit by Power Technology, Inc.  This was model: LDCU3/3663.  This type of laser is Neodymium Ytrrium Argon Garnett (Nd:Yag).

The laser has and output power of 10 mW and a wavelength of 532nm.  This laser has a beam diameter of 1mm with a tolerance of .2 mm.  The laser may be changed as long as the beam diameter is 1 mm or larger.

*Warning!! Do NOT stare directly into the laser beam emitter.  Will cause blindness.

2.2.3      Prototype

Figure 2-8 is the completed device.  It will be used to change the intensity of the light that goes in.  The angle of tilt of the device is a function of the intensity that comes out of the device.  The detector used to measure the intensity of light for this product must have a higher sensitivity than that of the detector used in the proof of principle prototype assembly experiment.  The recommended detector for use with this product is the New Focus 2151 Femtowatt Photoreceiver, which has a detector diameter is 1.0mm.  This detector measures wavelengths in the range of 300-1050nm with a maximum responsivity of 0.5 A/W.

 

Section 2.3

Experimental Setup

2.3      Experimental Setup and Procedure

Once the assembly is completed, the prototype is ready to set up.  All testing surfaces used should be at zero degrees in reference to the horizontal plane.  It should always be perpendicular to gravity.

 

  1. The prototype should be inserted into the bore of the magnet horizontally.  The side with the bearing should be inserted first.
  2. Shaft 1 should automatically align itself with gravity. Pin hole 1 should be pointing in the vertical direction with no angle of tilt. Pin hole 1 height should be adjusted so that it is aligned with pin hole 2.  This may be done using the set screw.
  3. Turn on the laser
  4. Turn on the laser power detector.
  5. Align the laser so that it passes through both pin holes.
  6. Align the beam detector with the output beam.
  7. Adjust the non-gravity pin hole until the laser power detector reads its maximum        value.
  8. Readings may now be taken as the angle of tilt changes.

 

3.0         Appendix 1: Prototype Parts

 

Figure 3‑3‑1: Front and Side View of Axial Cylinder with Mirror Mounts Attached

 

 

Figure 3‑2: Middle Shaft with Pin Hole Attachment

 

 

 

Figure 3‑3: Pendulum Shaft with Set Screw and Pin Hole Attached

 

Figure 3‑4: Base Cylinder of Prototype

 

 

 

Figure 3‑5: Pin Hole Attachment

 *