February 2013 Volume 7 - Number 2 Inside the Insider Welcome to the Insider Corporate News SignalCalc and SignalStar SignalForce and SignalSound

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1 February 2013 Volume 7 - Number 2 Inside the Insider Welcome to the Insider The Data Physics Internal Newsletter This is the inaugural issue of the Insider in the new Fiscal Year and brings as usual, information useful to the network of Data Physics personnel around the world. The news about recent applications is intended to help you identify new opportunities and the technical discussions are intended to improve your technical knowledge on various aspects of the products and solutions. Interesting applications featured this month include modal evaluation of tennis rackets and the need to remotely control a shaker amplifier from a control room with E-link. Technical articles compare the SignalCalc Ace on Quattro to the HP35670, the most successful standalone FFT Analyzer, discuss differentiating features of the SignalCalc Turbo user interface and highlight important aspects of head expander usage with shakers. There is also news of exciting new additions to the SignalForce product range. In trying to strike a balance between including too much and limiting the contents to a manageable size we may leave some of you dissatisfied. We would like to hear from you, whether to say you found something useful or to say we did not do justice in the treatment of one or other subjects. Also remember that you can contribute to this journal and help others do their job better. We can always use news about sales, applications or an interesting technical comment in the publication. You can us at insider@dataphysics.com. Corporate News Announcements, Openings, Web Seminars and Tradeshows SignalCalc and SignalStar Wilson Sporting Goods Uses SignalCalc for Modal Evaluation of Tennis Rackets From Bench Top to Laptop - FFT analyzers The SignalCalc Turbo User Interface A Top Differentiator against the Competition SignalForce and SignalSound E-Link Helps to Secure LE Order at COMAC SignalForce Configuration Changes Head Expanders

2 Announcements Data Physics is happy to announce the hiring of Dalia Summerour to the newly created position of Finance & Human Resources Manager, reporting to Sabine Castagnet, Chief Operating Officer. Dalia has over 25 years of experience in Accounting, Finance and HR matters and has a Bachelor s degree in Accounting from Golden Gate University. She recently served as Senior VP of Asset Management and as Regional Financial Controller for Grace Healthcare, headquartered in Chattanooga, Tennessee. Dalia worked as the HR & Accounting Manager for Splice Communications, based in Menlo Park, CA and prior to that as a Portfolio Accounting Manager for Citicorp Bankers Leasing Finance Corporation. Data Physics is also happy to announce the hiring of a new SignalForce Applications Engineer, Sai Mullapudi, who holds a Master of Science in Mechanical Engineering from the University of Cincinnati and a Bachelor of Science in Mechanical Engineering from Anna University in Chennai, India. Sai reports to Kevin McIntosh, Director Product Management, SignalForce and SignalSound, and was most recently employed as an Experimental Mechanics Engineer with Cummins Power Generation in Fridley, Minnesota. Openings Data Physics is seeking qualified applicants for a number of positions in various functions at its offices in San Jose, California, Corona, California and Hamden, Connecticut. Please see listings in the Careers Section of the Data Physics website for details. You are invited to refer suitable candidates with the promise of a monetary reward for the successful hiring of your referred candidates. The size of the reward will vary between $250 and $1000 depending on the position. Upcoming Events Web Seminars Register for upcoming Data Physics Web Seminars. Shaker Service 101 on Thursday, March 14, 2013 George Pearce, Manager, Shaker Service, will share tips and tricks acquired through years of experience in the field servicing every type of electrodynamic shaker. You will learn what you can do yourself, when it is best to call in the service team and what to do before they get to your facility so that your system is back up in no time.

3 Multishaker Testing: State of Technology and Applications on Wednesday, March 20, 2013 Thomas Reilly, Director, Product Management, SignalCalc and SignalStar, will present a web seminar on multishaker test applications. Data Physics is very active in this frontier technology and has recently supplied SignalStar Matrix systems for many applications in Aerospace, Defense, Automotive and Earthquake engineering. View Recordings of past Data Physics Web Seminars. Navcon Engineering Hands-On Modal Seminar in Fullerton, CA on March 19 to 22, 2013 Navcon Engineering will present a Hands-On Modal Testing & Analysis Seminar March 19-22, The training is intended for those engineers involved with modal test data acquisition, parameter estimation, test-analysis correlation and troubleshooting noise & vibration problems. This modal seminar is truly "HANDS ON". At least 50% of the time will be spent in Navcon's lab setting up analyzers, making measurements, acquiring, reducing and assessing modal data. Navcon Engineering Network s Hands-On Modal Testing Seminar is intended for those engineers and technicians involved with modal test data acquisition, parameter estimation, test-analysis correlation, finite element model updating and troubleshooting noise & vibration problems. It is Navcon s goal that the attendees are able to conduct modal and operational deflection shape tests from start to finish, on their own, upon completing the training. Tradeshows Visit the Data Physics website for a complete list of 2013 tradeshows. Instrumentation, Analysis and Testing Exhibition at Silverstone Race Track, UK on March 12, 2013 Data Physics (UK) Ltd. will exhibit at the event which emphasizes subjects such as residual strain effects and considerations, improvements in the Whole Testing & Predictive Process, KERS Standard & Hybrid Systems, and Electric Actuators. International TransPack Forum at Orlando, Florida USA on March 25 to 28, 2013 The International Safe Transit Association (ISTA), a leading developer of test protocols for global packaged products, presents the International TransPack Forum. The Forum brings together industry experts and testing specialists to exchange ideas and technological advancements related to transport packaging. Data Physics brings an expertise in vibration and shock testing. ESTECH at San Diego, California on April 29 to May 2, 2013 IIEST s 59th annual technical meeting will take place in the San Diego Marriot Del Mar. ESTECH has conference sessions and an expo covering a wide range of topics including design, test, and evaluation/product reliability; contamination control; aerospace; and nanotechnology. Data Physics is at booth 22.

4 Wilson Sporting Goods Uses SignalCalc for Modal Evaluation of Tennis Rackets Wilson Sporting Goods needs to test the modal response and damping condition of its tennis rackets. These tests can be used to not only compare different racket designs, but also the effects of different tennis racket dampeners. Many sports equipment manufacturers are concerned with the structural response of their products because poor dynamic response can affect the performance and feel of the product. Most common among these are racket and golf club manufacturers. Equipment to do this measurement includes: 1. A Data Physics SignalCalc Ace on Quattro 2. An accelerometer held by wax on the racket rim 3. An instrumented modal hammer The test is a basic structural impact test. The racket is excited by gently striking the rim with the hammer. The force imparted by the hammer and the acceleration response of the racket are processed to produce a frequency response function that can be used for analysis or export for modal curve fitting. A typical measurement of a tennis racket is shown below (note that this is not from a Wilson racket). The peaks in the frequency response function (FRF) correspond to the natural frequencies of the racket - the frequency of oscillation where the amplitude of response is greatest. The natural frequency of the tennis racket depends on the mass and stiffness distributions in the racket and the dampeners used on the racket. These natural frequencies in the racket head transmit into the handle where they can be felt by the user.

5 Founded in 1913, Wilson Sporting Goods is a sports equipment manufacturer located in Chicago, Illinois that makes gear for badminton, baseball, basketball, softball, football, golf, racquetball, soccer, squash, tennis, and volleyball. From Bench Top to Laptop FFT analyzers FFT analyzers have been around for over four decades. They have gained much acceptance over the years as engineers and scientists have uncovered a slew of applications for the FFT. As they have grown in popularity FFT analyzers have also developed into an industry, claiming many breakthrough advancements along the way. Of all the bench top FFT analyzers made, the HP/Agilent 35670A (Figure 1) has proven to be the most popular and most resilient. The 35670A analyzer set the bar for performance of small channel count analyzers. Each year, hundreds of these analyzers were fielded, and may thousands are still in use today. In fact, Agilent continues to offer the 35670A. Even though the typical customer is only replacing or adding to their currently installed systems, enough of these customers exist to maintain the product line. Figure 1: Agilent 35670A FFT Analyzer At launch, the 35670A outperformed all other analyzers to date. It was versatile, portable (sort of), and had advanced capabilities available such as order tracking and realtime octave measurement. It is no wonder that the 35670A has been such a popular dynamic signal analyzer. Since the introduction of the 35670A, the single most profound improvement in the world of FFT analyzers has been the amalgamation of digital signal processing hardware, the FFT, and the personal computer. The omnipresence of the PC in today s world does not need reiteration, and the joining of dynamic signal analysis with the PC means there are that many more outlets for data crunching, analysis, and sharing when operating on PC based analyzers. Most users who become aware of PC based analyzers migrate to them when replacing their aging bench top analyzers.

6 The SignalCalc line of dynamic signal analyzers is an obvious choice for these users migrating from older bench top analyzers. Specifically, the SignalCalc ACE on Quattro has proven to be an excellent channel-to-channel replacement system. The ACE on Quattro has many of the same features that made the 35670A such a popular choice. The Quattro hardware is robust and features the most up to date specifications in the industry, eclipsing the The analysis capabilities of both instruments are versatile. In addition to these similarities, more subtle similarities exist with measurement setup. While navigating the setup is very different because bench top analyzers use soft keys and hidden menus, the openness of the measurement setup is very similar. Many of today s current PC based analyzers are restrictive, cryptic, or simply difficult to setup the measurement. SignalCalc Dynamic Signal Analyzers make setup open, transparent, and easy to access. Additionally, the nomenclature used in defining measurements in SignalCalc is very similar to that of the 35670A. Despite the likeness, the ACE on Quattro has evolved in several areas over the 35670A analyzer which has remained frozen in design. The ACE on Quattro is even more portable, capable, and accurate. These improvements can be seen on both the hardware and software side of the analyzer. The hardware differences between the 35670A and the Quattro reflect the evolution of the state-of-the-art. Looking at the measurement bandwidth, the 35670A supports up to khz bandwidth, distributed between all of the channels. So with four input channels selected, the 35670A has up to 25.6 khz bandwidth. On the other hand, the Quattro is capable of 40 khz or 80 khz (optional) without adjusting the guard band ratio on every channel. The hardware differences also extend to the ADC resolution and dynamic range. The Quattro s has a 24bit ADC providing up to 120dB dynamic range, while the 35670A supports a 16bit ADC with up to 90dB dynamic range. SignalCalc Ace on Quattro software supports a broader range of applications than does the 35670A. The 35670A is sold as an FFT analyzer with available options for order tracking, realtime octave, and swept sine testing. The Quattro, also optionally, supports all these test modes along with many more, which span fields such as sound intensity and rotor dynamics. This makes the system even more versatile and opens up measurement options with existing and new users. Even within the common software options, SignalCalc extends the analysis capability. Graphing, for example, is much more customizable and user friendly with the SignalCalc PC based interface. Many of the graphing features simply were not possible on the monochrome screens that limited bench top analyzers. Figure 2: Order tracking and waterfall displays on Agilent 35670a and SignalCalc

7 In today s world, most data taken during an experiment will need to be processed, displayed, printed, or ed on a computer at some point in time. This is the natural environment of SignalCalc software, where signal exporting, time history recording and reporting are all available as, or instantly after, a test runs. Older bench top analyzers were limited to exporting screen shots to a floppy drive or transfer to a PC over GPIB or serial connection. The advances in PC technology, notably with huge storage capacity gains in disk drives, have also changed throughput of recorded time data. Because the Quattro is connected to a host PC, throughput to disk file sizes are only limited by the host PC s hard drive often granting the user the ability to store days of gap free data at high bandwidth. On the other hand, bench top analyzers can store a very limited amount of data, most often less than 32 MB. Modern, PC based dynamic signal analyzers offer users much better usability, performance, and data transfer than bench top analyzers. The SignalCalc Ace on Quattro analyzer makes a very logical and easy choice for users upgrading from older bench top analyzers both from a usability and performance stand point. Furthermore, HP/Agilent 35670A users are often very comfortable with the SignalCalc analyzer interface, and this allows those users a quick transition with little to no learning curve. The SignalCalc Turbo User Interface A Top Differentiator against the Competition SignalCalc Turbo delivers many features that meet and surpass the capabilities of competitive products. Multiple application coverage, expandable channel count, exceptional phase accuracy, unsurpassed dynamic range, and self-calibration are capabilities that appeal to most users. The SignalCalc Turbo user interface, above all, stands out universally as a key selling point that should be positioned front and center along with other select differentiators when comparing SignalCalc Turbo with the competition. SignalCalc Turbo is an advanced turbomachinery vibration analyzer, yet exceptionally easy to use compared to competitive systems such as the Bently ADRE 408. Appealing to new and experienced analysts alike, SignalCalc Turbo s intuitive setup and displays enable the user to setup a new project, begin capturing measurements, and display results quickly for analysis - and with relatively few keystrokes. User Setup User Setup with SignalCalc Turbo is both streamlined and efficient. As shown in the example in Figure 1, Input Transducer setup includes a convenient, customizable table of Channel, Machine, Phase Trigger Names and a Transducer Database. Information added to the table then becomes available in drop-down lists, making it easy to quickly configure a large number of input channels. Shortcuts, such as highlighting groups of channels to set parameters for multiple channels at the same time, also save valuable time and keystrokes.

8 Figure 1: Hardware/Input Transducer - Transducer Database Tables Figure 2: Hardware/Input Info Setting Parameters for Multiple Channels

9 Default measurement and acquisition parameters often require very little adjustment before initiating live measurement. As with channel and transducer setup settings, the user has the option of applying default settings as is, modifying them for each project, saving settings in templates for future use, or even customizing default settings themselves. Figure 3: Hardware/Input Info Measurement Panel Graphic Layouts All Graphic Layouts are pre-configured with useful default configurations that enable the user to immediately begin viewing results, both live and post-measurement, by simply clicking on a Graphic Layout button. With the convenient Channel Selector panel, the user now has full access to all Graphic Layouts and all channels without any pre-configuration of graphs. With any Layout open, the user can easily scroll between active channels using the toggle on the Channel Selector panel. Should the analyst desire to customize displays, simply right-clicking on any Layout button brings up the Layout Setup panel. Graph Attributes settings similar to those available with all Data Physics analyzers are also easily accessed by right-clicking on any open graph. Post-data acquisition, the user can leverage the Project Browser to conveniently select any Waveform Save or Vector Sample for viewing. As shown in the default Direct and 1X Filtered Orbit Timebase example below, the user selects the desired sample using the Project Browser. After clicking on the Orbit Timebase buttons to bring up data for the first channel pairing, the user then toggles the Channel Selector to view the Orbit Timebase for other channel pairs.

10 Figure 4: Convenient Features for Data Viewing By comparison, the many sophisticated steps required to bring up the same Orbit Timebase display with the Bently ADRE 408 system require an elaborate 7-page article description, as published in GE s Orbit magazine in April See page 18: Summary Among many advantages against the competition, the streamlined and efficient user interface employed in SignalCalc Turbo delivers an advanced turbomachinery vibration analyzer that is easy to use for both the new and experienced analyst. With a straightforward User Setup and default Graphic Layouts, the user can set up a new project and begin displaying live results for analysis in only a few minutes. Post-measurement, the user has immediate access to display of all samples, all channels, and all graph types by using the convenient Project Browser, Layout buttons, and Channel Selector with no need for configuration of elaborate plot sessions. When the user requires a different view, custom graph configuration along with comprehensive Graph Attributes settings is only a right-click away.

11 E-Link Helps to Secure LE-2016 Order at COMAC Commercial Aircraft Corporation of China, Ltd. (COMAC) recently ordered a model LE-2016/DSA10-200K water cooled shaker. The SignalForce LE-2016 shaker series is a robust and popular model with a legacy back to the Ling 335 shaker. The version of the shaker coupled with a 200 kva amplifier is rated at 20,000 lbf (90 kn) for both sine and random. In this case, the end users were very selective in choosing an appropriate shaker for their needs. Personnel from the Data Physics China office arranged visits to existing customers that have 2016 and 4022 water cooled shakers in Beijing and Shanghai. These visits successfully showed the reliability of the installed shakers and strengthened Data Physics reputation in the eyes of the customer. Furthermore, some shakers that have been in use for more than ten years were well reviewed by the existing users. COMAC has an additional requirement that the users need to be able to operate the amplifier remotely from the control room. The amplifier remote control needs to include gain control, voltage display, current display, water temperature display, alarm status display, and field choice selection. Data Physics engineers in China were able to show the capabilities of this software, which helped to win the order over an LDS solution offered by Bruel & Kjaer. The E-Link option continues to be a strong feature that is not only extremely practical, but also demonstrates Data Physics commitment to continuous product development. Figure1: E-Link Remote control

12 SignalForce Configuration Changes With the new fiscal year, there will be several significant configuration changes to the SignalForce price list. Data Physics will only be offering the LE-2016/DSA10-80K shaker system as a non-upgradeable system. A new model will be added to the price list, which will allow the customers to upgrade their amplifier to reach the maximum rated force of the LE-2016 shaker system. The new model will be an LE-2016/DSA10-140K. The shaker force ratings will be exactly the same - 18,000 lbf (80 kn) Sine and 13,000 lbf (57.8 kn) rms Random. The system utilizing the 80 KVA amplifier is not upgradeable without replacement of the amplifier. On the other hand, the new 140 KVA amplifier configuration will be easily upgradeable, giving the customer a more versatile system to start with. Along with the LE-2016 shaker system configuration change, there will be new additions to the SignalForce shaker lineup. The 3 inch (76.2mm) displacement versions of the LE-1216, LE-2016, and LE-4022 shakers will all be in the new price list. There will also be two new models added to the product range - the LE-1316 and LE shaker models. Both the LE-1316 and LE-2516 will offer up to 3 inch (76.2mm) displacement. The LE-1316 shaker system has been available and has actually been successfully tested and delivered to two US customers and is now widely available. The LE-2516 model is planned to be released in the second quarter of Along with the shaker configuration changes, you will also notice changes to the LE-DSA10 amplifier models. In the past, the LE-DSA10 amplifiers used generic part numbers for the rated output. For instance, the LE-DSA10-80K would have been an 80 KVA output model. However, this model amplifier was used on several different shaker models from the LE-1216 and LE-2016 to the LDS-954 and LDS-964. The problem with labeling amplifiers this way became apparent recently when production engineers were assembling and testing five different configurations of the LE-DSA10-80K, all for different shakers. The new method of labeling will incorporate the shaker model number in the configuration to prevent any confusion in configuring the proper AC and DC output voltages and currents. Head Expanders The head expander is a vibration fixture that attaches to the shaker armature to allow users to expand the armature head to a larger mounting area. Head expanders are available in various shapes circle, square, rectangle, hexagon, etc. Data Physics standard head expanders are round or square. Quality Head Expanders are constructed of magnesium and are designed for sound dynamic behavior. Magnesium is both lightweight and heavily damped, making it the ideal material for vibration test fixtures. Because magnesium is not as heavy as aluminum or steel, thicker segments may be used to build the head expander. This allows the end result to be more rigid with better performing dynamic characteristics. In order to produce a dynamically sound head expander, it is very important to use thick segments to construct the crate that forms the head expander. The voids in the welded crate like structure are then treated with a damping material for better dynamic behavior. This damping technique has evolved over 25 years and is a key aspect of building head expanders at Data Physics. The combination of sound design, use of magnesium, quality welding and the damping treatment, allows Data Physics to provide vibration test engineers some of the best performing head expanders on the market.

13 Head Expander Size To size a head expander properly, it is necessary to know the test requirements. If possible, there should be a discussion with the user, of all the information relating to the tests planned, such as maximum acceleration levels, frequency range, and axes of vibration. It is also essential to consider the physical characteristics of the test article(s) to be tested on the head expander. This discussion may require you to configure the head expander with guidance and load support. Information such as how many units the customer desires to test simultaneously is also important. Generally, the user should eliminate overhang on the mounting surface, but a slight overhang of the test article on the head expander can be acceptable. However, this depends on the dynamics of the test article and can really only be determined with experimentation. Head Expander Mass Despite being constructed of light weight magnesium, head expanders are not without weight. Though hollow, they are reinforced for better dynamic performance and the overall mass may be significant in the context of the required acceleration and the size of shaker. Adding this mass to the armature assembly always means that the user needs to evaluate or re-evaluate the capability of the shaker to run the test with the added mass. In sizing shakers for applications, the process is often iterative, taking into consideration head expander size, shaker force rating and the number of units to be tested. Head Expander External Guidance The general rule of thumb is, if the size of the head expander is more than 2.5 times the largest bolt circle on the shaker armature, external guidance will be required. External guidance will protect the shaker armature from overturning moments that can damage the armature or its internal guidance. Typically, the external guidance assembly also includes load support that provides static load support for test masses heavier than the shaker s load support. Note that external guidance and load support does not lessen or negate the requirement for dynamic force based on Newton s second law (F=M x A).

14 There are shakers with head expanders larger than twice the armature bolt circle that do not use external guidance. In these exceptional cases, the customer has to be sure to maintain the center-of-gravity (CG) of the product over the CG of the head expander. If the customer is willing to make that type of commitment in their test practices, any size head expander can be used. Note that in new sales situations it is necessary to minimize the customer s risk and exceptional solutions will require a customer s acknowledgement in writing. Head Expander Response Head expanders generally have a significant first bending mode, which can easily be observed. The frequency of this mode is very dependent on the size and construction of the Head Expander and is almost always lower than 2,000 Hz. For most tests, SignalStar controllers can control through this resonance out to 2,000 Hz. Larger head expanders that have more resonances in the test frequency band often require average control to ensure good control out to 2,000 Hz. Summary Head expanders are often required for vibration testing. Knowing as much information as possible about the test will allow users and engineers to select the proper head expander for the application. In selecting head expanders, users need to understand that head expanders do add mass and dynamic response to the test, and that high quality head expanders are designed and tested to minimize both the mass and dynamic response. Additionally, larger than average test loads may require external guidance and/or load support. Contributors Robert Bloomquist, Product Manager, SignalCalc Turbo Min Dai, Manager, Data Physics China Alfred Johnson, Applications Engineer Bourke MacDonald, Marketing Communications Specialist Kevin McIntosh, Director, Product Management, SignalForce and SignalSound Jim Prange, Business Manager, US Central Region Editor: Russell Zuppo, Director, Marketing Managing Editor: Sri Welaratna, PhD, President and CEO