Abstract:
A calibration system and method utilizes acceleration of a mass to generate a force on the mass. An expected value of the force is calculated based on the magnitude and acceleration of the mass. A fixture is utilized to mount the mass to a force balance, and the force balance is calibrated to provide a reading consistent with the expected force determined for a given acceleration. The acceleration can be varied to provide different expected forces, and the force balance can be calibrated for different applied forces. The acceleration may result from linear acceleration of the mass or rotational movement of the mass.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION(S) 
     This patent application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/642,613, filed on May 4, 2012, the contents of which are hereby incorporated by reference in their entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     The invention described herein was made in part by employees of the United States Government and may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to the field of precision force measurement systems. In particular, the present invention relates to a system for calibrating high precision multi-axis load cells such as wind tunnel force balances. An example of a wind tunnel force balance is disclosed in U.S. Pat. No. 5,663,497 entitled “Six Component Wind Tunnel Balance,” the entire contents of which are incorporated herein by reference. Strain gauge force balances are often used to measure forces applied to an object in a controlled test environment. These balances are commonly used to measure three components of aggregate force (axial, side, and normal, or vertical, forces; i.e. Fx, Fy, Fz), as well as three moments (roll, pitch, and yaw; i.e. Mx, My, Mz). Force balances have been utilized for years, especially in the aerodynamic research industry. Force balances are used in the estimation of important aerodynamic performance coefficients based on testing scaled aircraft models in wind tunnels. 
     Force balances have been calibrated manually, using a complex system of free hanging precision weights, bell cranks, and/or other mechanical components. Other methods may provide sufficient accuracy in some instances, but are often quite complex and labor-intensive, requiring a significant amount of time to complete each full calibration. To ensure accuracy, gravity-based loading is typically utilized. However, this often causes difficulty when applying loads in three simultaneous, orthogonal axes. A complex system of levers, cranks, and cables must be used, introducing increased sources of systematic error, and significantly increasing the time and labor intensity required to complete the calibration. 
     DESCRIPTION OF THE RELATED ART 
     Semi-automatic methods for calibrating force balances have been used in the art. Fully automated designs have been used to reduce the time involved in calibrating a balance; however, the new designs still have significant disadvantages. 
     These calibration systems are typically not portable, and must be installed at a fixed location. In addition, the calibration system accuracy may be difficult to experimentally verify. Because system accuracy is based on the combined accuracy of multiple load cells and position sensors, complex loads tend to make the resolution of force and moment vector orientation and magnitude relative to the coordinate system of the multi-axis load cell undergoing calibration extremely critical in overall system performance. 
     However, known force calibration systems suffer from various drawbacks. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention is a system and method wherein the mass utilized for calibration is held constant, and the acceleration is changed to thereby generate relatively large forces with relatively small test masses. Multiple forces can be applied to a force balance without changing the test mass, and dynamic forces can be applied by rotation or oscillating acceleration. If rotational motion is utilized, a mass is rigidly attached to a force balance, and the mass is exposed to a rotational field. A large force can be applied by utilizing a large rotational velocity. A centrifuge or rotating table can be used to create the rotational field, and fixtures can be utilized to position the force balance. The acceleration may also be linear. For example, a table that moves linearly and accelerates in a sinusoidal manner may also be utilized. The test mass does not have to move in a path that is parallel to the ground, and no re-leveling is therefore required. Balance deflection corrections may be applied passively by monitoring the orientation of the force balance with a three-axis accelerometer package. Deflections are measured during each test run, and adjustments with respect to the true applied load can be made during the post-processing stage. 
     A method of calibrating a force balance according to one aspect of the present invention includes providing a force balance to be calibrated. A test mass having a known magnitude is operably interconnected to the force balance, and the test mass is caused to accelerate by moving in a linear or a circular path. If the mass is rotated, the angular velocity generates a load on the force balance due to centripetal acceleration acting on the test mass. Alternately, the test mass may be moved and accelerated linearly. An expected force can be calculated utilizing the magnitude of the mass, position of the mass, and the acceleration of the mass. The output of the force balance is calibrated to provide a reading that is consistent with the magnitude of the expected force. The acceleration of the mass can be varied, and additional expected forces can be calculated for each acceleration. The expected forces can be utilized to further calibrate the force balance. 
     These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partially schematic view of an aircraft model supported by a force balance in a wind tunnel for testing; 
         FIG. 2  is a schematic view of the geometry of a calibration system according to one aspect of the present invention; 
         FIG. 3  is an isometric view of a centered system for calibrating a force balance; 
         FIG. 4  is an isometric view of an off-center system for calibrating a force balance; and 
         FIG. 5  is an isometric view of a system for simultaneously calibrating multiple force balances. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIGS. 3 and 4 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     The following nomenclature is utilized herein:
     ω=angular velocity   α=angle between the table rotational axis and earth&#39;s gravitational vector   θ=angle between the axis of the balance and the table rotation axis   R=arm distance (only used for the centered system)   D=moment arm distance along balance axis   m=attached mass   T X =translational offset between balance attachment point on the table and the axis of rotation   L=distance from the balance attachment point on the table to the balance moment center along the balance axis   φ=deflection angle of the arm   

     With reference to  FIG. 1 , a force balance  1  may be utilized to support a model aircraft  2  or other component in a wind tunnel  3  to measure forces acting on the model  2  due to airflow  4 . 
     A typical wind tunnel internal balance  1  is a six degree of freedom force and moment transducer, capable of measuring an aerodynamic normal force (NF), side force (SF), axial force (AF), pitching moment (PM), yawing moment (YM), and rowing moment (RM) by monitoring structural deformation with strain gauges. The balance is said to be “internal” because the instrument is mounted within the wind tunnel model. It will be understood that the present invention may also be utilized in connection with other types of force balances (e.g. external force balances). In the illustrated example, the force balance  1  includes a metric (cylindrical) end  5  that connects to the aircraft model  2 , and a non-metric (tapered) end  6  that is attached to a support structure  7  in the wind tunnel  3 . The present invention may also be utilized in connection with other types of force balances having different configurations. 
     A variable acceleration calibration system according to one aspect of the present invention utilizes centripetal and gravitational acceleration to apply loads to a force balance  1 . As discussed in more detail below, another aspect of the present invention includes utilizing linear acceleration to apply a variable load to a force balance. 
     If rotational motion/acceleration is utilized, a mass is rigidly attached to the force balance and it is exposed to a rotational field. The resulting (expected) force imparted by the attached mass is shown in equation (1).
 
 F=mg+mrω   2   (1)
 
     A large force can be applied using a relatively small amount of weight using a large rotational velocity. As a result, a smaller amount of weight is moved during the calibration process leading to a decrease in calibration time compared to known calibration systems. As discussed in more detail below, a centrifuge or rotating table can be used to create the rotational field, and fixtures may be utilized to position the balance. 
     A variable acceleration calibration system according to the present invention is advantageous in that the attached mass does not have a parallel (i.e. parasitic) load path to ground. Balance deflection corrections are applied passively by monitoring the orientation of the balance with a three-axis accelerometer package that provides an attitude sensing system. Deflections are measured during each run at specified angular velocities from which adjustments of the true applied load can be made during the post processing stage. 
     A two dimensional representation of a generic variable acceleration calibration system is shown in  FIG. 2 . Equations (2-4) determine the (expected) component loads on the balance. These governing equations assume constant rotational velocity. The loading event is periodic when α is non zero. However, this analysis calculates the average load during one revolution, allowing for a static representation of the (expected) loads exerted on the balance.
 
 NF=−mω   2   [T   x +sin(θ)( L+D )+cos(φ)cos(θ) R −sin(φ)sin(θ) R ] cos(θ)− mg  cos(α)sin(θ)  (2)
 
 AF=−mω   2   [T   x +sin(θ)( L+D )+cos(φ)cos(θ) R −sin(φ)sin(θ) R ] sin(θ)+ mg  cos(α)cos(θ)  (3)
 
 PM =[cos(φ) D −sin(φ) R]NF −[sin(φ) D +cos(φ) R]AF   (4)
 
     With reference to  FIG. 3 , a first calibration system  10  is referred to as a “centered system”. Force balance  1  is mounted to a rotational table  12  utilizing a mounting structure  13  and threaded fasteners  14  to thereby rigidly retain the force balance  1  with the axis “A” of the force balance  1  aligned with the rotational axis “R1” of a rotational table  12 . Rotational table  12  may comprise a known device that includes a powered actuator such as electric motor  11 , a drive system  9 , and a base  8 . As discussed in more detail below, powered actuator  11  and drive system  9  may also comprise known devices that are configured to provide linear movement and acceleration of table  12 . The rotational axis R1 is preferably aligned with the earths&#39; gravity vector. The independent variables in the system that need to be considered for calibration purposes are mass location, mass quantity, rotational velocity, and balance orientation. 
     Connecting structures or brackets  16 A and  16 B are rigidly secured to metric end  5  of balance  1 , and elongated vertically extending plates  18 A and  18 B are rigidly secured to the connection structures/brackets  16 A and  16 B, respectively. Although various connecting arrangements could be utilized, in the illustrated example threaded fasteners  20  connect the plates  18  to the connecting structures  16 . A plurality of rigid arms  22 A- 22 F are secured to the vertical plates  18 A and  18 B by threaded fasteners  24 . Support plates  26 A- 26 F of arms  22  rigidly support one or more test masses  28  having known masses. 
     Because the magnitude of the test masses  28 , the location of the test masses  28 , and the angular velocity of rotational table  12  is known, the total (expected) forces acting on force balance  1  can be calculated. A series of tests at different angular velocities can be performed to vary the forces acting on force balance  1  to thereby calibrate the force balance  1 . 
     Also, opposing force vector loading schemes can be achieved by attaching mass on opposite sides of rotational axis R1. These coupled opposing force vectors allow for pure moment application to the force balance  1 . As a result, the centered calibration system  10  is capable of employing a unique combination of simultaneously applied loads. An accelerometer package  30  is mounted to an upper end  32  of the calibration system  10 , and the coordinate system of the balance  1  is aligned with the coordinate system of the accelerometer package  30 . Deflection of the force balance  1  can be determined utilizing accelerometer package  30 , and the deflections can be taken into account with respect to the position of the test mass  28  when the applied loads/forces are calculated. Signals from the attitude sensing system  30  and force balance  1  are transmitted through the rotating table  12  utilizing slip rings (not shown). The various structural components and the accelerometer package  30  are preferably mounted utilizing dowels or the like to ensure that the components are assembled and aligned in a repeatable configuration. 
     A second “off-center” rotating system  40  ( FIG. 4 ) includes an elongated horizontal plate  42  that is secured to rotational table  12 . An angled mounting plate structure  44  is rigidly secured to the horizontal plate  42 , and balance  1  is mounted to angled surface  46  of mounting plate structure  44  by a mounting ring  48  or the like. The axis “A” of balance  1  extends at an angle θ relative to the rotational axis “R1” of rotational table  12 . Rotational axis R1 is preferably aligned with the gravitational vector of the earth. 
     The independent variables of the system  40  are the pitch angle, roll angle, attached mass, arm bracket location and balance position on the table  12 . In contrast to the centered system  10 , there is only one place where the applied force vector acts, which is at the center of gravity  50  of test masses  52 A and  52 B, and plate  54 , connecting structure  56  and other masses connected to balance  1 . For each loading configuration, the mass is equally spaced so that the center of gravity  50  of the group of masses is coincident with the axis A of the balance  1 . The off-center system applies a single force vector, and is therefore subjected to the single force vector loading constraint shown in equation (5).
 
−( RM )( AF )+( PM )( SF )−( YM )( NF )=0  (5)
 
     With further reference to  FIG. 5 , a calibration system  60  according to another aspect of the present invention includes a rotational table  12 A and a plurality of individual calibration units  62 . Each unit  62  includes a base  64  that is movably mounted to a linear guide  65 . The linear guides extend radially outwardly from the axis of rotation “R1” of the table  12   a . The linear guides  65  preferably comprise powered actuators that shift the bases  64  of the calibration units  62  in a linear, radial direction along horizontal axes “H1” as shown by the arrows “R2”. Various electrical or hydraulic powered actuators or the like may be utilized for the linear guides  65 . 
     Each calibration unit  62  includes a first powered rotary joint  72 , a short horizontally extending arm  74 , and a second rotary joint  76 . The force balances  1  are received in end connectors  78  of the second rotary joints  76 , and one or more test weights  80  and  82  are connected to the upper ends of force balances  1  by support plates/brackets  68  and  70 . The support plates/brackets  68  and  70  may be substantially similar to the corresponding structures described above in connection with the force calibration system  40  of  FIG. 4 . 
     In use, each individual calibration unit  62  may be moved to a specified radial position by selectively actuating powered linear guides  65 . It will be understood that the linear guides  65  may include a sensor that provides feedback to a controller (not shown) whereby the controller receives information concerning the position of each calibration unit  62 . 
     Also, the rotary actuators  72  can be utilized to rotate the individual force balances  1  about their horizontal axes H1 extending radially outward from the axis of rotation “R1” of the rotary table  12 A. Furthermore, each force balance  1  can also be rotated about an axis A1 upon actuation of powered rotary actuator  76 . The powered rotary actuators  72  and  76  may comprise electrically powered units having sensors or the like that provide information concerning the rotary angles of the components to a controller (not shown). 
     In use, the linear actuator  65  and powered rotary actuators  72  and  76  are actuated to position the test weights  80  and  82  in an initial position, and the table  12 A is then rotated at a selected angular velocity. In the illustrated example ( FIG. 5 ),  8  individual force balances  1  can be calibrated simultaneously. However, it will be understood that fewer force balances  1  may also be simultaneously calibrated utilizing the calibration system  60  of  FIG. 5 . Furthermore, additional calibration units  62  may be mounted to table  12 A utilizing additional linear guides  65  to provide for simultaneous calibration of more than 8 force balances  1 . 
     After the measurements for a first angular velocity and position of test weights  80  and  82  is taken, the test weights  80  and  82 , along with force balance  1 , can be moved to a second position by actuation of one or more of powered actuators  65 ,  72 , and  76 . In this way, the positions of the test weights  80  and  82  can be changed without stopping rotation of table  12 A, and without resetting the individual calibration units  62  and test weights  80  and  82 . 
     The expected forces to be generated by the test weights  80  and  82  can be calculated for a plurality of angular velocities of rotational table  12   a , and positions of test weights  80  and  82 . The individual force balances  1  can then be calibrated. It will be understood that the variables and equations utilized to calibrate the individual force balances  1  in the system  60  of  FIG. 5  are substantially the same as described above in connection with the systems  10  and  40  of  FIGS. 3 and 4 , respectively. 
     The calibration systems  10  and  40  described above may also be mounted to a linearly-oscillating table or other device that provides linear acceleration instead of rotational table  12 . Various types of tables and devices that are capable of generating linear acceleration are known in the art. For example, a linearly-oscillating table may provide sinusoidal acceleration of a known magnitude may be utilized. A table or other such device providing a period of constant acceleration may also be utilized. The forces imparted by the test mass due to linear acceleration are of the form F=ma. Equations of this type are well-known in the art, and they will not therefore be described in detail herein. It will be understood that flexing of the fixtures supporting the test mass may need to be taken into account under certain circumstances.