Ballistics Kistler system solutions for ballistic applications
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2 www.kistler.com Contents
Kistler solutions for ballistic applications 4 Various measuring arrangements 7 Special applications 8 Measuring chain 9 System overview 10 System components 11 Calibration and dynamic verification of pressure sensors for ballistics applications 12 Typical system configuration for continuous calibration 14 Re-calibration intervals for ballistic applications 15
www.kistler.com 3 Kistler solutions for ballistic applications
Quartz, the heart of the transducer
Kistler has been developing and producing piezoelectric quartz sensors for measuring pressure since 1957. These have stood the test of time and supplied reliable results under even the most extreme conditions. Quartz crystal is an excellent piezoelectric material. The following properties make it particularly ideal for use in pressure transducers: •• Outstanding stability •• High mechanical strength •• High rigidity •• Wide temperature range •• Sensitivity little affected by temperature •• No hysteresis •• Extremely good linearity
Why use piezoelectric sensors for internal ballistics pressure measurement? PiezoStar crystals are just one of many innovations from Kistler.
It is a physical property of some crystals, such as quartz, that if you mechanically deform them, e.g. by applying a load, they will generate a very small electrical charge, in the order of picocoulombs.
This phenomenon is called the piezoelectric effect, and the fact that this charge generation is both repeatable and highly responsive to dynamic change makes sensors based on this technology, i.e. quartz based piezoelectric sensors, ideal for ballistic pressure measurements.
When quartz experiences a mechanical load, it presents a charge proportional to the load.
4 www.kistler.com Ballistic terms fired. An accelerometer detects the moment when the trigger enables the mechanism to strike the primer of a cartridge with The industry defines the different areas of ballistics applications as the firing pin. follows: To monitor the pressure in the chamber with either drilled cartridge Internal ballistics or case mouth configuration, the high pressure sensor Type 6215 Internal ballistics are events inside the gun that occur from the time measures up to 6,000 bar. For shot shell ammunition, the Type the firing pin strikes the primer until the bullet exits the muzzle. 6239A allows a tangential measurement and therefore omits Measuring parameters of the primer is one of the most critical the need of drilling the plastic case. Port pressure measurements parts of acceptance tests to ensure safety and quality of along the barrel and at the end of the muzzle can also be done ammunition. It relates to the study of events inside the barrel with Kistler sensors. during an extremely short time frame. This can be down to a millisecond for small caliber rounds and up to a few milliseconds Transitioning into the domain of the external ballistic phase, for larger calibers. the flash at the muzzle can be detected for rate of fire measurement (ROF) or speed measurement, when the time of External ballistics the bullet leaving the barrel is of interest using the Flash Detector External ballistics are events that occur from the time the bullet Type Z21406-FD02. Measuring the projectile speed at specific leaves the muzzle until it strikes the ground/target downrange. distances, the Type 2521A light screen offers highest accuracy and a simple setup. Customer specific solutions like for e.g. wall Terminal ballistics mounted screens, redundant dual screens or different sizes can be Terminal ballistics is the science of what happens when a bullet made. With the measured speed and the mass of the projectile, strikes a target. the energy can also be determined.
Advice from the experts For terminal ballistics parameters, the Type 2523A target system There are three internationally recognized standards to control provides precise target data of the projectile coordinates as well as safety and quality of firearms ammunition. NATO regulates further statistical data. primarily standards in production for military issued ammunition, while C.I.P. and SAAMI focus on production standards for All these measurands are acquired by one central data acquisition ammunition made for the civil market. unit, the Type 2519A transient recorder. It can measure with up to 10 MS/s and can have 1 – 4 charge inputs as well as 1 – 4 voltage C.I.P. or Commission Internationale Permanente pour l’épreuve inputs. Statistics and a variety of calculation modules make des armes à feu portatives has many member countries across the analysis of the measured data very efficient. The raw data the globe, while SAAMI is The Sporting Arms and Ammunition will always remain and be stored, even if additional modifications Manufacturers’ Institute and primarily operates in North America. have been made to the signal. A simple report generator provides all data according to the standards. Calibration of the sensors Kistler provides complete solutions to cover the requirements and verification of the measuring chain can also be provided. and high standards of C.I.P. and NATO EPVAT Tests. For The ballistic system can be integrated to a Manufacturing the examination of internal ballistics procedures, Kistler provides Execution System (MES). measurement solutions to detect the initiation of a round being Kistler also provides consulting and training services.
Complete measuring chain unifying internal and external ballistic measurements and data acquisition.
www.kistler.com 5 The optimal sensor for internal ballistics
Kistler sets the standard in pressure measurement for ballistics. high pressure sensors are always met. From a new generation Piezoelectric technology was introduced to the field of of products, NATO has accepted the high pressure sensor ballistics by Kistler in the 1960s. In 1971, the high pressure Type 6215 as the new standard and replacement for 6203. sensor Type 6203 was stipulated by NATO as the standard for Especially for medium or large calibers, the Kistler portfolio offers ammunition tests. Kistler's continuous development program a highly accurate pressure sensor with a range up to 10,000 bar. is designed to ensure that your changing requirements for
Technical data Type 6217A 6215... 6213B* 6239A
e e Type 1699AA0,5
KIAG 10-32 neg. KIAG 10-32 neg.
6 ±0,05 HEX 5/16"
SW8 6 4,75 0,187 9
3 1,47 36, 5 37,35 M10x1 (6239AA_) 3/8-24 UNF (6239AB_) 29,5 swi el 0,86 21,85 18 t 5 6,1 0,24
0 0 10,5 -0,05 6,25 h7 -0,015 0 0,246 h7 -0,0006 M12x1
Key features ••High sensitivity ••NATO approved ••Highest pressure ••High sensitivity ••3 connector options (AC/225 LCGDSS- range ••Shoulder sealing ••Front-sealing SG1) ••Reference sensor design ••Excellent long-term ••Front-sealing version ••Different thread stability and service ••Excellent long-term ••Front-sealing options life stability and service ••Excellent long-term life stability and service life
Measuring range bar 0 ... 2,000 0 ... 6,000 0 ... 10,000 0 ... 1,500 Overload bar 2,400 6,600 11,000 2,000 Sensitivity pC/bar –13 –1.4 –1.2 –5.6 Natural frequency kHz >180 >240 >150 >300 Linearity %FSO <±0.5 <±1 <±0.5 ≤±0.5 Acceleration sensitivity mbar/g <2 <5 <5 axial ≤0.001 radial ≤0.0005 Operating temperature range °C –50 ... 200 –50 ... 200 –50 ... 200 –40 … 160 Thread M12x1 M10x1 M12x1 M10x1 or 3/8–24 UNF
Connection KIAG 10–32 neg./ KIAG 10–32 neg. KIAG 10–32 neg. 10–32 UNF BNC/TNC Applications mortar tube pressure, internal ballistic ballistic and hydraulic shot shell ammunition, airbag, safety systems, pressure for small pressure tangential and energetic material calibers recessed measurement, general purpose sensor
Detailed technical specifications can be found in the sensor specific data sheet. * Premium accuracy: Lin. ≤±0.3 Acc. sens. ≤0.2 – on request
6 www.kistler.com Various measuring arrangements
Different measuring positions are suitable for specific information, from the analysis of the entire gas pressure cycle to peak pressure values, to closed bomb and other ballistic applications.
Research & Development Ammunition acceptance testing and velocity timing, research & development Cartridge chamber Cartridge mouth measurement Pressure measurement along Tangential pressure measurement the barrel measurement
•• Comprehensive information •• Fast pressure rise, where •• Fast pressure rise, for •• Tangential measurement on the burning of the powder oscillations are possible excellent timing of in the chamber allows for •• Pressure measurement with •• No machining on the measurement pressure measurement of high quality, no oscillations cartridge necessary, therefore •• Expect lower pressure plastic shot shell cartridges •• Work intensive due to spot simple and fast characteristic at port or without the need to drill it drilling the cartridge case •• Applications mostly for muzzle position than in the •• C.I.P. allows and accepts and the necessary accurate ammunition acceptance and cartridge chamber tangential measurements, centering of the case qualification such as the as long as the correlation is •• Application for R&D + CIP NATO requirements known and mastered Measurement •• Sealing and distance rings allow a precise positioning of the sensor in the chamber
The sensor is exposed to the The volume of the dead zone in front of the sensor may oscillate The pressure of a shot shell hot combustion gases over the due to the small measuring hole. These oscillations, which are cartridge can be measured entire pressure characteristic. normally in the range of several kHz, are usually attenuated by through the plastic wall of fitting (electronic) filters in series with output. the casing. This increases the Important: efficiency of the test procedure •• Use thermal protection Important: due to massive time savings, •• Dead volume between sensor and barrel as small as possible because the cartridges don’t •• Use of diaphragm protector (in order to prevent sensor damage need to be drilled. due to abrasion particles) Important: Accessories like a dial gauge and cartridge dummies are available to determine the optimal position to conduct a reproducible result. Measurement comparison between cartridge chamber, cartridge mouth and along the barrel with a Type 6215 sensor from Kistler.
— Cartridge mouth — Cartridge chamber r — Barrel
ress re
. . ime m sec www.kistler.com 7 Special applications
Large caliber Propellant Cartridge base adapter Measurement in closed bombs Characteristic pressure measurement
ress re rise k si sec ress re si
It is only possible to install the sensor in a cartridge The closed bomb measurement is used for R&D and production monitoring of base adapter in the case of large calibers. As with chemical propelling charge. In most cases, the sensor is not directly mounted in the cartridge chamber measurement, this method the casing but – due to handling reasons – by an adapter. of installation provides information on the entire pressure characteristic.
Important: Important: • Use thermal protection or membrane protection • Dead volume between sensor and barrel keep as small as possible
Mounting bores and measuring chain
Sensor Type 6215 Sensor Type 6213B
mi . mi . recomme e ... recomme e ...
Direct mounting Mounting with diaphragm Direct mounting Mounting with diaphragm protector Type 6567 protector Type 6564
8 www.kistler.com Measuring chain
Typical measuring chain
BAControl Transient recorder software
Pressure sensor and accessories A highly insulating cable is Ballistic analyzer with high The DAQ Software stores (recommended to use with important to deliver the best speed data acquisition up raw data and provides cable Type 1619AA0,5) possible charge signal with to 10 Mbit/s and selectable powerful mathematical minimal losses to the DAQ filters. Measures charge (1 analysis functions to extract all device. to 4 channels) and voltage important parameters as well (1 to 4 channels) and fulfills all as data export and a reporting requirements for ballistic and functions. industrial measurements.
Accessories
Recommended alternative charge meters and charge amplifiers
Type Image Channels Frequency range Characteristics 5015 1 0 ... 200 kHz Charge meter with LCD display and menu-guided operation; direct display of measurements as well as maximum, minimum and mean values; LCD status display; remote control via digital inputs; RS-232C serial interface for parameter setting and measured data transfer.
5018A 1 0 ... 200 kHz This universal laboratory charge amplifier can be used for signal conditioning of all piezoelectric pressure sensors. Drift compensation for engine combustion applications; wide measuring range; direct signal evaluation; liquid crystal display and easy menu-driven screen.
Recommended cables
Type Application Connection Image Connection 1631 for sensor Types 10–32 pos. BNC pos. 6213B, 6215, 6217 1699AA0,5 for sensor Types 10–32 pos. 10–32 neg. 6213B, 6215, 6217 1603B Extension cable BNC neg. BNC pos.
www.kistler.com 9 System overview
Light screen Type 2521A Target system Type 2523A Port Muzzle Pressure pressure pressure sensor sensor sensor Type Accelerometer Type 6215 Type 6215A 603CAA Type 8274A5 Z21811 M10 Adapter 2519AZ200_Clamp
Connecting cables Cables Type 1631C... Type 2519AZ100A...
Transient recorder Type 2519A
Internal ballistics External ballistics Integrated signal conditioning, data acquisition and online analysis system Piezoelectric pressure sensor Type 6215 (according • Flash detector to NATO or CIP standard) • Light screen Transient recorder Type 2519A... • Target system • Charge and voltage inputs including • Chamber pressure DAQ software • Port pressure • Muzzle pressure • Accelerometer for firing detection
10 www.kistler.com System components High-end transient recorder Type 2519A for ballistic applications incl. application software
• Storage of raw data
• Postprocessing
• Application software with large number of computing methods for ballistics
• Data analysis according to NATO and CIP standards
• Maintenance free
• Compact and mobile instrument
• Integrated calibrator
• Input channels: 0 ... 4 charge inputs 0 ... 4 voltage inputs
• Low-pass filters: 2nd order
• Linearity: <0.1% FS
• Power supply: 12 V
• Power consumption: 25 W
Light screen Type 2521A • Robust and stiff design
• Protection IP66 (DIN EN 60529)
• Caliber range 4 ... 40 mm frameless >125 mm
• Velocity range 50 ... 3,000 m/s
• Velocity inaccuracy <0.2% @ 1 MSa/s 0.1% @ 5 MSa/s
• Reaction time: typ. 1 μs
• Working temp. –30 ... 45°C
Target system Type 2523A • Robust and stiff design
• Protection IP66 (DIN EN 60529)
• Caliber range 4 ... 40 mm
• Velocity range 50 ... 3,000 m/s
• Velocity inaccuracy <0.2% @ 1 MSa/s 0.1% @ 5 MSa/s
• Reaction time typ. 1 μs
• XY coordinate inaccuracy <5 mm or <0.5% of XY range, or 0.5 · caliber (greater value, 200 ... 1,500 m/s, project. base trig.)
• Working temp.: –30 ... 45°C www.kistler.com 11 Calibration and dynamic verification of pressure sensors for ballistics applications
The demanding conditions inherent to ballistic testing prescribe Definitions of main calibration strict quality control and maintenance for all measurement equipment. Pressure sensors, in particular, require regular expressions maintenance and re-calibration. Stepwise calibration Calibration of piezoelectric pressure sensors Pressure is applied in discrete steps. At each step, the applied Numerous guidelines and standards are available for the pressure is allowed to stabilize before rapidly dropping to calibration of pressure sensors, but only a few guidelines include atmospheric conditions. The output from the Unit Under Test quasi-static procedures for piezoelectric measurement equipment. (UUT) is measured directly before and after the pressure drop, The ISA-S37.10, for example, calls for a quasi-static calibration thus recording the change in charge output resulting from the procedure in which “the source of calibration pressure may be change in pressure. either continuously variable over the range of the instrument or may be provided in discrete steps, as long as the pressure is A stepwise calibration is typically conducted with a deadweight returned to zero after each step.” Consequently, there are three tester (also known as piston pressure gauge) that uses known quasi-static procedures for the calibration and verification of traceable weights to apply pressure to a fluid. Deadweight piezoelectric pressure sensors: testers are primary standards, i.e. the pressure measured by a deadweight tester is derived from other, fundamental quantities: • Stepwise calibration: length, mass and time. National Metrology Institutes and – for calibrating working standards accredited laboratories typically use high quality deadweight • Continuous calibration: testers to calibrate pressure standards (or reference sensors). – standard procedure for the day-to-day calibration of test sensors Continuous calibration • Dynamic verification: Piezoelectric pressure sensors are typically calibrated using – to confirm the functionality of a test sensor under highly a so-called continuous calibration procedure: i.e. a comparison of dynamic pressure loading the output signal of the UUT with the one of a reference sensor, while continuously increasing the pressure from zero to full scale and then back to zero.
Accredited laboratory Primary standard Stepwise calibration Piston gauge (Dead-weight)
Customer Continuous laboratory calibration Working standard Type 6963A8000
Pressure generator Type 6906
Dynamic 'Dynamic' verification working standard Unit Under Type 6213BK Test (UUT) Pressure pulse generator Type 6909
12 www.kistler.com Calibration methods and traceability tio l t r s
tio l etrolo ic l stit te is mem er o t e
te wise r s er t r s li r tio l or tories ccre ite tio l t e wiss ccre it tio er ice c li r tio ser ice e. . istler s te wise orki t r s e ere ce e i me t se i istler li r tio l or tories c stomer c li r tio l or tories is c li r te i istler s l or tor istler istler stomer o ti o s ro ctio ser ice l or tor e s reme t e i me t li r te me s reme t e i me t e s reme t lic tio
Cartridge mouth pressure measurement
The test sensor's sensitivity is typically defined as the slope of Calibration prerequisites a 'best straight line' through the calibration curve (test system It is essential that the calibration equipment is maintained in output vs. reference system output). good working order. It is generally recommended that working standards and amplifiers used in calibration laboratories are The continuous calibration is generally recommended and calibrated at least once per year. widely accepted as the standard procedure for the calibration of It is also important that the insulation of the high-insulation piezoelectric high pressure sensors. connecting cables is checked regularly. Cables with less than 1013 Ω insulation resistance should no longer be used for Dynamic verification calibration. Further recommendations: The functionality of a sensor is verified under dynamic loading conditions similar to those found in internal ballistic testing. • The sensor insulation resistance should exceed 1012 Ω The output of the Unit Under Test is compared with that of • Always use the correct mounting torque as specified for each a reference sensor, while rapidly applying and removing pressure. sensor type Pressure pulses up to 6,000 bar with gradients in excess of • Use the correct tools when mounting and removing sensors 3x106 bar/s are typically used for a dynamic verification. or adapters • Always use the correct calibration adapters A dynamic verification is conducted to confirm a sensor's functionality; it is typically conducted in addition to (and not as replacement of) a continuous calibration.
www.kistler.com 13 Typical system configuration for continuous calibration
Reference sensor Pressure generator Calibrator Calibration SW Unit Under Test i l co itio i oc me t tio t c isitio t m eme t l tio Passt auf «Zweckform» CD-Etiketten Nr. 6015
Calibrate Type Z18906A
Calibration Software for Windows®
Order No.: 33889/10 Charge No.: 4429420
www.kistler.com
© 2013 Kistler Group, Switzerland 900-609e-01.13
Calibrate Type Z18906A
Calibration Software for Windows®
Order No.: 33889/10 Charge No.: 4429420
www.kistler.com
© 2013 Kistler Group, Switzerland 900-609e-01.13
Calibration adapter e.g. 6925A Type Z21014-0022 Type Z21014-0022 UUT UUT [Charge] Charge S Unit Under Test UUT [Voltage] Voltage
Reference Sensor Charge S Ref [Charge]
16 1C 696 A8000 5959A... 6906
C or aptop Operating s ste : Windows / Windows Serial nterfa e: 1 S
CalibrateTM Software Included with 5959A...
Typical system configuration for dynamic verification
Reference sensor Type 2553AQx Version 2.0 Datum 11.02.2013 Name Cat Blatt 5959 Typical System Pressure impulse generator Transient recorderBESCHRIFTUNG Typical 5959 Calibration System
KOMPLETTER PFAD Unit Under Test Y:\152-MARKETING-001-ORIGINALE\DOKUMENTE\PROSPEKT P\400-339\TYPICAL SYSTEM 5959A 6906 6963.VSD
Unit Under Test Reference sensor Type 6215 Type 6213K Reference
Unit Under Test
Pressure pulse generator Transient recorder SW for Type 6909 Type 2519A... Type 2519A...
6213BK 1631C2 Ref [e.g Charge Input B]
UUT UUT [e.g. Charge Input A] Ethernet USB Unit Under Test E.g. 6215
6213A... Mounting adapter 2519 e.g. 6212A2
or to 6909 er ti s stem i ows i ows ter ce t er et
llistic a l zer so tw re cl e wit
14 www.kistler.com Re-calibration intervals for ballistic applications
Kistler instruction manual for sensor Type 6215 Sensitivity vs fired rounds, Type 6215 •• Peak pressure <5,000 bar: every 1,000 rounds •• Peak pressure >5,000 bar: every 200 rounds •• If lin ≥±1.5%, the transducer shall be disqualified from further
testing
•• In case of dynamic verification with Type 6909: if ΔS ≥±2.0% e at peak, recalibration on dead weight tester or with 6906 is
requested i it it s e General recommendations
Dynamic verification at expected peak pressure before each ire ro s ballistic measuring campaign •• Analysis: if Δp ≥±2.0% (at peak pressure), complete Lifetime sensitivity change of sensor Type 6215 recalibration is needed •• With ballistic analyzer: check for any discontinuities •• Equipment: pulse generator Type 6909 with transient recorder •• Sensor was used at powder manufacturer Type 2519A •• Recalibration after every 50 rounds •• Interval: before each ballistic measuring campaign •• Very stable until approx. 25,000 rounds Recalibration (S, Lin) Re-calibration intervals for Type 6215 •• Analysis: if ΔS ≥±5% from original calibration, discard sensor; if Lin ≥±1.5%, discard sensor NATO EPVAT Guideline, section 12.5 •• Use sensitivity of this recalibration for any further measurements •• Sensitivity constant to be measured prior and after test, but at •• Equipment: continuous pressure generator Type 6906 with least after 300 rounds calibrator •• Complete calibration (S, Lin) after less than 1,000 rounds •• Interval: at least every 300 rounds or once per year*) •• If ΔS ≥±2.0% from previous calibration, or ΔS ≥±10% from original calibration, or Δlin ≥±1.0% from original calibration, *) In case peak pressure is >80% of nominal range, intervals shall be reduced then the transducer shall be disqualified from further testing. to 100 rounds.
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