Application Note: Calibration at Toyota Motor Corporation Using Vibration Transducer Calibration System Type 9610
Application Note: Calibration at Toyota Motor Corporation Using Vibration Transducer Calibration System Type 9610
Application Note: Calibration at Toyota Motor Corporation Using Vibration Transducer Calibration System Type 9610
dB a H r(f)
+ 20 A
H A(f)
S x(f)
+ 10
S u(f)
H B(f)
B
0 a H u(f)
A
H A(f)
– 10 S x(f)
200 500 1 kHz 2 5 10 20 50 100 940151e
870553/1e
Fig.1 Frequency response of a damaged accelerometer Fig.3 Principle of improved back-to-back calibration by substitu-
tion
2
standard accelerometer does not have
to be a primary (absolute) calibrated
IEEE–488 Signal Analyzer
standard reference accelerometer. Vi-
2035
bration Transducer Calibration Sys-
tem Type 9610 employs a standard
Delta Shear Accelerometer Type
4371 as a working standard acceler-
ometer.
Much more than just providing an Preamp. Ch. A Ch. B Gen.
extremely low total calibration uncer- Printer Input Direct Direct Output
IBM-compatible
IBM PS/2 PC
tainty value (approximately 1% [2]),
the improved FFT calibration by sub- Precision
Conditioning Attenuator
stitution technique also provides a Amplifier 5936
number of distinct benefits. Most im- 2626 Conditioning
Ref 2 Amplifier Vibration
portantly, it provides calibrations 2626 Transducer
which are intrinsically independent Ref 1 Multiplexer
of all system inaccuracies except for 5923
8305
those occurring due to the standard
2712
reference accelerometer and the pre- 4371
Output
cision attenuator*.
An important consequence of this Power Output Input AC
is that it makes system self-calibra-
tion unnecessary, enhancing calibra- Vibration Exciter Shaker
tion efficiency and reliability. In 4808 4809 Power Amplifier
addition, improved FFT calibration 2712 932448e
by substitution reduces the need for Fig.4 Vibration Transducer Calibration System Type 9610
recalibration of system components,
because only the above-mentioned in-
struments need to be recalibrated. tion” philosophy, attempting to mini- erence Accelerometer, with participa-
mize production waste and maximize tion from Brüel & Kjær, The National
A full description of the improved
productivity. Institute of Standards and Technolo-
FFT calibration by substitution tech-
In the Toyota Motor Corporation, gy (NIST), USA, and Physikalisch-
nique and its implementation in Vi-
one section of the Technical Admin- Technische Bundesanstalt (PTB),
bration Transducer Calibration
istration Division - the “Calibration Germany, were carried out during
System Type 9610 can be found in
Center” – controls calibration of pie- 1990 and 1991. The results explicitly
references [3] and [4].
zoelectric accelerometers. confirmed the consistency and the ac-
For the calibration laboratory, curacy of Vibration Transducer Cali-
there are a number of obvious bene- bration System Type 9610 [5].
The Vibration Transducer fits in automating the calibration Secondly, Vibration Transducer
Calibration System Type process. Since installation, and after Calibration System Type 9610 uses
9610 in use at the Toyota months of intensive use, the Calibra- continuous control to ensure the
tion Center emphasizes the following quality and reliability of the calibra-
Head Office Technical benefits of Vibration Transducer Cal- tion process and the linearity of the
Center ibration System Type 9610: DUT. This is achieved by measuring
❍ High, consistent accuracy the coherence# between the two chan-
Founded in August 1937, the Toyota ❍ Reduced operator dependency nels. Furthermore, Vibration Trans-
Motor Corporation has grown to be a ❍ Faster calibration ducer Calibration System Type 9610
world leading car manufacturer with ❍ Consistent philosophy performs a number of verifications**
more than 70 000 employees and ❍ Database management capability to ensure that the system, the stand-
sales representatives around the ❍ Reduction of calibration costs
ard reference accelerometer and the
world. Armed with a constant striv- ❍ Company calibration strategy op-
standard voltage reference are in a
ing for automotive perfection, Toyota timization stable working condition. The refer-
Motor Corporation has over the years ence frequency response function is
These benefits have been accom-
made several significant contribu- also checked in order to check the
plished in Vibration Transducer Cal-
tions to automotive technology. mounting and the integrity of the
ibration System Type 9610 by taking
As a natural consequence of striv- a number of measures. The most im-
ing for perfection, Toyota Motor Cor- † Vibration Transducer Calibration Software
portant are outlined in the following. WT9301, controlling the calibration process,
poration has constantly focused on Firstly, by removing tedious, yet retrieves pertinent data from the data base,
cost-efficient solutions for its various critical, work and allowing the oper- sets up the analyzer, transfers the measured
needs. The best known example of data from the analyzer and processes them to
ator to concentrate on the few crucial give the calibration result. In this process, the
this is probably the “Lean Produc- manual tasks, operator dependency operator is carefully guided by the software.
has been drastically reduced. This, in Manual action is needed at transducer mount-
* Bus-controlled Precision Attenuator Type ing/removal and if a situation is detected that
5936 is used in Vibration Transducer Calibra- connection with intelligent computer- requires manual correction (loose cables,
tion System Type 9610 to minimize the con- based interactive decision making†, wrong preamplifier settings, lack of connec-
tribution to systematic error by eliminating ensures high and consistent accuracy. tions, etc.)
range switching in Multichannel Analysis # The coherence function is a measure of the
System Type 3550 Comparison (Round Robin) calibra- linearity between the two input channels to
tions of a Brüel & Kjær Standard Ref- the Multichannel Analysis System Type 3550
3
Conclusions
The evolution of the traditional back-
to-back calibration method into the
FFT-based improved back-to-back
calibration by substitution method
has been discussed along with the
features and benefits of implement-
ing the technique in Vibration Trans-
ducer Calibration System Type 9610.
Also, by examining the use of Vi-
bration Transducer Calibration Sys-
tem Type 9610 at Toyota Motor
Corporation, it was shown how the
system has enabled the Calibration
Center to further optimize their cal-
ibration strategy, increase productiv-
ity and calibrate with more accuracy
and more confidence.
Fig.5 Vibration Transducer Calibration System Type 9610 in use at the Calibration References
Center
[1] M. Serridge and T. R. Licht:
standard reference accelerometer prisingly, reported a reduction in cal- “Piezoelectric Accelerometers and
and working standard accelerometer. ibration costs. Vibration Preamplifiers”,
This ensures a consistent calibra- Finally, by combining the FFT cal- Brüel & Kjær Handbook BB 0694
tion philosophy with a constant and ibration technique with a PC to man- [2] Tech. Review, no.2, 1987:
thorough focus on error reduction. age data, data retrieval, trend T. R. Licht and H. Andersen,
Thirdly, the combination of random analysis, calibration comparisons, Brüel & Kjær: “Trends in Acceler-
excitation and the improved FFT cal- etc. are easy and straightforward. ometer Calibration”
ibration by substitution provides very According to the Calibration Cent- [3] Brüel & Kjær Product Data sheet
fast calibrations. Obtaining a typical er, the above factors were all carefully BP 1426: “Vibration Transducer
calibration (sensitivity as well as examined prior to purchase in order Calibration System Type 9610”
phase at 1550 frequencies) takes ap- to evaluate their usefulness and their [4] User Manual: “Vibration Trans-
proximately three minutes, including impact on the calibration strategy. ducer Calibration System Type
all manual work. The center explains: “Today’s auto- 9610”
A natural consequence of this is mobile customers are extremely de- [5] E. Schonthal & T. R. Licht: “Com-
higher calibration productivity and manding and critical, they do not parison of Accelerometer Calibra-
the Calibration Center has, not sur- accept half solutions – and neither do tions Performed on a Software
we. The Vibration Transducer Cali- based System to Calibrations Ob-
bration System Type 9610 provides tained from two National Labora-
us with fast, reliable and accurate tories”, Proc. Nat. Conf. of
** The verification procedures are divided into
three: System Verification, Standard Voltage calibrations and fits perfectly well Standards Laboratories, Albu-
Verification and Standard Charge Verifica- into our quality optimization strategy querque, New Mexico, USA, Au-
tion. System Verification involves a series of due to its innovative improved FFT gust 1991
measurements to validate the stability of the
system. Standard Voltage Verification and calibration by substitution tech-
Standard Charge Verification are performed nique”.
to ensure the validity of the Standard Refer- Fig. 5 shows Vibration Transducer
ence Accelerometer and the Calibration Set
Type 3506 which are used as charge and volt- Calibration System Type 9610 in use
age standards, respectively at the Calibration Center.
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