1. Error Calculations for Hydraulic Pressure Transducer

Specifications
 
Pressure Transducer Range 0-3000 Psi
Transducer Accuracy +0.5% FS
Transducer Repeatability + 0.1% FS
Transducer Zero Balance +1.0% FS Typical
Transducer Full Scale Balance + 1.0% FS Typical
Thermal Effects on Transducer Zero +0.02% FS
Thermal Effects on Transducer Span + 0.02% FS

 

Transducer Assumptions

Transducer Response Time: <5msec

Transducer Hysteresis: 0.1%

Power Supply Variation: None Piston Multiplier: 15:1

Amplification Variation: None Ppeak/H: 2,000 psi

Vibration Variation: None Ppeak/N: 24,000 psi

Acceleration Variation: None

Thermal Range: Case 1 = 70-120F,  Case 2 = 95-105F
 
 

Total Absolute Transducer Error
 
Item: Max Var-% Interval Calculation-% Squared-%
Accuracy 0.5 - 0.50 0.25
Zero Balance 1.0 - 1.00 1.00
FS Tolerance 1.0 - 1.00 1.00
Temp/Zero 0.005/oF 50oF 0.25 0.0625
Temp/Span 0.002/oF 50oF 1.00 1.00 

Total: 3.3125

Absolute Transducer Error at Nozzle Total = 1.82%

+ 54.6 x 15 = +819psi= +3.4% Error Error = +4.6psi

+ 819 @ 24,000 = + 3.4% Error @ Hydraulics

Repeatability Error
 
Item: Max Var-% Interval Calculation-%  Squared-% 
Repeatability 0.1 - 0.1 0.01
Hysteresis 0.1 - 0.1 0.01
Temp/Zero 0.005/oF 10oF 0.05 0.0025
Temp/Span 0.02/oF 10oF 0.20 0.400 

Total: 0.4225

Repeatability Error at Nozzle:

+19.5x15= +292.5 psi Error _Total = + .65

+292 @ 24,000 = 1.22% Error

Error = +19.5 psi @ Hydraulics


2. Error Calculations For Quartz Mold Transducers

Specifications:
 
Pressure Range: 0-30,000 Psi

0-2000 Bar
Accuracy: + 1.0%
Acceleration:  + 0.04%
Thermal Effects on Zero: + 0.0 
Thermal Effects on Span: + 0.2%

Assumptions

Hysteresis: 0.1%

Power Supply Variation: None, Piston Multiplier 15:1

Amplication Variation: None Ppeak/H: 2,000 psi

Vibration Variation: None Ppeak/M: 20,000 psi

Acceleration Variation: 100G'S

Thermal Range: Case 1 = 50F,  CASE 2 = 50F

Case 1: Total Absolute Transducer Error
, 
Item Max Var-% Interval Calculation-%  Squared-%
Accuracy: 1.0 - 1.0 1.0
Acceleration: 0.04 - 0.04 0.0016
Hysteresis: 0.10 - 0.1 0.01
Temp/Span: 0.02 50oF 1.0 1.00 

Total = 2.0116

Absolute Error at Mold:

+425 @ 24,000= 2.1% Error

Total = 1.418%

Case 2: Repeatability Error
 
Item Max Var-% Interval Calculation-% Squared-% 
Repeatability: 0.20 - 0.2 0.040
Hysteresis:  0.10 - 0.1 0.010
Temp/Span:  0.02 50oF 1.0 1.0
Acceleration 0.04   0.04 0.0016

Total = 1.0516

Repeatability Error at Mold:

+308 @ 20,000= 1.54% Error

TOTAL = +1.025%


3. Error Calculations For Mercury Nozzle Transducers

Specifications:

Pressure Range 0-30,000 PSI

Accuracy + 1.0%

Zero Balance + 1.0%

Full Scale Balance + 1.0%

Thermal Effects On Zero + 0.05%

Thermal Effects On Span + 0.02%

Assumptions:

Hysteresis: 0.3% Piston Multiplier: 15:1

Power Supply Variation: None Ppeak/H: 2,000 psi

Amplification Variationn: None P/peak/N: 24,000 psi

Vibration Variation: None ú P, H-N: 20%

Acceleration Variation: None

Thermal Range: Case 1 = 4F, Case 2 = 4F

Case 1: Total Absolute Error
 
Item Max Var % Interval Calculation% Squared%
Accuracy: 1.0 - 1.0 1.0
Zero Bal: 1.0 - 1.0 1.0
FS Tolerance: 1.0 - 1.0 1.0
Temp/Zero: 0.05/oF 50oF 2.5 6.25
Temp/Span 0.02/oF 50oF 1.0 1.0 

Absolute Accuracy at Nozzle: Total = 10.25

+960 @ 24,000= 1.72% Error

Total = +3.20%

CASE 2: Repeatability Error
 
Item: Max Var-% Interval Calculation-% Squared-% 
Repeatability: 0.2 -  0.2 0.04
Hysteresis: 0.3 -  0.3 0.09
Temp/Zero: 0.05 - 1.0 1.0
Temp/Span: 0.02 - 0.4 0.16

Repeatability Error at Nozzle: Total = 1.29

+340.7 @ 24,000= 1.42% Error

TOTAL = +1.136%


4. Error Calculations For Sapphire Nozzle Transducers

Specifications:

Pressure Range: 0-30,000 PSI

Accuracy + 0.1%

Zero Balance: + 0.0% (Set Pot)

Full Scale Balance: + 0.0% (Set Pot)

Thermal Effect On Zero: + 0.1%

Thermal Effect on Span: + 0.2%

Assumptions:

Hysteresis: None

Power Supply Variation: 0.0% Piston Multiplier: 15:1

Amplification Variation: 0.0% P/peak/H: 2,000 Psi

Vibration Variation: 0.0% P/peak/N= P/peak/M = 24,000 PSI

Acceleration Variation: 0.0% ú P, H-N: 20%

Acceleration: None

Thermal Range: Case 1 = 4F, Case 2 = 4F

Case 1: Total Absolute Error
 
Item Max Var-% Interval Calculation-% Squared-%
Accuracy: 0.5 - 0.5 0.250
Zero Balance: 0.0* - 0.0 0.000
FS TOL: 0.0* - 0.0 0.000
Temp/Zero: 0.0* 4oF 0.00 0.000
Temp/Span:  0.2 4oF 0.08 0.004

Absolute Accuracy at Nozzle: Total = 0.254

+150 @ 24,000= +0.62% Error

Total = +0.50%

Case 2: Repeatability Error
 
Item: Max Variable-% Interval Calculation-% Squared-% 
Repeatability: 0.1 - 0.10 0.010
Hysteresis: 0.0 0.00 0.00 0.00
Temp/Zero: 0.0* 4oF 0.00 0.00
Temp/Span: 0.2 4oF 0.08 0.0064

Total = 0.0164

Repeatability Error at Nozzle: Total = +0.13%

+38.4 @ 24,000= +0.19% Error

*Temp/Zero = set to 0 @ melt temp


5. Error Calculations for Load Cell Ejector Pin Units

Specifications:
 
Pressure Range: 0 - 550 Lbs (AVG SIZE)
Accuracy: + 1.0%
Zero Balance: + 0.01%
Full Scale Balance: + 0.01%
Thermal Effects on Zero + 0.01%
Thermal Effect on Span: + 0.01%

Assumptions:

Hysteresis: 0.0%

Power Supply Variation: None Piston Multiplier: 15:1

Amplification Variation: None P/peak/M: 20,000 psi

Vibration Variation: None Pin Friction: 5 lbs

Acceleration Variation: None

Thermal Range Variation: Case 1 = 70-80F Case, 2 = 70-80F

Case 1: Total Absolute Error
 
Item Max Var-%. Interval Calculation-%  Squared-%
Accuracy: 1.0 -  1.0 1.0
Zero Balance: 0.01 -  0.01 0.0001
FS Balance: 0.01 -  0.01 0.0001
Temp/Zero: 0.01 10oF 0.10 0.01
Temp/Span: 0.01 10oF 0.10 0.01

Other: Pin Frict 5lb.

Total = 1.0202

Absolute Accuracy at Mold:

10.55 lb X 20,000 = + 384 psi Error

550 lb Total = +1.01 %

+ 422 psi = 1.9% Error Error= +5.55 lb

5.00 lb

10.55 lb

CASE 2: Repeatability Error
 
Item: Max Var. %Interval Calculation-% Squared-% 
Repeatability: 0.1 - 0.10 0.010
Hysteresis: 0.2 _ 0.20 0.040
Temp/Zero: 0.01 10oF  0.10 0.010
Temp/Span: 0.01 10oF 0.10 0.010

Other: Pin Friction + 5LB

Repeatabiilty Error at Mold: Total = 0.070

Total = +0.265%

+6.46 lb X 22,000 =+ 258 psi Error Error = + 1.46 lb.

550 lb 5.00 lb.

+258 @ 20,000 = 1.29% Error 6.46 lb.