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BallisticsKistler system solutions for ballistic applications

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Kistler: the byword for advances in engine monitoring, vehicle safety and vehicle dynamics. Our products deliver data that plays a key part in developing efficient vehicles for tomorrow’s world.

Measurement technology from Kistler ensures top performance in sport diagnostics, traffic data acquisition, cutting force analysis and many other applications where absolutely reliable measurements are required despite extreme conditions.

By supporting all the stages in networked, digitalized production, Kistler’s systems maximize process efficiency and cost- effectiveness in the smart factories of the next generation.

Absolute Attention for tomorrow’s world

Kistler develops solutions for challenges in measurement technology with a portfolio that comprises sensors, electronics, systems and services. We push the frontiers of physics in fields such as emission reduction, quality control, mobility and vehicle safety: our products deliver top performance to meet the standards of tomorrow’s world, providing the ideal basis for Industry 4.0. This is how we pave the way for innovation and growth – for our customers, and with our customers.

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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

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When quartz experiences a mechanical load, it presents a charge proportional to the load.

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?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.

PiezoStar crystals are just one of many innovations from Kistler.

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Complete measuring chain unifying internal and external ballistic measurements and data acquisition.

Ballistic terms

The industry defines the different areas of ballistics applications as follows:

Internal ballisticsInternal ballistics are events inside the gun that occur from the time the firing pin strikes the primer until the bullet exits the muzzle.Measuring parameters of the primer is one of the most critical parts of acceptance tests to ensure safety and quality of ammunition. It relates to the study of events inside the barrel during an extremely short time frame. This can be down to a millisecond for small caliber rounds and up to a few milliseconds for larger calibers.

External ballisticsExternal ballistics are events that occur from the time the bullet leaves the muzzle until it strikes the ground/target downrange.

Terminal ballisticsTerminal ballistics is the science of what happens when a bullet strikes a target.

Advice from the expertsThere are three internationally recognized standards to control safety and quality of firearms ammunition. NATO regulates primarily standards in production for military issued ammunition, while C.I.P. and SAAMI focus on production standards for ammunition made for the civil market.

C.I.P. or Commission Internationale Permanente pour l’épreuve des armes à feu portatives has many member countries across the globe, while SAAMI is The Sporting Arms and Ammunition Manufacturers’ Institute and primarily operates in North America.

Kistler provides complete solutions to cover the requirements and high standards of C.I.P. and NATO EPVAT Tests. For the examination of internal ballistics procedures, Kistler provides measurement solutions to detect the initiation of a round being

fired. An accelerometer detects the moment when the trigger enables the mechanism to strike the primer of a cartridge with the firing pin.

To monitor the pressure in the chamber with either drilled cartridge or case mouth configuration, the high pressure sensor Type 6215 measures up to 6,000 bar. For shot shell ammunition, the Type 6239A allows a tangential measurement and therefore omits the need of drilling the plastic case. Port pressure measurements along the barrel and at the end of the muzzle can also be done with Kistler sensors.

Transitioning into the domain of the external ballistic phase, the flash at the muzzle can be detected for rate of fire measurement (ROF) or speed measurement, when the time of the bullet leaving the barrel is of interest using the Flash Detector Type Z21406-FD02. Measuring the projectile speed at specific distances, the Type 2521A light screen offers highest accuracy and a simple setup. Customer specific solutions like for e.g. wall mounted screens, redundant dual screens or different sizes can be made. With the measured speed and the mass of the projectile, the energy can also be determined.

For terminal ballistics parameters, the Type 2523A target system provides precise target data of the projectile coordinates as well as further statistical data.

All these measurands are acquired by one central data acquisition 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 inputs. Statistics and a variety of calculation modules make the analysis of the measured data very efficient. The raw data will always remain and be stored, even if additional modifications have been made to the signal. A simple report generator provides all data according to the standards. Calibration of the sensors and verification of the measuring chain can also be provided. The ballistic system can be integrated to a Manufacturing Execution System (MES). Kistler also provides consulting and training services.

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The optimal sensor for internal ballistics

Kistler sets the standard in pressure measurement for ballistics. Piezoelectric technology was introduced to the field of ballistics by Kistler in the 1960s. In 1971, the high pressure sensor Type 6203 was stipulated by NATO as the standard for ammunition tests. Kistler's continuous development program is designed to ensure that your changing requirements for

high pressure sensors are always met. From a new generation of products, NATO has accepted the high pressure sensor Type 6215 as the new standard and replacement for 6203. Especially for medium or large calibers, the Kistler portfolio offers a highly accurate pressure sensor with a range up to 10,000 bar.

Technical data Type 6217A 6215... 6213B* 6239A

5

SW8

9

6

0,05

29,5

5 36,3

M12x1

-

6

0

±0,05

10,5

KIAG 10-32 neg.

18

Type1699AA0,5

KIAG 10-32

Type1699AA0,5

4,8

0

–0,1

ø6

SW 8ø9

37,4

15,8

4,7

ø8,5

M10x1

swivelnut

KIAG 10-32

3818

5

SW 8

Type1699AA0,5

M12x1ø4

,8 0

–0,

01

ø6

ø9

ø10,5 0 – 0,05

KIAG 10-32 neg.

6,25 h7 -00,015

0,246 h7 -00,0006

6,1

0,24

21,8

50,

86

4,75

0,18

7

37,3

51,

47

M10x1 (6239AA_) 3/8-24 UNF (6239AB_)

HEX 5/16"

Key features • High sensitivity • 3 connector options • Front-sealing • Excellent long-term stability and service life

• NATO approved (AC/225 LCGDSS-SG1) • Front-sealing • Excellent long-term stability and service life

• Highest pressure range • Reference sensor version • Front-sealing • Excellent long-term stability and service life

• High sensitivity • Shoulder sealing design • Different thread options

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 ≤0.001radial ≤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./ BNC/TNC

KIAG 10–32 neg. KIAG 10–32 neg. 10–32 UNF

Applications mortar tube pressure,airbag, safety systems, energetic material

internal ballistic pressure for small calibers

ballistic and hydraulic pressure

shot shell ammunition, tangential and 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

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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 measurement

Cartridge mouth measurement Pressure measurement along the barrel

Tangential pressure measurement

• Comprehensive information on the burning of the powder

• Pressure measurement with high quality, no oscillations

• Work intensive due to spot drilling the cartridge case and the necessary accurate centering of the case

• Application for R&D + CIP Measurement

• Fast pressure rise, where oscillations are possible

• No machining on the cartridge necessary, therefore simple and fast

• Applications mostly for ammunition acceptance and qualification such as the NATO requirements

• Fast pressure rise, for excellent timing of measurement

• Expect lower pressure characteristic at port or muzzle position than in the cartridge chamber

• Tangential measurement in the chamber allows for pressure measurement of plastic shot shell cartridges without the need to drill it

• C.I.P. allows and accepts tangential measurements, as long as the correlation is known and mastered

• Sealing and distance rings allow a precise positioning of the sensor in the chamber

The sensor is exposed to the hot combustion gases over the entire pressure characteristic.

Important: • Use thermal protection

The volume of the dead zone in front of the sensor may oscillate due to the small measuring hole. These oscillations, which are normally in the range of several kHz, are usually attenuated by fitting (electronic) filters in series with output.

Important: • Dead volume between sensor and barrel as small as possible • Use of diaphragm protector (in order to prevent sensor damage due to abrasion particles)

The pressure of a shot shell cartridge can be measured through the plastic wall of the casing. This increases the efficiency of the test procedure due to massive time savings, because the cartridges don’t need to be drilled.

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.

Various measuring arrangements

— Cartridge mouth— Cartridge chamber— Barrel

–500

0

500

1,000

1,500

2,000

2,500

3,000

3,500

0,5 1 1.5 2 2.5 3

Time [m/sec]

Pres

sure

[ba

r]

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Sensor Type 6215 Sensor Type 6213B

min. 4recommended 6 ... 15

min. 4recommended 6 ... 15

Direct mounting Mounting with diaphragm protector Type 6567

Direct mounting Mounting with diaphragm protector Type 6564

Mounting bores and measuring chain

Large caliber Propellant

Cartridge base adapter Measurement in closed bombs Characteristic pressure measurement

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

0 20,000 40,000 60,000 80,000 100,000

Pressure [psi]

Pres

sure

ris

e [k

psi/

sec]

6213B

It is only possible to install the sensor in a cartridge base adapter in the case of large calibers. As with the cartridge chamber measurement, this method of installation provides information on the entire pressure characteristic.

The closed bomb measurement is used for R&D and production monitoring of chemical propelling charge. In most cases, the sensor is not directly mounted in the casing but – due to handling reasons – by an adapter.

Important:• Use thermal protection or membrane protection

Important:• Dead volume between sensor and barrel keep as small as possible

Special applications

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Recommended alternative charge meters and charge amplifiers

Recommended cables

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.

Type Application Connection Image Connection

1631 for sensor Types 6213B, 6215, 6217

10–32 pos. BNC pos.

1699AA0,5 for sensor Types 6213B, 6215, 6217

10–32 pos. 10–32 neg.

1603B Extension cable BNC neg. BNC pos.

Accessories

Measuring chain

Typical measuring chain

BAControl Transient recorder software

Pressure sensor and accessories (recommended to use with cable Type 1619AA0,5)

A highly insulating cable is important to deliver the best possible charge signal with minimal losses to the DAQ device.

Ballistic analyzer with high speed data acquisition up to 10 Mbit/s and selectable filters. Measures charge (1 to 4 channels) and voltage (1 to 4 channels) and fulfills all requirements for ballistic and industrial measurements.

The DAQ Software stores raw data and provides powerful mathematical analysis functions to extract all important parameters as well as data export and a reporting functions.

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Internal ballistics External ballistics Integrated signal conditioning, data acquisition and online analysis system

Piezoelectric pressure sensor Type 6215 (according to NATO or CIP standard)

• Chamber pressure• Port pressure• Muzzle pressure• Accelerometer for firing detection

• Flash detector• Light screen• Target system

Transient recorder Type 2519A...• Charge and voltage inputs including

DAQ software

System overview

AccelerometerType 8274A5

Pressure sensorType 6215

Port pressure sensorType 6215A

Muzzle pressure sensor Type 603CAA Z21811M10 Adapter2519AZ200_Clamp

Light screen Type 2521A Target system Type 2523A

Cables Type 2519AZ100A...

Transient recorderType 2519A

Connecting cablesType 1631C...

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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/s0.1% @ 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/s0.1% @ 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

System componentsHigh-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 inputs0 ... 4 voltage inputs

• Low-pass filters: 2nd order

• Linearity: <0.1% FS

• Power supply: 12 V

• Power consumption: 25 W

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Calibration and dynamic verification of pressure sensors for ballistics applications

AccreditedlaboratoryStepwise calibration(Dead-weight)

Customerlaboratory

Unit UnderTest (UUT)

Continuouscalibration

Dynamicverification

Primary standardPiston gauge

Working standardType 6963A8000

Pressure generatorType 6906

'Dynamic'working standard

Type 6213BK

Pressure pulsegeneratorType 6909

The demanding conditions inherent to ballistic testing prescribe strict quality control and maintenance for all measurement equipment. Pressure sensors, in particular, require regular maintenance and re-calibration.

Calibration of piezoelectric pressure sensorsNumerous guidelines and standards are available for the calibration of pressure sensors, but only a few guidelines include quasi-static procedures for piezoelectric measurement equipment. The ISA-S37.10, for example, calls for a quasi-static calibration procedure in which “the source of calibration pressure may be either continuously variable over the range of the instrument or may be provided in discrete steps, as long as the pressure is returned to zero after each step.” Consequently, there are three quasi-static procedures for the calibration and verification of piezoelectric pressure sensors:

• Stepwise calibration: – for calibrating working standards

• Continuous calibration: – standard procedure for the day-to-day calibration of test

sensors• Dynamic verification:

– to confirm the functionality of a test sensor under highly dynamic pressure loading

Definitions of main calibration expressions

Stepwise calibrationPressure is applied in discrete steps. At each step, the applied pressure is allowed to stabilize before rapidly dropping to atmospheric conditions. The output from the Unit Under Test (UUT) is measured directly before and after the pressure drop, thus recording the change in charge output resulting from the change in pressure.

A stepwise calibration is typically conducted with a deadweight tester (also known as piston pressure gauge) that uses known traceable weights to apply pressure to a fluid. Deadweight testers are primary standards, i.e. the pressure measured by a deadweight tester is derived from other, fundamental quantities: length, mass and time. National Metrology Institutes and accredited laboratories typically use high quality deadweight testers to calibrate pressure standards (or reference sensors).

Continuous calibrationPiezoelectric pressure sensors are typically calibrated using a so-called continuous calibration procedure: i.e. a comparison of 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.

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The test sensor's sensitivity is typically defined as the slope of a 'best straight line' through the calibration curve (test system output vs. reference system output).

The continuous calibration is generally recommended and widely accepted as the standard procedure for the calibration of piezoelectric high pressure sensors.

Dynamic verification The functionality of a sensor is verified under dynamic loading conditions similar to those found in internal ballistic testing. The output of the Unit Under Test is compared with that of a reference sensor, while rapidly applying and removing pressure. Pressure pulses up to 6,000 bar with gradients in excess of 3x106 bar/s are typically used for a dynamic verification.

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.

Calibration methods and traceability

Measurement application

Calibration laboratories

Nationalcalibration service

NMI

Kistler production

Kistlerservice

Customer laboratory

Calibration laboratories accredited by

the Swiss Accreditation Service

e.g. Kistler's 'SCS-049'

Reference equipment used in Kistler and

customer calibration laboratories is

calibrated in Kistler's laboratory 'SCS-049'

Calibrated measurement equipment

National Metrological Institute is a member

of the CIPM MRA

Transfer Standards

Working Standards

Measurement equipment

National Standards

Stepwise

Stepwise

Continuous

Cartridge mouth pressure measurement

Calibration prerequisites It is essential that the calibration equipment is maintained in good working order. It is generally recommended that working standards and amplifiers used in calibration laboratories are calibrated at least once per year. It is also important that the insulation of the high-insulation connecting cables is checked regularly. Cables with less than 1013 Ω insulation resistance should no longer be used for calibration. Further recommendations:

• The sensor insulation resistance should exceed 1012 Ω• Always use the correct mounting torque as specified for each

sensor type• Use the correct tools when mounting and removing sensors

or adapters• Always use the correct calibration adapters

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Typical system configuration for continuous calibration

Pressure generatorReference sensor

Unit Under TestCalibrator Calibration SW

• Signal conditioning• Data acquisition• Evaluation

• Documentation• Data management

CalibrateType Z18906A

Calibration Softwarefor Windows®

Order No.: 33889/10Charge No.: 4429420

www.kistler.com

© 2013 Kistler Group, Switzerland

Passt auf «Zweckform» CD-Etiketten Nr. 6015

CalibrateType Z18906A

Calibration Softwarefor Windows®

Order No.: 33889/10Charge No.: 4429420

www.kistler.com

© 2013 Kistler Group, Switzerland

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BESCHRIFTUNG Typical 5959 Calibration System Type 2553AQx Version 2.0

KOMPLETTER PFADY:\152-MARKETING-001-ORIGINALE\DOKUMENTE\PROSPEKT P\400-339\TYPICAL SYSTEM 5959A 6906 6963.VSD

Datum 11.02.2013 Name Cat Blatt 5959 Typical System

6906

1631C2

PC or Laptop Operating system: Windows XP / Windows 7Serial Interface: 1 x USB

Charge

Voltage

Type Z21014-0022

Unit Under Test

Reference Sensor

Charge

Type Z21014-0022

5959A...

Ref [Charge]

UUT [Voltage]UUT [Charge]

USB

USB

6963A8000

UUT

Calibration adaptere.g. 6925A

CalibrateTM SoftwareIncluded with 5959A...

Typical system configuration for dynamic verification

1631C2Ref [e.g Charge Input B]

UUT [e.g. Charge Input A]UUT

6213BK

6909

25196213A... Mounting adapter e.g. 6212A2

Unit Under TestE.g. 6215

PC or Laptop Operating system: Windows XP / Windows 7Interface: 1 x Ethernet

USB

Ballistic analyzer software Included with 2519

Ethernet

Pressure impulse generatorReference sensor

Unit Under TestTransient recorder

Unit Under TestType 6215

Reference sensorType 6213K

Pressure pulse generatorType 6909

Reference

Unit Under Test

Transient recorderType 2519A...

SW forType 2519A...

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Sensitivity vs fired rounds, Type 6215

–2

–1

0

1

2

3

4

5

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000

Fired rounds

Sens

itivi

ty C

hang

e [%

]

• Sensor was used at powder manufacturer • Recalibration after every 50 rounds • Very stable until approx. 25,000 rounds

Re-calibration intervals for Type 6215

NATO EPVAT Guideline, section 12.5 • Sensitivity constant to be measured prior and after test, but at least after 300 rounds

• Complete calibration (S, Lin) after less than 1,000 rounds • If ΔS ≥±2.0% from previous calibration, or ΔS ≥±10% from original calibration, or Δlin ≥±1.0% from original calibration, then the transducer shall be disqualified from further testing.

Lifetime sensitivity change of sensor Type 6215

Re-calibration intervals for ballistic applications

Kistler instruction manual for sensor 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% at peak, recalibration on dead weight tester or with 6906 is requested

General recommendations

Dynamic verification at expected peak pressure before each ballistic measuring campaign • Analysis: if Δp ≥±2.0% (at peak pressure), complete recalibration is needed

• With ballistic analyzer: check for any discontinuities • Equipment: pulse generator Type 6909 with transient recorder Type 2519A

• Interval: before each ballistic measuring campaign

Recalibration (S, Lin) • Analysis: if ΔS ≥±5% from original calibration, discard sensor; if Lin ≥±1.5%, discard sensor

• Use sensitivity of this recalibration for any further measurements • Equipment: continuous pressure generator Type 6906 with calibrator

• Interval: at least every 300 rounds or once per year*)

*) In case peak pressure is >80% of nominal range, intervals shall be reduced to 100 rounds.

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