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An Overview
INTRODUCTION
2 THE SIGNIACANCE OF M ECHANICAL M EASUREMENT
3 FUNDAMENTAL M ETHODS OF MEASUREM ENT
4 THE GENERALIZED MEASURING SYSTEM
s TYPES OF INPUT QUANTmEs
6 M EASUREMENT STANDARDS
7 CALIBRATION
8 UNCERTAINTY: ACCURACY OF RESULTS
9 REPORTING RESULTS
10 FINAL REMARKS
INTRODUCTION
It has been said, "Whatever exists, exists in some amount." The detennination of the amount
is what measurement is all about. If those things that exist are related 10 the practice of
mechanical engineering, then the de!ermination of their amounts conslilutes the subject of
mechanical measurements.1
The process or the act of measurement consists of obtaining a quantitative comparison
between a predefined standard and a measurand. The word measurand is used to designate
the particular physical parameter being observed and quanlified; that is, the input quantity
to the measuring process. The act of measurement produces a result (see Fig. I ).
The standard of comparison must be of the same character as the measuranid, and
usually, bu! not always, is prescribed and defined by a legal or recognized agency or
organization-for example, the National Institute of Standards and Technology (NIST),
fonnerly called the National Bureau of Standards (NBS), the International Organization for
Standardization (ISO), or the American Naiional Standards Institute (ANSI). The me:ter, for
example, is a clearly defined siandard of length.
Such quantities as temperature, strain, and the parameters associated with fluid flow,
acoustics, and motion, in addiiion to the fundamental quantities of mass, length, time, and
so on. arc typical of those within the scope of mechanical measurements. Unavoidably,
Processor
Measurand Result
(input)
comparison
(measurement) (readout)
3
The Process of Measurement: An Overview
answer, no perfect measure. "2 It is quite important that engineers interpreting the results of
measurement have some basis for evaluating the likely uncertainty. Engineers should never
simply read a scale or printout and blindly accept the numbers. They must carefully place
realistic tolerances on each of the measured values, and not only should have a doubting
mind but also should attempt to quantify their doubts. We will discuss uncertainty in more
detail in Section 8.
4
The Process of Measurement: An Overview
....-
Catibration Auxfliary power Auxiliary power
in�t Indicator
''
(not always required) (usually required )
'' ·� � - Recorder
Senses desired input to exclusion Modifies transduced signal into Provides an indication or
final stage. recording in form that can be
evaluated by an unaided human
of all others and provides fonn usable by
Usually increases amplitude
sense or by a control ler. Records
analogous output
and/or power, depending on
requirement. May also selectively data digitally on a computer
IDirect
alphanumeric readout
Hydraulic-pneunuuic: Buoyant Hydraulic-pneumatic: Piping. lndicalors (digital type):
float, orifice, venturi. vane, valving, dashpots, plenum
propeller chambers
Optical: Photographic film. Optical: Mirrors, lenses, optical Recorders: Digital printing, inked
photoelectric diodes and filters, optical fibers. spatial filters pen and chart, direct phot1>graphy.
transistors, phOlomultiplier tubes. (pinhole, slit) magnetic recording (hard disk)
holographic plates
Controllers: AU types
Stem
Compression
spring
Piston
Cylinder
(a)
- - ----- - - '
' '
-
'
-
'
Sensor-transducer
'
'
• Signal
:
Readout
Piston/cylinder Spring
'
concfiUoning
' (Scale and
Input
(Pressure lo (Fon:a lo '
: (None) '
pressure
lorce)
index)
displacement)
·- - - - - - - .. - - .!
(b)
FIGURE 3: (a) Gage for measuring pressure in automobile tires. (b) Block diagram of tire-gage
functions. In this example, the spring serves as a secondary transducer.
To illustrate a very simple measuring system, let us consider the familiar tire gage
used for checking automobile tire pressure. Such a device is shown in Fig. 3(a). It consists
of a cylinder and piston, a spring resisting the piston movement, and a stem with scale
divisions. As the air pressure bears against the piston, the resulting force compresses the
spring until the spring and air forces balance. The calibrated stem, which remains in place
after the spring returns the piston, indicates the applied pressure.
The piston-cylinder combination constitutes a force-summing apparatus, sensing and
transducing pressure to force. As a secondary transducer, the spring converts the force to
a displacement. Finally, the transduced input is transferred without signal conditioning to
the scale and index for readout [see Fig. 3(b)].
The Process of Measurement: An Overview
1. Static-<:<>nstant in time
2. Dynamic-varying in time
(a) Steady-state periodic
(b) Nonrepetitive or transient
Of course. the unchanging, static mcasurand is the most easily measured. If the system
is terminated by some form of meter-type indicator. the meter's pointer has no difficulty
in eventually reaching a definite indication. The rapidly changing. dynamic measurand
presents the real measurement challenge.
Two general forms of dynamic input are possible: steady-stale periodic input and
transient input. The steady-stale periodic quantity is one whose magnitude has a definite
repeating time cycle, whereas the time variation of a transient quantity docs not repeat .
"Sixty-cycle" line voltage is an example of a steady-slate periodic signal. So also are many
mechanical vibrations, after a balance has been reached between a constant input exciting
energy and energy dissipated by damping.
An example of a pulsed transient quantity is the acceleration-lime relationship accom
panying an isolated mechanical impact. The magnitude is temporary. being completed in
a matter of milliseconds, with the portions of interest existing perhaps for only a few
microseconds. The presence of extremely high rates of change, or wavefronts. can place
seven: demands on the measuring system.
l Although lhe accelerometer may be susceptible to an analysis of "stages" within i1self, we shall forgo such
an analysis in this ex.ample.
Stage 1 Stage 2 Stage 3
Sensor-lransducer Signal-conditioning system i Recording-readout system
I
I
I
I
i
I
Integrating I I Data-acquisition
Fitter circuit
Ampllller
computer
·Printer
Tlme,s
Computer graph
at every instant during its motion. A sensor that responds to velocity will produce: an output
signal having a time variation analogous to the time change in the auto's speed. We refer to
such a signal as an analog signal because it is analogous to a continuous physical process.
An analog signal has a value at every instant in time, and it usually varies smoothly in
magnitude.
Some quantities, however, may change in a stepwise manner between two distinct
magnitudes: a high and low voltage« on and off, for instance. The revolutions of a shaft
could be counted with a cam-actuated electrical switch that is open or closed, depending on
the position of the cam. If the switch controls current from a battery, current either flows
with a given magnitude or does not flow. The current flow varies discretely bet ween two
values, which we could represent as single digits: I (flowing) and 0 (not Hewing). The
amplitude of such a signal may thus be called digital.
Many electronic circuits store numbers as sets of digits-strings of ls and Os-with
each string held in a separate memory register. When digital circuits, such as those in
computers, are used to record an analog signal, they do so only at discrete points in time
. because they have only a fixed number of memory registers. The analog signal, which has
a value at every instant of time, becomes a digital signal A digital signal is a set of discrete
.
numbers, each corresponding to the value of the analog signal at a single specilfic instant
of time. Clearly, the digital signal contains no information about the value of tine analog
signal at times other than sample times.
Mechanical quantities-such as temperatures, fluid-flow rates, pressure, stress, and
strain-normally behave timewise in an analog manner. However, distinct advantages
are often obtained in converting an analog signal to an equivalent digital signal for the
purposes of signal conditioning and/or readout. Noise problems are reduced or s1Jmetimes
eliminated altogether, and data transmission is simpler. Computers are designed to process
digital information, and direct numerical display or recording is more easily accomplished
by manipulating digital quantities.
6 M EASUREMENT STANDARDS
As stated earlier, measurement is a process of comparison. Therefore, regardless of our
measurement method, we must employ a basis of comparison-standardized units. The
standards must be precisely defined, and, because different systems of units exist, the method
of conversion from system to system must be mutually agreed upon.
Most importantly, a relationship between the standards and the readout scale of each
measuring system must be established through a process known as calibration.
7 CALIBRATION
At some point during the preparation of a measuring system, known magnitudes of the input
quantity must be fed into the sensor-transducer, and the system's output behavior· must be
observed. Such a comparison allows the magnitude of the output to be correctly interpreted
in terms of the magnitude of the input. This calibration procedure establishes the correct
output scale for the measuring system.
By performing such a test on an instrument, we both calibrate its scale and prove its
ability to measure reliably. In this sense, we sometimes speak ofproving an instrument. Of
10
The Process of Measurement: An Overview
course, if the calibration is to be meaningful, the known input must i tsel f be derived from
a defined standard.
If the output is exactly proportional to the input (output = cons tant x input ), then
a single simultaneous observation of input and output will suffice to fix the constant of
proponionality. This is called single-point calibration. M ore often, however, multipoint
calibrations are used, wherein a number of different input values are applied. Multipoint
calibration works when the output is not simply proportional, and, more generally, improves
the accu racy of the calibration.
If a meas ur ing system will be used to detect a time-varying input, then the calibration
should ideally be made using a time-dependent input standard. Such dynamic cal i bration
can be di fficult, however, and astatic calibration, using a constant input signal, is frequently
substituted. Naturally, this procedure.is not optimal; the more nearly the calibration standard
corresponds to the measurand in all its characteristics, the better the resulting measurements.
Occasionally, the nature of the system or one of its components makes the introduc
tion of a sample of the basic input quantity di ffi cul t OI' impossible. One of the important
characteristics of the bonded resistance-type strain gage is the fact that, through quality con
trol at the time of manufacture, spot calibration may be appl ied to a complete lot of gages.
As a result, an indirect calibration of a strain-measuring system may be provided through
the gage factor s up p l ied by the manufacturer. Instead of attempting to apply a known unit
strain to the gage installed on the test s tructure-which , if possible, would often result in an
ambiguous situation-a resistance change is substituted. Through the predetermined gage
factor, the system's suain response may thereby be obtained.
a day-the average is very close to 60 Hz. The wandering is random and the moment
to-moment error in the frequency meter readout (from this source) is called
precision, or
random, error.
Randomness may also be introduced by variations in the measurand itself. If a
number of hardness readings is made on a given sample of steel, a range of readings will
be obtained. An average hardness may be calculated and presented as the actual hardness.
Single readings will deviate from the average, some higher and some lower. Of course,
the primary reason for the variations in this case is the nonhomogeneity of the crystalline
structure of the test specimen. The deviations will be random and are due to variations in
the measurand. Random error may be estimated by statistical methods.
9 REPORTING RESULTS
When experimental setups are made and time and effort are expended to obtain results, it
normally follows that some form of written record or report is to be made. The purpose
of such a reconl will determine its form. In fact, in some cases, several versions will be
prepared. Reports may be categorized as follows:
1. Executive summary
2. Laboratory note or tech nical memo
3. Progress report
4. Full technical report
S. Technical paper
Very briefly, an executive summary is directed at a busy overseer who wants only
the key features of the work: what was done and what was concluded, outlined in a few
paragraphs. A laboratory note is written to be read by someone thoroughly familiar with the
project, such as an immediate supervisor or the experimentalist himself or herself. A full
report tells the complete story to one who is interested in the subject but who has not been
in direct touch with the specific work-perhaps top officials of a large company or a review
committee of a sponsoring agency. A progress report is just that-one of possibly several
interim reports describing 1he current status of an ongoing project, which will eventually be
incorporated in a full report. Ordinarily, a technical paper is a brief summary of a project,
the extent of which must be tailored to fit either a time allotmenl at a meeting or space in a
publication.
Several factors are common to all the various forms. With each type, the first priority
is to make sure that the problem or project that has been tackled is clearly stated. There is
nothing quite so frustrating as reading details in a technical report while never being certain
of the raison d'etre. It is extremely importanl 10 make certain 1hat the reader is quickly
clued in on the why before one attempts to explain the how and the results. A clearly stated
objective can be considered the most important part of the report. The.entire report should
be written in simple language. A rule stated by Samuel Clemens is not inappropriate: "Omit
unnecessary adverbs and adjectives."
12
The Process of Measurement: An Overview
be sufficient, including a sentence or two statin g the problem . a block diagram of the
experimental setup, and some data presented either in tabular form or as a plotted diagram.
Any pertinent observations not directly evident from the data should also be included.
Sufficient information should be included so that the experimenter can mentally reconstruct
the situation and results I year or even years hence. A date and signature should always be
5
included and, if there is a possibility of important developments stemming from the work,
such as a patent, a second witnessing signature should be includL'<I and dated.
9.2 Full Report
The full report must relate all the facts pertinent to the p roj ect . II is even more important in
this case to make the purpose of the project comp le tel y clear, for the report will be read by
persons not closely assoc iated with the work. The full report should also include enough
detail to allow another pro fessional lo repeal the measurements and calculations.
One format that has much merit is to make the report proper-<he main body-short
and to the point, releg ati ng to appendices the supporting materials, su ch as data, detailed
descriptions of equipm ent, review of literature, sample calculations, and so on. Frequent
reference to these mate rial s can be made throughout the report proper, but the option to
peruse the de tai ls is left to the reader. This scheme also provides a good basis for the
technical paper, should it be planned.
93 Technical Paper
A primary purpose of a technical paper is to make known (to advertise) the work of the
writer. For this reason, two particularly important portions of the writing are the problem
statement and the results. Adequately done, these two item s will attract the attenti on of
other workers interested in the particular field , who can then make direct contact with the
writer{s) for additional details and discussion.
Space, number of words, limits on illustrat ions, and perhaps lime are all factors
m aking the preparation of a technical paper particularly challe n gin g . Once the problem
statement and the p ri mary results have been adeq uately established, the rem aining available
space may be used to summarize procedures, test setups, and the like.
10 FINAL REMARKS
An attempt has been made in th i s chapter to provide an overall preview of the problems
of mechan ical measurement. In conformance with Section 9, we have tried to state the
problem as fu lly as possible in only a few pages.
PROBLEMS
3. For the thermometer of Problem 2, specify how practical single point calibration may be
obtained.
4. Set up test procedures you would use to estim at e, with the aid only of your present judgment
and experience, the magnitudes of the common quant it ies list ed.
13
The Process of Measurement: An Overview
5. Consider the impac1 frame shown in Figure 5. Mass M, which travels along gui�le rails, is
raised to an initial height H and released from resl Discuss how you would me:asure the
mass velocity just prior to impacl wilh lhe leSI ilem in order to accounl for friction between
mass M and lhe guide rails.
I
H
Test
Item