ISSN 1068-798X, Russian Engineering Research, 2007, Vol. 27, No. 5, pp. 296–298. © Allerton Press, Inc., 2007.
Original Russian Text © G.M. Trompet, A.Ya. Krasil’nikov, 2007, published in STIN, 2007, No. 5, pp. 18–20.
Vibratory Contact Transducer for the Metric Module
of Multipurpose Machine Tools
G. M. Trompet and A. Ya. Krasil’nikov
DOI: 10.3103/S1068798X07050140
The monitoring instruments with a vibrating sensor
are used in the feedback chains in fabricating the high-
precision parts on the multipurpose machine tools [1].
The primary element of these instruments is the vibra-
tory contact transducer (Fig. 1), operating in accor-
dance with the following principle.
The sensor 3 is driven harmonically by the electro-
magnet 2, whose armature 1 is rigidly coupled with the
sensor. With the frequency of the current supplying the
electromagnet equal to 50 Hz, the sensor performs 100
oscillations per second. Along with the sensor, there
oscillates the armature 6 that is located between the
poles of the permanent magnet 4, which induces an
EMF in the winding of the induction coil 5, the core of
which surrounds the armature 6.
If the sensor is brought into contact with the surface
that is being machined, thereby limiting the range of its
oscillations, in the course of the change of the position
of this surface as a result of the removal of the machin-
ing allowance, the amplitude and range of the oscilla-
tions of the sensor will increase, which leads to increase
of the output current (or the EMF) that is recorded by
the readout instrument.
In the general case, the measurement process is sto-
chastic. For its study it is necessary to examine the
shaping of the signal in the transducer and describe it
mathematically. The vibratory contact transducer can
be represented as an ensemble of two units that are cou-
pled with one another. The first unit (the vibrator)
includes the driving electromagnet 2 and the sensor 3
(the oscillatory system); the second unit (the generator)
is an oscillatory system consisting of the permanent
magnet 4, the induction coil 5, and the armature 6.
Using Kirchhoff’s second law, after the appropriate
transformations, we can write the equation of the elec-
tromagnet circuit:
i e r = U 0 sin ( ωt ) – W e dΦ e /dt,
where ie is the current in the electromagnet winding; r
is the active electric resistance of the winding;
U0 sin(ωt) is the supply voltage with the amplitude U0
and the frequency ω; t is the variable time; We is the
number of the turns of the winding; Φe is the magnetic
flux in the given circuit; and dΦe/dt is its rate of change.
We write the differential equation of motion of the
oscillatory system with a single degree of freedom in
the form
I z ϕ̇˙ + hϕ̇ + kϕ = Q 1 + Q 2 + Q 3 , (2)
where Iz is the moment of inertia of the oscillatory sys-
tem relative to the Z axis of the XYZ coordinate system
(see Fig. 1); ϕ is the angle of its rotation relative to the
Z axis; h is the coefficient of resistance (decay of the
oscillations); k is the coefficient of bending elasticity
(stiffness); Q1 and Q2 are, respectively, the disturbing
moments that are determined by the action of the elec-
tromagnet and the permanent magnet; Q3 is the disturb-
ing moment that is due to the stochastic process arising
in the interaction of the oscillatory system with the part
that is being monitored, the variable dimension of
which in the machining process can be represented by
a definite relationship [2].
In the general case, the electromagnet armature
attraction force F = Φ2/(2µ0S), where Φ is the magnetic
flux; µ0 is the magnetic permeability of the air in the
gap; and S is the area of the gap. Then
Q 1 = l 1 Φ e / ( 2µ 0 S e ); Q 2 = l 2 Φ m / ( 2µ 0 S m ),
2 2
(3)
where l1 is the distance from the Z axis of rotation of the
armature 1 to the point of application of the force F1
that is developed by the electromagnet; l2 is the distance
from the Z axis of rotation of the generator armature 6
to the point of application of the force F2 that is devel-
oped by the permanent magnet; Φe and Φm are, respec-
tively, the magnetic fluxes of the electromagnet and the
permanent magnet; Se and Sm are, respectively, the areas
of the gaps between the armature and core of the elec-
6 Y Z
l2 l1
(1) F2 1
δ1
~ ir X
N S .
hϕ
~ U0 sin(ωt)
4 kϕ
5
3 F1 2
Fig. 1. Scheme of vibratory contact transducer.
296
 VIBRATORY CONTACT TRANSDUCER FOR THE METRIC MODULE 297

tromagnet and the generator armature and the end sur- δ3 1

face of the core. ΦM
2
ΦM

S
In the general case, the magnetic flux is a complex, S

nonlinear, and often ambiguous function of the current. Φ2M

However, with small values of the magnetic inductance
Φ1M

N
N
in the air gap (which is the case in the vibratory contact Φ1M δ'2
transducer), we can consider this function to be linear. Φ1M
δ2
Then Φe = Weie/Re, where Re is the overall resistance of 3
the electromagnet circuit. Substituting in this formula δ4
the value Re = (δ1 – l1ϕ)/(µ0Se) (where δ1 is the air gap
between the armature and the core of the electromag-

δ4
net; see Fig. 1), we find the law of the variation of the S
magnetic flux of the electromagnet:

δ'4
Φ e = µ 0 S e W e i e / ( δ 1 – l 1 ϕ ). (4) Φ1M Φ2M Φ1M

The expression for the magnetic flux of the perma- Fig. 2. Distribution of magnetic fluxes in generator with
nent magnet in the general form [3] Fm = Hlm/RΣ, where δ2 < δ '2 .
H is the coercive force of the magnet; lm is its length;
and RΣ is the overall resistance of the magnetic circuit.
We write the generator equation in the following
We shall examine the magnetic circuit of the trans- form [3 and 4]:
ducer (Fig. 2), consisting of the permanent magnet 1,
the air gap δ3 between the surface of the magnet and the dΦ 1m di
- = L -------g + i g r Σ ,
E = – W g ------------ (6)
generator armature 2, and the air gap δ2 between the dt dt
armature 2 and the end surface of the generator core 3.
We see that the flux Φm splits into two parts: the flux where E is the EMF; Wg is the number of the generator
Φ1m, traveling through the core 3 and the air gap δ4 winding turns (coil 5, see Fig. 1); L is the generator
winding inductance; ig is the current in the generator
between the end surface of the core and the surface of winding; rΣ is the overall electrical resistance, consist-
the magnet; and the flux Φ2m, traveling only through the ing of the resistance of the winding, the conductors, and
air gap δ 4' . the load.
We express the magnetic flux Φ1m in terms of the
It is evident that the magnetic circuit consists of
overall magnetic flux Φm by the following relation:
series and parallel segments, and its overall magnetic
resistance RΣ = Rm + Rm-a + Ra + Ra-t + R1R2/(R1 + R2), Φ1m = {R1R2/[(R1 + R2)R1]}Φm. If R1 = R2 = R, then
where Rm is the resistance of the permanent magnet; Φ1m = Φm/2. We can determine the winding inductance
Rm-a is the resistance of the air gap δ3; Ra is the resis- from the formula [4] L = µ0St-m W g /(2δ4). Substituting
2

tance of the generator armature; Ra-t is the variable the expressions for Φ1m and L in formula (6), we obtain
resistance of the air gap δ2, which depends on the
change of the angle ϕ and the value of δ2; R1 is the resis- W dΦ µ 0 S t-m W g di g
2
tance of the circuit of the magnetic flux Φ1m; and R2 is – -------g ----------m- = ---------------------
- ------- + r Σ i g . (7)
the resistance of the circuit of the magnetic flux Φ2m. 2 dt 2δ 4 dt

Considering that the magnetic resistances Rm-a and The correctness of the mathematical model (1) to (7)
Ra-t of the air gaps are far larger than the resistances Rm was verified by comparing the results that were
obtained in testing the actual instrument (Fig. 3a) with
and Ra of the steel elements, and taking the clearances the data that were obtained by solving the system of
δ4 = δ '4 , their areas St-m = S 't-m , and resistances R1 = R2 = R equations (1) to (7) (Fig. 3b).
to be the same, we can consider with an adequate These equations constitute a complex nonlinear sys-
degree of certainty that tem, which influences the form of the oscillations.
However, in view of their small influence on the output
Hl m signal, the signals are represented in Fig. 3 as harmonic;
Φ m = --------------------------------------- it is assumed that Q3 = 0. The results of the comparison
R m-a + R a-t + R/2
(5) make it possible to conclude that the mathematical
µ 0 Hl m model corresponds to the real instrument with regard to
= -------------------------------------------------------------------------------------
-,
δ 3 /S m-a + ( δ 2 – l 2 ϕ )/S a-t + δ 4 / ( 2S t-m ) the phase, frequency, and amplitude of the signal.
The foregoing equations describe the operation of
where Sm-a and Sa-t are the areas of the gaps δ3 and δ2. the vibratory contact transducer and the shaping of the

RUSSIAN ENGINEERING RESEARCH Vol. 27 No. 5 2007

298 TROMPET, KRASIL’NIKOV

(a) The proposed mathematical model makes it possible

to: (1) calculate the output parameters of the transducer
6V
0.8 mA
on the basis of the specified technological conditions
(for example, with respect to the magnitude of the
machining allowance); (2) identify the zones of stable
operation of the transducer; and (3) study the influence
of the stochastic process of the measurement of the
dimensions of the parts during their inspection in the
(b) machining process on the metrological indices of the
6V entire metric system.
0.85mA

Fig. 3. Signal shaping in the real instrument (a) and in the
mathematical model (b): solid line is the electromagnet sup-
ply voltage; dashed line is the transducer output signal;
dash–dot line is the rotation angle ϕ of the oscillatory sys-
tem.
signal that reaches the display. The control commands
that are directed to obtaining the exact dimension of the
part that is being machined are generated on the basis
of the magnitude of this signal.
REFERENCES
1. Trompet, G.M., Fedotov, V.A., and Aleksandrov, V.A.,
Factory Tests of a Metric Module on a Multipurpose
machine tool, Mashinostroitel’, 2005, no. 7, pp. 16–18.
2. Shachnev, Yu.A. and Alekseenko, V.V., Improving Sig-
nal Shaping Accuracy in the Coordinate Monitoring
Devices, Izvestiya vuzov. Mashinostroenie, 1976, no. 8,
pp. 19–22.
3. Gevondyan, T.A. and Kiselev, L.T., Pribory dlya izme-
reniya i registratsii koleblanii, Moscow, Mashgiz, 1962.
4. Kuvshinskii, V.V. and Trompet, G.M., Compensation
Circuit with Vibrogenerator Sensors for Improving
Dimensional Monitoring Accuracy, Izvestiya vuzov.
Mashinostroenie, 1983, no. 7, pp. 28–31.

RUSSIAN ENGINEERING RESEARCH Vol. 27 No. 5 2007