9. Challenges Associated with In Situ Calibration of Load Cells in Force-Limited Vibration Testing

The difference in mounting configuration between flight and test can significantly impact the effectiveness of the test in environmental vibration testing. Many tests are performed with large electrodynamic shakers, which utilize interfaces that seek to replicate a fixed base, such as slip tables and head expanders. This fixed base configuration is rarely seen in flight configurations; rather a more realistic configuration would include a flexible mounting structure with its own compliance and dynamics. This causes significant over- and under-tests in various frequency bands depending on the differences between the test article and fixture dynamics.

The traditional way of avoiding these high loads is to limit the acceleration responses at multiple locations on the test article. However, the effectiveness of this approach is highly dependent upon the validity of the test article’s analytical in order to derive accurate acceleration response limit specifications. Also, this technique requires limiting the acceleration responses at many locations throughout the test article, which may not be implementable due to such things as access issues and cleanliness issues. An improved environmental vibration testing technique known as force limiting incorporates measurements of the forces between the test article and shaker system interface and limiting them to a specification that more accurately replicates the interface impedance of the structure the test article will be mounted to in flight. In effect, this transforms the high mechanical impedance at the test article to shaker interface to more closely match the mechanical impedance of the flight interface, which avoids producing the unrealistically high interface loads.

Typically, force gauges or load cells are used to measure these interface forces. However, utilizing load cells can present a multitude of challenges depending upon such things as their installation method, geometric layout, and test fixture setup. Regardless, it is important to perform an in situ calibration of the load cells prior to vibration testing at any significant levels. This chapter will discuss the challenges associated with utilizing load cells during the NASA Evolutionary Xenon Thruster – Commercial (NEXT-C) gridded ion thruster proto-flight vibration test performed at the NASA Glenn Research Center’s Structural Dynamics Laboratory.