Willrich Precision

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Product Application
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AIR FLOW GAGING
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 Why Talk About Air Flow Gaging?
• Manufacturer’s of small holes
need a way to measure them
• Mahr Federal is a known leader in
air gaging, including exotic
applications
• Flow is a natural element of back-
pressure systems
• No air tooling required

1/19/2015 2
 Dimensional Air Gage Applications

• Requires two components

– Air Tooling
– Reflective Surface (Restriction)
• Master
• Part

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 Dimensional Air Gage Applications
What’s Happening with Flow and Pressure

+ +

Flow Pressure

0 Distance + 0 Distance +

Flow increases as the Pressure increases as the

distance between the nozzle distance between the
and restriction/gap increases nozzle and restriction
/gap decreases

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 Basic Difference in Flow Gaging

+ +
Air Tool

Pressure Flow

PART

0 Distance + 0 Orifice Size +

Pressure is created and Flow increases as the opening

increases as the distance of the nozzle/orifice increases
between the nozzle/orifice and to atmosphere (no restriction)
restriction decreases

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 Flow Gaging

What is flow gaging?

In basic terms, flow or flow rate is a measure of the amount of
air/gas or liquid that flows through a particular device per
some unit of time.

Units of measure are;

liters/minute
cm3/minute
milliliters/second (for very low flow rates)

1/19/2015 6
 Air Flow Gaging - Basic Math

Pressure Difference
Flow Rate
(volume/time)
p1 p2

Discharge
Coefficient Air Density A
Surface Area (kg/m3)
of Opening

• Air Density Factors :

•Temperature
•Humidity
•Altitude
•Specific Gas Constant(dry air)
• Discharge Coefficient : Based on shape of orifice (~0.61 for a flat plate orifice)

1/19/2015 7
 Basic Flow/Back Pressure System

p1 p2

• Most flow gages typical for large air volume flow

systems, like HVAC systems
• Less concern for dimension, more concern about
controlling volume displacement and air handling
• The lower the flow rate the more unstable it is
• For measurement use, normally low input pressure
used (~10psi)

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 Balanced Air System

pref

p1 p2

• Balanced air system allows more stability for low flow

rates and increase in input pressure used (~30 psi)
• Flow measures a dimensional maximum value only. It
cannot explore the surface or geometry.
• Flow requires some form of un-interrupted hole(s)
• For Flow, part replaces the air tool
• Higher operating pressure allows for increased flow
resulting in faster response

1/19/2015 9
 Air Flow Gaging – Application Elements

• Commonly qualified using 2 points, Pass/Fail

only (min/max master)
• Fixed input pressure/flow rate allows ability to
convert to dimensional value
• The lower the flow rate the slower the reading
response
• Finding defects/clogs in multiport components
is possible (surface area A)
• Magnification/Gain set to masters used
• The larger the range of hole sizes to measure
the more masters needed

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 Types of Components
Measurable by use of Flow

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

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 Types of Flow Components

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

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 Types of Flow Components

Valves

Needles Plunger

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors Barrel

Custom Small Hole Parts
Tip
Hub
Needle

1/19/2015 13
 Types of Flow Components

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

1/19/2015 14
 Types of Flow Components

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport and Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

1/19/2015 15
 Types of Flow Components

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

1/19/2015 16
 Types of Flow Components

Valves

Needles

Nozzles (Injection Molding, Compressor, etc.)

Multiport Miniature Parts

Simple Fixed Restrictors

Custom Small Hole Parts

1/19/2015 17
 Air Flow Measuring Systems
• STANDARD CATALOG AIR GAGE
• Column or bench amp with min/max mastering
• Some orifice sizes fit into standard product measuring range
• Other orifices require minor gage modification

• PC BASED AIR GAGE

• Uses air electronic modules direct to pc
• Configurable with multiple modules
• Ability to correct linearity over long ranges

1/19/2015 18
 Air Flow Gaging – Case Study I

• Column/Bench Air Gage

• Must match flow to the back-pressure
type system
• Custom master restrictor and bleed
combination may be needed
• Requires min and max masters
• The smaller the orifice size measured
the shorter the span of the masters is
needed
• Minimize air hose lengths as much as
possible
• Limited to measurement of one orifice
size*

1/19/2015 19
 Air Flow Gaging – Case Study II

• Air PC Gage System

• Able to measure multiple orifice
sizes
• Ability to correct linearity and
maintain accurate readings
throughout range
• Requires 3 master set minimum for
each air module used (calibration)
• Each module uses its own regulated
circuit

1/19/2015 20
 Air Flow Gage System
• Full PC Benchtop Gage System
• Integral Windows based touchscreen computer
• Air-to-electronic modules with usb connection
• Control solenoids interfaced via IO module and power
supply
• External fixture designed specific to part

1/19/2015 21
 Air Flow Gaging Application
System Specification:
• Part orifice sizes can range from 0.004in./0.1mm to
0.040in./1.0mm diameter

• Part tolerance spans from 0.003in./0.08mm to

0.027in./0.69mm
• The system is designed to measure maximum diameter of a
small thru-hole orifice.
• The flow rate (lpm) is calculated based on the fixed balance
system and measured diameter size.

1/19/2015 22
 Flow Gage Technical Setup
• QA/Engineering maintenance of remote part file

• Periodic calibration check with masters (master

gage when needed)
• Technician setup of machine#, mold#, and part#
to be run in production (operator need only enter
machine#)

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 Gage Operation
• Operator Selects a part to measure and is
prompted to enter a machine number or any
needed user information

1/19/2015 24
 Gage Operation
• Gage retrieves all part information from remote
file and enters data collection mode

1/19/2015 25
 Gage Operation
• No Mastering required by the operator
• Part placed firmly in gage fixture and data is
collected (manual or automatic)
• Timers control gage idle time and allowed lot
measurement time
• No external sensor needed
• At lot completion, exit back to main screen

1/19/2015 26
 Air Flow Gage Principle
• Orifice diameter sizes from 0.004 to 0.039 inch in
0.001±0.0001 inch increments (36 masters)
• Targeted accuracy 0.0001 inch and Repeat
0.00004 inch
• Only 3 Masters needed for gage operation /
checks
• Each valve component has hundreds of part
numbers
• Automatic data collection without a part present
sensor
• Built-in auto-scaling between multiple modules

1/19/2015 27
 Air Flow Gaging

• “The” system to measure small hole sizes

1/19/2015 28
 Air Flow Gaging

What is important to remember about

Air Flow Gaging?
• Simple 2-point measurement (pass/fail)
• Flow is non-dimensional – meaning it can
measure max size only, not geometry or
shape
• Air Gaging offers an easy solution – don’t
over think it

1/19/2015 29