I think you're right, DRC1. You have to make your own peace with the tests you use, and have an idea of the real accuracy you can expect in order to use them responsibly-you said it well.
You know, I came across a paper written or sponsored by CME regarding what the efficiency is of their automatic hammers. They also compare the repeatability of the automatic hammer with the old manual safety hammer. The paper had interesting results in it, and it was worthwhile to read, but there were a few things that didn't add up to me. For example, the actual efficiency they measured for their automatic hammers with trip release approached 90-100% in some cases, if I remember right. Now while they were measuring the energy ratio delivered to the anvil rather than to the spoon, these values approaching 100% still didn't make sense to me. The paper also address repeatability of the results.
Using some common sense, first of all, the noise created by the pounding is energy lost. Anyone who knows what the test sounds like knows that you'll lose part of your hearing if you don't have protection, stand right by it, and do for years. To me, that's a lot of energy lost already in the noise created. Secondly, I think a lot of the vibration is lost in vibration-you can definitely feel the vibration created-there's a lot of it. That's energy lost too. Thirdly, there's lots of heat buildup-things get hot. Fourthly(?), field conditions probably have other variations that produce energy sinks too compared to the conditions during their research. On top of this, I know of very few mechanical systems that have an efficiency of 70% or above. Heck, most cars have a real efficiency of what, 30-40%? (My car is probably more in the 10% range with everything that's wrong with it)
After considering all these things, I used a raw efficiency of hammer to anvil of about 70% of the theoretical free fall energy, which is accepted by most for an auto hammer with trip release. That 70% was used as the basis in my estimates given above. Just some extra info. Let me know if you're interested in knowing the authors, date, etc. of that paper-I'll get that info to you if anyone's interested. Or if you contact CME, they were good enough to send me a copy for free. Like I said there are some interesting things in it...
Does anyone else have an opinion about the real efficiency of hammer to anvil? I'd be interested to hear.