Like many other types of sensors, torque sensors are measured using strain gauge technology. The sensor is usually a metal elastomer with a strain gauge mounted on it. Strain gauges are firmly attached to the elastomer.
If an external load is applied to the sensor, the measuring body will deform and the resistance of the strain gauge will change accordingly. In this way, the magnitude of the load can be measured by the change in resistance. This applies not only to torque sensors, but also to load cells, force sensors, and other types of sensors. However, torque sensors have some peculiarities.
1. Typical design of torque sensor
Unlike load cells or force transducers, the measuring body of a torque transducer is not subjected to a tensile load when used, but is torsionally affected by lever torque or torque. Therefore, torque sensors require special strain gauges to measure this type of load, i.e. torque. Two typical torque transducer designs are shaft and flange.
Shaft Torque Transducer:
Shaft torque transducers consist of a measuring shaft, which may also be hollow. The strain gauge is mounted on the shaft, sometimes on a tapered section in the middle, depending on the model, and the shaft is sealed by a housing. The shaft or rotor can be moved or rotated, while the housing or stator is fixed. The two parts are connected to each other by low-friction, zero-clearance bearings. The sensor is generally connected to the test structure or test bench via hub couplings at both ends of the shaft. These couplings come in a variety of shapes and sizes.
Torque Flange:
The structure of the measuring flange is basically similar to the measuring shaft, but the appearance is completely different. They also consist of a hollow shaft, although this axis is very short. The flanges are located at both ends of the shaft. This enables the sensor to be integrated into the structure or test bench via a threaded connection. The measuring flange includes a rotor and a stator. However, unlike the measuring shaft, the rotor is not completely enclosed in the housing. Therefore, there is no need for a bearing assembly.
2. Non-contact measurement data transmission
This is also a significant difference between a rotating torque sensor and other sensors such as a force sensor or load cell, which cannot use cables for power supply and data transmission due to rotation, as the cables become entangled when the rotor rotates. To avoid this, a contactless connection is required to transmit signal or electrical energy from the stator to the rotating rotor to power the installed strain measurement circuit.
The electronics are installed in the measuring body. The strain bridge signal is amplified, filtered, and digitized before being transmitted wirelessly to the stator. Depending on the application, the data can then be output via a frequency or voltage signal or digitally via a fieldbus.
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