Unlike load cells or force transducers, the measuring body of a torque transducer is not subjected to a tension 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. Typical torque transducer designs are available in two configurations, shaft and flange.
Shaft Torque Transducer:
Shaft torque sensors consist of a measuring shaft, which may also be hollow. The strain gauge is mounted on the shaft, sometimes on the tapered section in the middle, depending on the type in detail, the shaft is sealed by a housing. The shaft or rotor is capable of moving or rotating, while the housing or stator is fixed. These two parts are connected to each other by low-conflict, zero-clearance bearings. The sensor is generally connected to the test structure or test bench by means of 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 flange sits at both ends of the shaft. This allows the sensor to be threaded for integration into a structure or test bench. The measuring flange includes the rotor and stator. However, unlike the measuring shaft, the rotor is not completely enclosed in the housing. As a result, there is no need for a bearing assembly.
The non-touch measurement data transmission is a clear difference between torque sensors and other sensors. Due to rotation, it is not possible to use cables for power supply and data transmission, which wrap around each other when the rotor rolls. In order to avoid this, a non-touch connection is required to transmit signals or electrical energy from the stator to the rolling rotor to power the installed strain measurement circuit.
The electronic device is installed in the measuring body. The strain gauge bridge signal is amplified, filtered, and digitized before being wirelessly transmitted to the stator. The data can then be output via a frequency or voltage signal, as well as a fieldbus digital output, such as EtherCAT or Profinet, depending on the application.
When measuring torque, the sensor does not always rotate. Typical applications for non-rotating equipment are standard testing machines and mixers. In the latter, the sensor is supported by a motor housing, and the drive shaft passes through the central hole of the sensor.
In most applications, the sensor is part of the rotating drive train between the object to be measured and the dynamometer. For example, the object to be measured may be an internal combustion engine, a gearbox, or an electric motor.
In addition to torque, the torque sensor is also capable of recording other measuring variables. This is optional. The most important parameter is the rotational speed, which can be measured by passing through a translucent slotted disc on the rotor. When the sensor rolls, the beam is interrupted by a certain distance. When the time window is constant, the rotational speed can be calculated by simply passing the number of pulses.
Another important feature of interest to many users is power, which can be calculated by multiplying torque by rotational speed. In addition, many torque sensors have a built-in temperature sensor, which informs, for example, the operating temperature of our sensors or drive trains.
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