Unlike load cells or force transducers, the measuring body of a torque transducer is not subjected to a tension load during operation, but is affected by the lever torque or torque, which can be changed. Therefore, torque sensors require special strain gauges to measure this type of load, i.e. torque. There are two typical configurations for torque transducers, which are shaft and flange.
Shaft Torque Transducer:
Shaft torque sensors consist of a measuring shaft, which may also be hollow. The strain gauge device is on the shaft, sometimes the device is on the tapered section in the middle, depending on the type, and 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 usually connected to the test structure or test bench by 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 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 closed 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. Because of the rotation, it is not possible to use the cables for power supply and data transmission, because the cables become entangled 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 strain measurement circuit of the device.
Electronic devices are measured in the 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 or also via a fieldbus digital output, such as EtherCAT or Profinet, depending on the use.
When measuring torque, the sensor does not always rotate. Typical use of non-rotating equipment is to standardize testing machines and mixer measurements. 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 use, the sensor is part of the rotary 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, only the number of pulses that need to pass is required to calculate the rotational speed.
Another important feature of interest to many users is power, which can be calculated by multiplying torque by 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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