Torque sensor system

APPLICATION NOTE
Research
2 Torque Sensor System Application Note
Disclaimer
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to the contents hereof and specifically disclaims any implied warranties of merchantability
or fitness for any particular purpose. Pi Research shall not be liable for any errors
contained herein or for incidental or consequential damages in connection with the
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material.
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changes in the content hereof without obligation to notify any person of such revision or
changes.
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includes a declaration of the warranty and limitation of liability which apply to all
Pi Research products and services.
Health and Safety information
Under the terms of European and UK Health and Safety Legislation, Pi Research is
required to classify any hazardous materials in the product it supplies and to provide
relevant safety information to users.
Any hazardous materials in Pi products are clearly marked with appropriate symbols.
Product Safety Data Sheets relating to these materials are available on request.
3
Contents
Safety information ................................................................................... 5
Transmitter unit battery safety........................................................ 5
Disposal of used batteries .............................................................. 6
About this document ............................................................................... 7
Introduction .............................................................................................. 8
System requirements .............................................................................. 9
Installation .............................................................................................. 10
Drive shaft preparation ................................................................. 10
Fitting strain gauges ..................................................................... 11
Fitting a torque sensor transmitter ............................................... 14
Fitting a torque sensor transmitter battery ................................... 15
Fitting a torque sensor receiver .................................................... 16
Setup and test ........................................................................................ 17
Torque sensor transmitter checks ................................................ 17
Torque sensor receiver checks .................................................... 18
Torque sensor monitor software ......................................................... 19
Starting the torque sensor monitor software ................................ 20
Communications port .................................................................... 21
Baud rate ...................................................................................... 21
Team code .................................................................................... 22
Graph scale .................................................................................. 23
Start and stop monitoring of the sensor ....................................... 24
Toolbar button .............................................................................. 25
4 Torque Sensor System Application Note
System test and calibration .................................................................. 26
System test ................................................................................... 26
Possible failures ........................................................................... 28
Calibration..................................................................................... 31
Version 6 Setup channel calibration ............................................ 32
Zeroing and aging of sensors ....................................................... 35
Logging issues .............................................................................. 36
Interpreting torque data ........................................................................ 37
Hop/waddle mode......................................................................... 37
Start and steering ......................................................................... 38
Gear change ................................................................................. 39
Off load zero estimation ............................................................... 40
Torque difference/sum ................................................................. 41
Frequency response ..................................................................... 42
Alternative method to plot frequency response ........................... 43
Specifications......................................................................................... 44
Torque sensor transmitter ............................................................ 44
Torque sensor transmitter battery ................................................ 45
Strain gauge ................................................................................. 45
Torque sensor receiver ................................................................ 45
Connectors ................................................................................... 46
Dimensions ............................................................................................. 48
Torque sensor transmitter ............................................................ 48
Torque sensor receiver ................................................................ 49
Parts numbering .................................................................................... 50
Kits ................................................................................................ 50
Contact information............................................................................... 52
5
Safety information
Transmitter unit battery
safety
For full safety information on the batteries read the Product Safety Data Sheet LST 01
Lithium /Thionyl Chloride Cells. A copy of this Product Safety Data Sheet is available
on request from Pi Research.
The battery in the transmitter unit contains a number of chemicals and materials, which
could potentially be hazardous if they leak from the battery.
If a battery exceeds 150C it may leak electrolyte. If a battery is leaking electrolyte take
the actions detailed below.
Accidental Release Measures
I Do not breath vapours.
I Do not touch the liquid with bare hands. Use rubber gloves.
I If the skin has come into contact with the electrolyte it should be washed
thoroughly with water.
I Graphite powder should be used to absorb the exudation.
I Seal the leaking battery and graphite powder in plastic bag and dispose of
as Special Waste according to local regulations.
First Aid Measures
Inhalation
Remove from exposure, rest and keep warm. In severe cases obtain medical attention.
Skin Contact
Wash off skin thoroughly with water. Remove contaminated clothing and wash before
reuse. In severe cases obtain medical attention.
6 Torque Sensor System Application Note
Eye Contact
Irrigate thoroughly with water for at least 15 minutes. Obtain medical attention.
Ingestion
Wash out mouth thoroughly with water and give plenty of water to drink. Obtain medical
attention.
Further Treatment
All cases of eye contamination, persistent skin irritation and casualties who have
swallowed the electrolyte substance or have been affected by breathing its vapours should
be seen by a Doctor.
Disposal of used
batteries
Do not incinerate used batteries. Such abuse can result in loss of seal, leakage, and/or
explosion of the battery.
Dispose of used batteries in accordance with appropriate local regulations.
7
About this document
This document covers the installation and use of the Pi Propshaft torque sensor system.
Some procedures in the document require prior knowledge of Pi PC Software, especially
in the use of graphs, math channels and naming channels. Refer to your PC Software
Guide for more information.
To help you interpret torque data, sample graphs are shown in a section entitled
Interpreting torque data.
8 Torque Sensor System Application Note
Introduction
The Pi Torque sensor system uses a Torque sensor transmitter in conjunction with strain
gauges and a Torque sensor receiver, to measure the torque being applied to a drive shaft.
Strain gauges are fitted to a drive shaft and are connected to a torque sensor transmitter
which is also fitted on the drive shaft. The torque sensor transmitter converts the output
from the strain gauges into a data stream which is then transmitted to a receiver located
on the car close to the transmitter unit.
The analogue output from the Torque sensor receiver is connected to an analogue
channel of a Pi data logger. The logged data can be then be analysed using
Pi PC Software.
The strain gauges should be fitted onto the drive shaft by Pi Research. The Torque sensor
transmitter units and Torque sensor receiver units can be fitted by your engineers or by
Pi Research.
Torque sensor transmitter units can be manufactured to fit drive shafts with diameters
between 25mm and 30mm. Torque sensor transmitter units can be manufactured to other
sizes on request.
To allow Torque sensor transmitters to be used on both drive shafts simultaneously,
different transmit frequencies are available.
Always consult Pi Research for recommended gauge installations.
9
System requirements
To use the Pi Torque sensor system you need a Pi Research Data Logging System.
Whilst the Propshaft torque sensor system does not require specific system boxcode or
PC Software releases, you should consult with Pi Research to ensure that your system
boxcode and PC software are compatible with the Propshaft torque sensor system.
10 Torque Sensor System Application Note
Installation
This section gives information on installing the Torque sensor system.
Drive shaft preparation
It is imperative that the torque sensor transmitter is a precise fit onto the drive shaft.
The loads imposed on the torque sensor transmitter unit are large, and the worst effect
occurs when the drive shaft is under full power at a speed where there is insufficient
traction to stop the wheel from spinning.
Under these circumstances, the drive shaft twists under the imposed loading, and then
when the wheel becomes free, the only restraining effect is the inertia of the wheel,
bearing and brake assembly. This allows between 100g and 200g of rotational shock to
be experienced by the torque sensor transmitter unit. The effect of this is to try and spin
the drive shaft inside the clamping area of the torque sensor transmitter unit. Following on
from this, when the recoil of the drive shaft stops, the torque sensor transmitter unit tries
to continue rotating around the drive shaft, attempting to free itself from the drive shaft.
The contact area on the drive shaft is much smaller than the bored section of the torque
sensor transmitter unit, and most of this is only providing a stabilising effect. The clamping
force is provided on a small ring about 2mm to 3mm wide directly in line with the clamp
bolts. It is imperative that the surface of the contact area of the torque sensor transmitter
unit after boring is smooth and flat, without being polished. This gives the best contact
between the drive shaft and the torque sensor transmitter unit which enables the rotational
shock loads to accelerate the whole sensor in sympathy with the drive shaft.
If this does not happen, the torque sensor transmitter unit rotates and rips the wires from
the strain gauge anchor points.
In summary, the drive shaft must be:
I smooth, with no ripples or no high spots;
I perfectly cylindrical;
I unpolished and clean.
11
Fitting strain gauges
When fitting strain gauges to drive shafts:
I choose a position on the drive shaft so that the strain gauges are not in
areas of high temperature or will be subjected to heat soak. It is advisable
to stick temperature sensitive labels at 50mm (2") intervals along the drive
shafts to obtain their thermal profile before fixing the gauge and torque
sensor transmitter unit locations;
I use high extension strain gauges. Refer to Pi Research for specifications;
I surface preparation is vital and the area where the strain gauge will be
fitted on the drive shaft should be etched to provide a good surface for the
strain gauge to adhere to;
I use only silicone rubber as the sealing material;
I do not use teflon tape, use only a tape that bonds to silicone rubber;
I use 26AWG wire to Raychem 55 specification to connect the strain gauges
to the torque sensor transmitter unit;
I keep the wires between the strain gauge and the torque sensor transmitter
unit as short as possible and use a fabric type tape to secure them to the
shaft;
I crimp the wires from the strain gauge to the torque sensor transmitter unit
connector. DO NOT use solder.
Typically the drive shafts will twist considerably, hence the strain gauges will need to be
bonded to the drive shafts with a flexible adhesive.
The connecting wires and temperature compensation wires will also need to be mounted
such that they can move with the twisting of the drive shaft but are not free to vibrate and
fracture.
12 Torque Sensor System Application Note
Fitting and connecting strain gauges
The torque sensor transmitter unit and strain gauges should be fitted to a drive shaft
before the drive shaft is fitted to a vehicle.
1 Clean the drive shaft at the etched areas where the strain gauges are to be
fitted.
2 Fit two strain gauges on to each drive shaft so that they will measure torque.
The two strain gauges on each drive shaft must be fitted along the long axis of the drive
shaft, diagonally opposite each other.
3 Seal the strain gauges to the drive shaft using silicone rubber.
4 Loosely fit the torque sensor transmitter unit onto the drive shaft at the
position chosen. (Refer to the steps 1 and 2 in the section To fit a transmitter
unit below.)
5 Remove the lid from the torque sensor transmitter unit and measure the
lengths of wire required to connect the strain gauges to the torque sensor
transmitter unit.
The wires should reach to the end of the friction clamp on the torque sensor transmitter
unit.
6 Cut the wires to length.
7 Strip off 2.5mm insulation from each wire, fold the wire back and place it in
the socket contact part with conductors innermost.
For the HE14 connector details, refer to the Connectors section of the Specifications
section of this document. Location of the mating connector at the torque sensor transmitter
unit is shown in the next figure.
8 Using the size 2 position on the crimping tool, crimp the socket contact to form
the metal and then finish with the size 1 position on the crimping tool.
9 Crimp the wire clamp part of the contact using the size 2 position on the
crimping tool to form the metal and then finish with the size 1 position on the
crimping tool.
Note: Dont forget to connect the torque sensor transmitter battery lead to the HE14
connector.
10 Tape the wires to the shaft so that they will not move when the shaft is
rotating.
13
11 Mate the HE14 connector to the transmitter unit.
This completes the fitting of the strain gauges. To continue the installation, refer to the
To fit a transmitter unit instructions in the next section.
Strain gauge and
power connector
pin 1
pin 5
Location of torque sensor transmitter strain gauge and power connector
14 Torque Sensor System Application Note
Fitting a torque sensor
transmitter
When fitting a torque sensor transmitter on a drive shaft:
I choose a position near to the centre the drive shaft where the torque
sensor transmitter is not in an area of high temperature or will be subjected
to heat soak. Temperatures in excess of 60C (140F) can reduce battery
life. At 80C (176F) the battery life is half that at 50C (122F);
I ensure that the torque sensor transmitter is the correct size for the drive
shaft diameter;
I fit the red coloured transmitter to the left hand drive shaft and the green
coloured transmitter to the right hand drive shaft (left and right hand when
standing at the rear of the car looking forward);
I ensure that the torque sensor transmitter unit will not come into contact
with parts of the car under extreme movement, for example, parts of the
suspension.
To fit a torque sensor transmitter unit:
1 Clean the drive shaft and inside mounting faces of the torque sensor
transmitter unit with brake cleaner.
2 Place the two halves of the torque sensor transmitter unit around the drive
shaft and fit the bolts so that you can see only one bolt head and one nut at a
time. This ensures that they do not upset the balance of the drive shafts.
3 Adjust the position of the torque sensor transmitter unit so that the gauge
wires are held in the clamping area of the torque sensor transmitter unit lid.
Make allowances for taping required to hold the wires to the drive shaft. The
gauge wires should not be tight or have room to wobble about.
4 Tighten the nuts evenly, and finally torque each nut to 8 Nm (6lbf/ft)
(70lbf/in).
5 Fit the lid on the torque sensor transmitter unit.
6 Fit the torque sensor transmitter unit battery (see next page).
15
Fitting a torque sensor
transmitter battery
The torque sensor transmitter battery is a 3.6V Lithium Thionyl Chloride cell. The only cell
certified for use is the SAFT LS14250.
WARNING: Do not allow batteries go above 150C as they may vent. If venting
does occur, handle the batteries using gloves, and wash your hands after
touching a venting battery. Graphite powder should be used to absorb the
exudation. Seal the leaking battery and graphite powder in plastic bag and
dispose of as Special Waste according to local regulations. For full handling
instructions read the Product Safety Data Sheet which is available on request
from Pi Research.
When fitting a battery:
1 Remove any plastic and paper labelling from the battery to reveal metal
casing.
2 Clean the battery metal casing with brake cleaning fluid.
3 Insert the battery with the positive connection towards the metal bolt in the
battery compartment.
4 Tighten the closing screw with a small coin. Do not use a screwdriver as you
might apply too much force and distort the battery compartment.
5 Use a fabric tape to seal the cover against dust and water.
6 Fit locking wire through the holes on both sides of the battery case. This will
prevent the battery from being thrown out if the battery compartment cover
becomes loose.
16 Torque Sensor System Application Note
Fitting a torque sensor
receiver
Fitting the torque sensor receiver
When fitting the torque sensor receiver:
I choose a position where the torque sensor receiver is not in an area of high
temperature or will be subjected to heat soak. The temperature must not
exceed 80C (176F);
I the receiver should not be mounted near to a source of electrical
interference e.g. inside any bodywork near the engine. (The rear crash
structure is an ideal site on F1 cars.);
I fit the torque sensor receiver with the red coloured base to the left hand
side of the car and the torque sensor receiver with the green coloured base
to the right hand side of the car, when viewed from the rear of the car
looking forward;
I line of sight operation between the correct torque sensor transmitter unit
and the torque sensor receiver is required;
I the siting should be such that one torque sensor receiver is screened as
much as possible from the other torque sensor receiver;
I looms must be screened and must be run separately as far as is possible;
I looms must not have any loops at the torque sensor receiver;
I use anti vibration mounts;
I do not run other cables or looms, or place objects made from carbon fibre,
close to the plastic cover of the receiver unit.
17
Setup and test
It is important that you take time to check over the Torque sensor system before running
to ensure that you get the best information possible from it.
Torque sensor
transmitter checks
1 Remove the lid of the torque sensor transmitter unit and check the gasket
seals. Replace any that are worn.
2 Check that the wires from the strain gauges are not nicked or chafed and that
the wires into the connector are OK.
If a repair is needed then consider extending the wires and moving the transmitter a little
further down the shaft. Secure the wires to the shaft with a fabric reinforced tape, not tie
wraps. Tie wraps may damage to the wires.
3 Check that the connectors have not had any dust ingress.
4 Use a contact cleaner such as Servisol contact cleaner to blow any dust from
the internals.
5 Carefully check the wires to the strain gauge and make sure that they are not
crossing each other in the area of the rubber gasket seal. Refit the lid.
6 Remove the battery from the battery compartment and clean the battery with
brake cleaner.
7 Check the transmitter battery terminal connection has not become loose.
If it is a new battery, remove the labels and clean the battery with brake cleaner.
8 Fit the battery into the battery compartment and fit the cover. Use a fabric tape
to seal the cover against dust and water.
9 Check that the battery voltage is greater than 3.2V when powering the sensor.
Fit a new battery if the voltage is below 3.2V.
10 Fit locking wire through the holes on both sides of the battery compartment.
This will prevent the battery from being thrown out if the battery compartment
cover becomes loose.
18 Torque Sensor System Application Note
Torque sensor receiver
checks
1 Clean the torque sensor receiver unit using Servisol contact cleaner.
2 Ensure that the torque sensor receiver unit is securely fixed to the vehicle.
3 Check that the loom is secure and does not interfere with any other fittings on
the vehicle.
4 Apply power to the torque sensor receiver unit. The illumination of the LEDs
indicates the following:
LED colour Indicates
Red Torque value is stable.
Yellow Data is being received. The LED is dimmed or flashing when noise is
received.
Green Data with the correct codes has been decoded and output. Cancels
after 10ms if no valid data packet has been received.
Red
LED
Yellow
LED
Green
LED
Torque sensor receiver LED indicators
Note: The torque sensor transmitter sleeps to conserve power. This shows as a pulsing
of the yellow and green LEDs on the torque sensor receiver. The European
specification unit sleeps for approximately 1.5 seconds, the USA specification for 10
seconds (FCC regulations). If the transmitter notices that significant activity is
occurring, then data will be transmitted and the red LED will extinguish to signify this.
19
Torque sensor monitor software
The Torque sensor monitor software is a stand alone program which you use to check the
readings being sent by a torque sensor transmitter to a torque sensor receiver. This
enables offset and calibration values to be obtained away from the full logger system.
The Torque sensor monitor software is a 32-bit program and will function correctly using
Windows 98. Windows NT is not supported.
The Torque sensor monitor software operates using the debug loom provided. The debug
loom connects a torque sensor receiver to a COM port on a PC. The debug loom also has
terminals to connect to a 12V power supply, and terminal sockets which provide a ground
and an analogue output signal for measurement using a meter.
The Torque sensor monitor software, a help file and a team code file are supplied on a
floppy disk.
To install the torque sensor monitor software on your computer:
1 Create a suitably named folder on your hard disk.
2 Insert the floppy disk containing the torque monitor software into the floppy
disk drive. Copy the entire contents of the floppy disk into the new folder.
3 Create a shortcut on the desktop to the file tork32.exe in the folder you
created in step 1 above.
A Pi Torque icon is created on the desktop.
Refer to the documentation that came with your computer for details on how to create a
shortcut.
20 Torque Sensor System Application Note
Starting the torque
sensor monitor
software
To start the torque monitor software:
1 Locate and double click on the Pi Torque icon on the desktop. The Torque
Sensor Monitor window appears.
Torque Sensor Monitor window
21
Communications port
You can choose either COM1 or COM2 as the communications port. This option may only
be changed when the program is not monitoring a torque sensor.
To select a communications port:
1 Choose "Port" from the main menu. A drop down menu appears.
The current selection is shown dimmed and checked. The alternative port is shown in
normal text.
2 You can accept the current setting by selecting "Port" again, or you can click
on the alternative value to choose it.
The selection must correspond to the port on your computer to which the torque sensor
receiver debug loom is connected. The default value is COM1.
Baud rate
You can choose 9600 baud or 19200 baud for the data rate for the selected COM port.
This option may only be changed when the program is not monitoring a torque sensor.
To select a baud rate:
1 Choose "Baud Rate" from the main menu. A drop down menu appears.
The current selection is shown dimmed and checked. The alternative value to which the
baud rate may be set is shown in normal text.
2 You can accept the current setting by choosing "Baud Rate" again, or you can
click on the alternative value to choose it.
The selection must correspond to the baud rate set on the torque sensor system. The
default value is 9600.
You will be advised if your torque sensor system runs at the 19200 baud rate.
22 Torque Sensor System Application Note
Team code
You can choose the team code number for the torque sensor in use. You will be advised
of the team codes for your sensors when they are despatched to you. This option may only
be changed when the program is not monitoring a torque sensor.
To select a Team code:
1 Choose Team from the main menu. The Select code button appears.
2 Click on the button. The Select Team Code dialog appears.
3 Choose the appropriate code from the list.
If the code chosen from the list does not match the code for the torque sensor system
connected to the PC no data will be displayed during monitoring and monitoring will stop
automatically after a short period.
If you purchase additional torque sensors you can join the new team code file and the
current team code files together.
To join team code files
1 Insert the floppy disk containing the new team code definition file into the
floppy disk drive of your computer.
2 Start an MS-DOS session.
Refer to the documentation that came with your computer for information on starting a
DOS session.
3 Make sure that you are in the Torque sensor folder.
4 Type copy /B torque.def torque.def+A:torque.def and press
the (Enter) key.
The details from the torque.def file on the floppy disk will be appended to the
torque.def file on the hard disk.
23
Graph scale
The graph scale determines the span of the graphical display from fine (a range of +50 to
50) to coarse (a range of +5000 to 5000). The scale may be changed while monitoring
is in progress, in which case the graph will be cleared and the graph will start again from
the left hand side.
To change the graph scale:
1 Choose Scale from the main menu. A drop down menu appears.
The current selection is shown dimmed and checked. The alternative value is shown in
normal text.
2 You can accept the current value by choosing Scale again, or you can click
on the alternative value to choose it.
If the graph scale is set to fine and the graph has been filled completely, the monitor
program will automatically recalculate the graph axes to offset the graphical display about
the last reading. For example if the last measured value was 5, the new graph range will
be from +55 to 45.
24 Torque Sensor System Application Note
Start and stop
monitoring of the
sensor
The torque sensor receiver unit contains a receiver module and a signal processing
module.
The torque sensor monitor software works by accepting 50 readings at a time from the
receiver module. This is the raw data before it is processed by the decode and analogue
circuitry in the signal processing module prior to being sent to the logger.
The torque sensor monitor software displays certain values in a window on the PC. These
values are shown in the next table.
Torque monitor window Remarks
Current The last value of the 50 readings.
Maximum The maximum value of the 50 readings.
Minimum The minimum value of the 50 readings.
Filtered This is the value that the signal processing module would
use to generate an analogue output signal.
Average The mean value of the 50 readings. This value is used
to plot a point on a graph.
The range of the torque raw value is 4096 to +4095 counts. At zero torque the value
should be inside the range +50 to 50 counts.
Note: The transmission range of the torque sensor system is short (10m) and requires
line of sight between the torque sensor transmitter unit and the torque sensor receiver
unit. Torque sensor receivers will therefore not decode correctly data from torque
sensor transmitters which are screened by walls or other obstructions, or from cars
which are out on the track.
25
Toolbar button
The button on the toolbar indicates the monitoring status. When the button is green the
system is not monitoring, and when it is red the system is monitoring. If no sensor is
detected from starting monitoring of the sensor, monitoring will automatically stop. If a
sensor is connected after monitoring has started, the sensor will not be detected. Stop and
restart the monitoring to ensure the sensor is detected.
To start monitoring:
1 Choose Start from the Monitor menu, or press the green button on the
toolbar.
Torque Sensor Monitor window when monitoring is in progress
To stop monitoring:
1 Choose Stop from the Monitor menu, or press the red button on the toolbar.
26 Torque Sensor System Application Note
System test and calibration
This section gives details on testing and calibrating the torque sensor system after
installation. Although parts of this section refer to Pi Version 6 PC software, if you are using
different Pi PC software for setting up channels and analysing data, you should refer to
the relevant manuals for information.
To perform a system test you need the following items:
I a torque sensor receiver debug loom;
I a PC with the torque sensor monitor software installed;
I a 12V power supply.
System test
To perform a system test:
1 Disconnect the torque sensor receiver being tested from the logging loom.
Connect the torque sensor receiver debug loom to the torque sensor receiver.
2 Connect the torque sensor receiver debug loom to the selected COM port on
the PC.
3 Connect the torque sensor receiver debug loom to the 12V power supply. The
red plug is for +ve and black plug is for ve.
4 On the PC run the torque sensor monitor software and start monitoring.
Check the current value on the PC display.
This should be within 50 counts from zero.
5 Twist the drive shaft. Hold the drive shaft in this position until the torque
sensor receiver acquires new data from the torque sensor transmitter
(2 seconds for European specification systems and 10 seconds for USA
specification systems).
27
You can use your hands to twist the drive shaft or you can turn the wheel on the end of
the drive shaft. The engine end of the drive shaft must be turned in its normal direction.
The wheel end of the drive shaft must be turned backwards.
The current value on the PC display should change by a few counts.
6 Twist the drive shaft in the opposite direction.
The value on the PC display should change by a similar amount in the opposite direction.
The sign of the calibration value used depends on the sense that the strain gauges have
been wired and the side that the drive shaft is being used on. It is normal for one side to
have a positive sign and the other side to have a negative sign.
7 Disconnect the torque sensor receiver debug loom from the torque sensor
receiver. Connect torque sensor receiver to the logging loom.
8 Repeat the above test, using Watch Channels in raw mode in Version 6 Setup.
For information on watching channels refer to your PC Software Guide.
It is normal to get more sensitive results from the torque sensor monitor software as the
values from the torque sensor system are transmitted as a 13-bit number and have not
been measured at 12-bit resolution in a logger.
28 Torque Sensor System Application Note
Possible failures
Intermittent RF Failure
Intermittent RF failure usually exhibits a stepped response, with flat lining at a non zero
value being the extreme case. This flat lining can also be caused by a flat battery in the
torque sensor transmitter, although it will normally be preceded by a gradual shift in the
zero point and ultimately flat lining near the zero point. It will also exhibit flat lining if the
battery restraint is inadequate and the battery is thrown from the battery compartment.
The graph below shows the effects of RF failure. The output signal from the torque sensor
receiver freezes at some value for a period of time, from a very short interval (and
therefore difficult to spot) to a much longer interval. The reason for this is that the receiver
gets no updated messages, so holds the last value received.
The main difference between RF failure and gauge failure is that the error values are not
repeated (as in gauge failure) but are essentially random, and are usually in the range
normally seen by the sensor.
transmitting correctly
transmitter failed
Example of RF failure
29
Gauge failure
Gauge failure also exhibits flat lining but usually at a maximum, minimum or zero reading.
This may not be exactly zero as it will be offset by the original error in the gauge zero point,
but this is normally small (50 counts).
The graph below shows the output of a system when a wire fatigue failure occurred on the
strain gauge. The output is sometimes present but keeps returning to zero counts (raw)
which is its most negative value.
Gauge failure
30 Torque Sensor System Application Note
Power up
On power up, the torque sensor transmitter unit sends a series of synthesized sine signals.
The sine signal frequencies are at 16.96Hz, 1.06Hz, 2.12Hz, 4.28Hz, 8.48Hz and finally
16.96Hz again. The reception of these sine signals during normal use indicates that the
sensor has detected some disturbance in its power. This could be either from a loose
battery connection, or intermittent contact in the connection plug, or intermittent shorting
due to chafed wiring.
31
Calibration
Care should be used when calibrating the drive shafts. Two similar drive shafts can match
each other quite closely, with typically less than 5% difference between them. To get
quantitative readings, calibration should be performed over as wide an operating range as
possible, without damaging the drive shafts.
The output from the torque sensor system is very linear, so multi-point calibration is not
required. (Track noise exceeds any error introduced by non-linearity).
The calibration range should cover, if possible, just on load e.g. 5%, to full load in top gear.
Remember to share the expected torque values between the two drive shafts. This should
encompass about 10% to 20% of the total range of the sensor (half of the range being
negative).
The value entered into the logging is a measurement of the torque required to generate
a 1 count change at 12-bit resolution or 10-bit resolution in the logged reading. This
resolution is governed by the logger.
If the torque sensor monitor software is used to calibrate the shaft, then the resolution of
the logger must be taken into account by multiplying the value of torque per count from
the torque sensor receiver output at 13-bit resolution, by two for a 12-bit resolution logging
system, and by eight for a 10-bit resolution logging system. Beware of rounding errors.
Always calculate directly from the original numbers.
Examples of recorded data and calibrations for different system resolutions are given in
the following section, Version 6 Setup channel calibration in this document.
32 Torque Sensor System Application Note
Version 6 Setup channel
calibration
You will need to calibrate a channel using Version 6 Setup. Details on calibrating a channel
are given in the Setup section of Version 6 PC Software Guide. You use an ax+b calibration
type for the channel.
Example data and calibration information for different logger resolutions are given below.
Example recorded data
Nominal Actual load Readings in Torque Monitor software
5% load 44Nm +68
100% load 880Nm +1360
13 bits =
(880 44)
1360 68
=
836
1292
= 0.64706 Nm per count
Calibration for 13-bit resolution
12 bits = =
1.29412 Nm per count
(880 44) x 2
1360 68
1672
1292
=
Calibration for 12-bit resolution
10 bits = =
5.17647 Nm per count =
6688
1292
(880 44) x 8
1360 68
Calibration for 10-bit resolution
To ensure best accuracy in the final measured values do not round numbers at
intermediate stages of the calculation e.g. do not round 0.64706Nm per count to
33
0.65 Nm per count because this would give a 10-bit value of 5.2Nm per count and an error
of +0.45%.
No-load (0%) readings from the torque sensor monitor software may not be exactly zero.
This is due to small imbalances of the strain gauge resistor bridge caused by movement
of the metal of the drive shaft and any residual errors of the sensor or bridge attachment.
This error should be within 25 counts.
You will need to set the maximum and minimum calibrated channel values in Version 6
Setup. Refer to the Changing channel parameters section of the Version 6 PC Software
Guide for full details on changing the channel parameters.
To set the maximum and minimum values:
1 Choose Change Channel Parameters ... from the Calibrate menu. The
Channel Parameter Editor dialog appears.
2 In the Units box enter Nm.
3 Set the Precision value to 3.
4 Set the Max value to 6000, and the Min. value to 6000.
5 Choose OK.
You must now enter the calibration values. You will need to enter a value for a Y co-ordinate
and an X co-ordinate for two points.
34 Torque Sensor System Application Note
To enter calibration values:
1 Select the Ins button. The Co-ordinate entry dialog appears.
2 Enter the Y value and then the X value for the two points.
3 From the Calibrate menu choose Calibration Type, and then check the ax+b
option.
Enter the values you have calculated from your recorded data. The values in the table
below are examples only and your own data will give different values.
Points for ax+b calibration in Version 6 Setup
Co-ordinate entry 12-bit 10-bit Value
Y co-ordinate 1 0 0 Nm
X co-ordinate 1 2048 512 counts
Y co-ordinate 2 1294.12 517.647 Nm
X co-ordinate 2 3048 612 counts
Note: In the above table the Y co-ordinate 2 value is scaled to allow a sensible number
of counts difference to be used between the X co-ordinate 1 and 2 values.
35
Zeroing and aging of
sensors
Zeroing of the sensors on the car should be done at the beginning of the day, and if it is a
new drive shaft, at other reasonable intervals for about the first 20 laps. After this period
the drive shafts and strain gauges settle down to a consistent zero point. If it is noted that
this zero is beginning to move again, be prepared to change the shaft as it is almost
certain that the strain gauges will fail totally soon. (The only other reason for the zero to
move is that the torque sensor transmitter battery is going flat.)
A zero can be checked for a moving car by plotting left torque against right torque and
viewing the data for 100Nm for each axis. What will probably appear is a crossing point
for the drive shafts when an upshift gear change occurs, but only when the car is going
straight. This is illustrated in the Offload zero graph in the Interpreting torque data section
of this application note.
Recalibration of a new shaft after the first test day should be considered as the settling
down period may have slightly changed the calibration.
Shafts which operate in excess of their elastic limit will continue to show progressive creep
of the zero position.
36 Torque Sensor System Application Note
Logging issues
To log the torque sensor system data you will need to create two analogue channels in
Version 6 Setup. If you give similar names to the channels e.g. Torque_RR and Torque_RL
the two channel names will appear in channel list close together. This will help when
creating math channels or graphs.
The frequency response of the sensor is designed to give an upper 3dB limit at 25Hz. The
logging rate should therefore be chosen appropriately and 100Hz or more is
recommended. Logging at too slow a rate will result in an aliased display at each gear
change.
Some reasons why the data is not as expected can be:
I Variability due to fluctuations in the track. Check the wheel contact forces,
and push rod strains. Check for contact with kerbs.
I Effect of the springiness of the drive shaft. Look at RPM and wheelspeed.
The differences appear much more exaggerated in the drive shaft.
I Violence of gear changes. This can be up to 8 times the normal loading and
violent gear changes are frequently the cause of strain gauge failure.
I How straight is the straight? Check with steering angle, crosswind effects
etc.
I Relaxation of the built up torque in a shaft when the wheel unsticks. Check
the wheel contact forces, look at wheelspeed.
37
Interpreting torque data
This section contains graphs of data, and explains how to interpret the graphs. This should
help you when examining graphs of your own data.
Hop/waddle mode
This graph is a distance graph, with right torque and left torque channels plotted against
distance.
The traces at 3405 seconds show the oscillations set up in the shafts running in phase,
(hop mode) where the energy is built up in the shafts and then transferred to the car. At
3411 seconds the suspension changes to a situation where the energy is built up in one
shaft in preference to the other. This energy is then transferred to the car while the energy
is built up in the other shaft, (waddle mode).
At 3440 seconds the waddle mode starts again but changes abruptly at 3443 seconds
when it returns to hop mode.
Hop/waddle mode
38 Torque Sensor System Application Note
Start and steering
This graph shows pulling out of the garage and turning a corner. The graph is a time graph
which has three channels; Steering Angle, right torque, and left torque. The graph shows
a spike at 4344 seconds, which is probably a gear selection. Then left and right traces
follow each other as the torque is applied. There is probably no wheelspin here. Steering
is turned at 46 seconds which generates differing torques and the torque traces diverge.
At 47.5 seconds the torque input exceeds that of the tyres and the traces start to converge
violently, probably as a result of wheelspin. Wheelspin is probably evident until about 50
seconds where the steering is beginning to straighten. At approximately 52 seconds the
throttle is closed and the torque in the shafts falls away rapidly and in phase with each
other. As the steering is returned to straight the traces gently track each other.
The sections of this graph which give confidence in the correctness of the data are the
correlation between the left and right traces up to 46 seconds and the section where the
traces fall rapidly at 52.1 seconds.
The correlation between the two traces when the car is running straight, with little power
input, should be close.
Start and steering graph
39
Gear change
This is a time graph which has three channels; torque, right wheelspeed and RPM.
The graph shows a gear change at approximately 134.50 seconds. When the power is
applied the wheel slips slightly at 134.66 seconds and produces little torque in the shaft.
When the grip returns, it slows the wheel and the engine RPM is reduced quite rapidly as
the rotational energy is transferred into the shaft generating a large increase in the torque.
The energy in the shaft then causes the car to increase in speed and the torque reduces,
the load on the engine falls away and the RPM increases. This produces an oscillating
system between the engine, shaft and tyre, which dies away over the next 0.5 seconds.
torque
rpm
wheelspeed
Time graph showing the effect of a gear change on torque
40 Torque Sensor System Application Note
Off load zero estimation
This XY plot, using dots, of left torque against right torque for a section of the data where
there are gear changes along a fixed straight (in fixed zoom area mode). The scales have
been set to show just the section where there is little torque (100Nm on both axes).
It shows a concentration of dots in the centre which are centred on zero horizontally but
at about 6 vertically. This could be caused by drag in the bearings or brakes. It would be
prudent to check the shaft zeros when the car is at rest in the garage.
This type of graph can be used to check the zeros around the track, and can be used to
identify where a problem has occurred. This allows you to use the data up to the point
where the fault appears.
Off load zero estimation
41
Torque difference/sum
Two math channels, torque difference and torque sum were created in Version 6 Analysis
PC Software. The graph below is an XY plot, using dots, of these two math channels.
Torque difference is the vertical axis and torque sum is the horizontal axis. The graph
shows the action of the differential and a concentration of dots at the full power straight
ahead condition.
These types of graph are not always aligned with the zero difference line, as some circuits
are not of the "straights with corners" type, but have a more circular plan. This causes a
bias to one side as significant amounts of time are taken cornering with power applied.
When the sum is less than zero the car is slowing and a differential action can clearly be
seen. At the smaller area of 0 to 1.5 the differential action is less clear but still exists.
full power straight
off power/braking on power/accelerating
Plot of torque difference against torque sum
42 Torque Sensor System Application Note
Frequency response
With torque sensor data from a full lap plotted against frequency, a graph of the frequency
response of the engine, drive shaft and wheel is generated.
The graph below shows the right torque sensor signal frequency response.
You could equally graph the left torque signal or gain a comparison by plotting both left
and right signals on the same graph.
DC content
natural roll-off of
chassis/tyre effects
peak possibly due
to chassis effects
Frequency response of the right torque signal
43
Alternative method to
plot frequency response
There is another way to generate a plot which removes the problem of the DC components
in the data. This method utilises the math function Deriv3 in Version 6 Analysis software.
In Version 6 Analysis create a math channel of the form:
UserFn ( choose , Throttle > 90 , Deriv3 ( Torque_RR + Torque_RL ) , 0 )
This will produce a graph which gives a plot of the frequencies of the drive train, wheels
etc.
The graph below is a frequency plot and shows two laps plotted against a math channel
of the form above (which is named torque_freq). The smoothing is set to 63 points and
linear scales are used.
lap 1 lap 2
Alternative frequency plot
Care should be taken in its interpretation as there seems to be some variability in the
graph produced from laps even on the same outing. This is probably due to differences in
the driving. The inclusion of the throttle term in the math channel helps to clarify the result
displayed on the graph.
44 Torque Sensor System Application Note
Specifications
Torque sensor
transmitter
Torque sensor transmitter specifications
Description Value
Shaft size 2530mm
1
Max RPM 2200
Centrifugal loading 0.5g per Km/h
Battery life at 20C 100% on 32h, 10% on 147h
Battery life at 50C 100% on 15h, 10% on 79h
Battery life at 80C 100% on 7.5h, 10% on 53h
Measurements 240 readings/sec
Resolution 13 bits
Gain of strain gauge amplifier 35.42
Transmit frequency 400450MHz
2
Operating temperature +10C to +80C (+40F to +176F)
Weight 150g including battery
Environmental IP642
1
Outside this range contact Pi Research.
2
Transmit frequency depends upon use.
45
Torque sensor
transmitter battery
The torque sensor transmitter battery is a 3.6V Lithium Thionyl Chloride cell. The only cell
certified for use is the SAFT LS14250.
Strain gauge
Please contact Pi Research for strain gauge specifications.
Torque sensor receiver
Torque sensor receiver specifications
Description Value
Resolution 12 bits
Frequency response 0 25Hz
Gain of receiver 1 or 2
Operating voltage 10V 16V DC
Output 2.505V
Offset 2.505V
Operating current 50mA
Operating temperature +10C to +80C (+40F to +176F)
Weight 75g
Environmental IP65
46 Torque Sensor System Application Note
Connectors
Strain gauge connection details
Connection Wire colour Connection Wire colour
Excitation +ve Red Excitation ve Blue
Signal +ve Green (or White) Signal ve Yellow (or Black)
Torque sensor transmitter connector details
Connector Mating connector
AMP HE14 (5 pin plug) AMP HE14 (5 pin socket)
Torque sensor transmitter connector pin details
Pin Function Pin Function
1 Battery +ve 4 Signal ve
2 Excitation +ve 5 Excitation ve (Ground)
3 Signal +ve
47
Torque sensor receiver connector details
Connector Mating connector
AS0-06-05SN-HE AS6-06-05PN-HE
AS0-06-05SN-HE
Torque sensor receiver connector pin details
Pin Function Pin Function
1 +12V 4 no connection
2 Ground 5 no connection
3 05V output (no shaft load = 2.5V)
48 Torque Sensor System Application Note
Dimensions
Torque sensor
transmitter
64.0
2.52"
6
4
.
o
2
.
5
2
"
43.8
1.72"
62.0 typical
2.44" typical
8.0 typical
0.32" typical
38.0
1.50"
Note:
The diameter when rotating
is 66.0 mm (2.60").
Dimensions in millimetres and inches
49
Torque sensor receiver
2
6
.
5
(
1
.
0
4
"
)
48.0 (1.89")
8
6
.
5

(
3
.
4
0
"
)
9
2
.
5

(
3
.
6
4
"
)
6
.
0
(
0
.
2
5

)
1
2
.
5
(
0
.
5
"
)
2
.
5
(
0
.
1
0
)
"
M4
3 posns
1
4
4
.
0

(
5
.
6
6
"
)
18.0
(0.71)
18.0
(0.71)
Dimensions in millimetres and inches
50 Torque Sensor System Application Note
Parts numbering
Kits
Torque sensor kit Europe
Kit Part Number Quantity
Torque sensor kit Europe 30B-050331
Comprising
Torque sensor Tx RHS Europe 01B-050322 1
Torque sensor Tx LHS Europe 01B-050323 1
Torque sensor Rx RHS Europe 01B-050324 1
Torque sensor Rx LHS Europe 01B-050325 1
Installation kit 13B-050294 1
Torque sensor kit USA
Kit Part Number Quantity
Torque sensor kit USA 30B-050332
Comprising
Torque sensor Tx RHS USA 01B-050326 1
Torque sensor Tx LHS USA 01B-050327 1
Torque sensor Rx RHS USA 01B-050328 1
Torque sensor Rx LHS USA 01B-050329 1
Installation kit 13B-050294 1
51
Installation kit
Kit Part Number Quantity
Installation kit 13B-050294
Comprising
Switch cleaner super Servisol 32A-0048 1
Tx battery 06B-0012 4
Rx debug/monitor loom 03E-1634 1
Tx gaskets 10B-050338-1 4
Crimp tool 28A-0002 1
Torque sensor system Application Note 29B-071175 1
Right side Rx sensor loom 03E-1569
1
1
Left side Rx sensor loom 03E-1569
1
1
Twin shaft strain gauge kit 13B-050332 1
1
State length of loom when ordering
Twin shaft strain gauge kit
Kit Part Number Quantity
Twin shaft strain gauge kit 13B-050332
Comprising
Gauging instructions 29B-071176-1E 1
Gauges 21A-0078 4
Tx battery loom 03E-1635 2
Tx connector 09G-0209 2
Crimp terminal 09F-0044 20
52 Torque Sensor System Application Note
Contact information
For more information about Pi products and details of worldwide authorised agents,
please contact:
Pi Research
Brookfield Motorsports Centre
Twentypence Road
Cottenham
CAMBRIDGE
UK Customer Support Tel +44 (0) 1954 253600
CB4 8PS Fax +44 (0) 1954 253601
Pi Research, Inc.
8250 Haverstick
Suite #275
Indianapolis
IN 46240 Tel +1 (317) 259-8900
USA Fax +1 (317) 259-0137
Research
Part Number: 29B-071175-6E
November 2003
Pi Research, 1998, 2001, 2003
Pi and the Pi logo are trademarks of Pi Group Limited
www.piresearch.com