Evolution and future

of torque measurement
technology

by Dr. Wilfried Krimmel

Dr. W. Krimmel, has been employed in the field of torque measurement technology since 1981.
Lorenz Measurement Technology GmbH
Obere Schlossstr. 131
73553 Alfdorf, Germany
Presented by;

Tel: 416 754 3168

Fax: 416 754 2351
www.physicomcorp.com
sales@physicomcorp.com
Evolution and future of torque measuring technology

1 SG-measurement technology
The historical evolution of torque measurement technology
begins with the year 1678. In this year, Robert Hooke de-
scribed the proportionality between the material extension and
F
the corresponding material tension in the well-known Hooke-
schen law. l
l

l Tension strud stressed under force F

= E = E with E = elasticity modulus
l
For the further evolution development, only year 1833 has an importance
again.

R+R

R-R
The bridge circuit was then described by Huter-Christie by which smallest
voltage changes can be measured. Nevertheless that the switching re-
ceived the name of the second inventor Wheatstone later, the actual
fame belongs to this English inventor. U0

UM
U M R

R+R
R-R
~
U0 R

Thomson, who later was called Lord Kelvin (the temperature scale was designated after him) detects the
connection between mechanical extension e of a resistance wire and its resistance- change in 1856.

l R l = longitudinal change of the resistance wire

= ~
R = resistance change of the wire
l R

Thereafter, this, experiments with resistance wires were sequently carried out again; e.g.Nernst experi-
mented with them in 1917 to measure pressure on combustion engines.
However, it still lasted up to1938 for the first model of a freely appliqued strain gauge.
At that time the first restistance strain gauge was developed by Prof. A.C. Ruge. Already three years later
the first industrially produced wire-SG was available at the market and scattered very fast.

For the opening of the SG sensors produced industrially guaranteed in 1952 the new foil- strain gauge. It
was etched by foils coated with resistance material. Contemporary SG are being produced today. In the
same year, the first foil SG were offered for the torque measurement.

This way, stationary SG torque sensors could be manufactured. These sensors helped to solve many prob-
lems in evolution and experiment by means of reaction momentum measurement. However, measurements
are the most important and also the most frequent effort for torque sensors in the rotating shaft line. The evo-
lution still lasted some years here in order to be able to offer usable SG torque sensors on the market.
Evolution and future of torque measuring technology

2 First rotating torque sensors

If a shaft is burdened below an axial torque, it warps
Angle meas.system
around an angle, proportional to the torque. This angle can
be measured with an angle measuring system. According
to this principle, the first rotating torque sensors with induc-
tive measuring system were already set up briefly in 1945 Mt
and offered on the market. Carrier frequencies of some
hundred kHz were implemented to supply the sensor. In
this way, the necessary coil systems were small. The am-
plitude of the AC voltage- measurement signal was propor-
tional to the rotation angle of the measuring system and
had the same frequency as the supply voltage.
Mt Torsion
.
Principle for an angle-measuring torque sensor

In order to supply the measuring system arranged

Rotor on the rotating shaft and for the transfer of the am-
plitude-modulated measurement signal, turning
transducers were inserted which were set-up ac-
cording to the principle of a transformer. A coil of
the transformer is attached in the stator, the second
is ordered concentrically to the first coil on the rotor.
If amplitude modulated measurement signals are
transmitted via this kind of turning transducer, its
coupling factor enters directly into the result of the
measurement.
Through axial or radial displacements, non-circular
Air gap Stator Shaft run, changes of the magnetic material characteris-
Principle scetch for a transf, turning transducer tics and by magnetic shunts, measurement errors
can occur.

The first transfer of the measurement sig-

nals of a SG-bridge which was applied on Shaft with SG brushes and sliprings
a rotating shaft was carried out in 1952
with slip rings.

Transfer of the supply voltage through slip

rings and the initial tension requires a certain
care. The slip rings must become isolated
from the shaft and from each other, even
smallest insulation faults can cause consider- Sectional view through a slipring sensor
able measurement errors. The surface pres-
sure of the sliding contacts must be chosen in
such a way, that on the one hand an as small as possible contact resistance, sufficient safety against lift-off
due to vibrations and error in roundness of the slip rings is available, but on the other hand no too strong
heating-up and too strong abrasion occurs. A careful processing of the surfaces is also decisive in addition to
the material selection.
Special difficulties are to be expected at high circumferential speeds. Some sensors are furnished with lift-off
appliances for the brushes which are only fitted for the measurement. Disadvantage of this technique is that
the slip rings and coal brushes wear out and therefore must be renewed.
Evolution and future of torque measuring technology

To retain a sensor with stable and

maintenance-free signal transmission, a
Stator Rotor
torque sensor was developed which
enables slip ring-free transfer of the
measurement signals of a SG bridge.
Through AC supply of the bridge, an
amplitude modulated AC voltage,
Supply-
voltage
SG-
Full bridge
proportional to torque is received at the
output of the bridge. Both the AC voltage
necessary for supply, the SG bridge and
that measurement signal can be
Transformer transmitted via a turning transducer.
tur.transducer
In this way, the victory of the rotating torque
sensors on SG basis could not be held up
anymore.
Meas.signal- With electronics becoming smaller and
output smaller in 1971, it became possible to
integrate an amplifier onto the rotating shaft
was designated for the supply to the SG
bridge and was used for preparation of the
Block circuit diagram for rotating sensors with measurement signal. A transformer turning
AC-supply transducer was used for supply to the
transducer; the second for the frequency-modulated transfer of the measurement signal.
In the meantime, SG technology was advanced, also. Today the sensors are set up in a compensated
manner, temperature and creep compensated. The great advantage of SG technology consists in the
fact that the compensation of the disturbance signals can be carried out directly at the point of
measurement. The temperature dependence of the elasticity modulus of the implemented materials is
e.g., for steel approx. 3% per 100K temperature change. Since this disturbance signal comes into the
rating of the sensor directly, it must be compensated correspondingly.
At angle measuring sensors a compensation, if at all, is carried out the in the amplifier, so that it is
always to be relied on a reaction to changes in temperature of the nominal value. Angle-measuring
sensors further have to fight with the problem that they require relatively large rotation angles for the
measurement of torque, which leads to torsion-tender sequences that only allow slow measurement
procedures.
By the electronics becoming smaller and smaller and in this way the improved transmission possibilities
of the measurement signals, the market has changed in such a manner that today many torque sensors
are provided with integrated amplifiers.
Evolution and future of torque measuring technology

3 Modern rotating torque sensors

The first torque sensors normally had signal analog outputs. At these interfaces, disturbances through
neighboring power modules and drives are possible, especially in case of long incoming leads and high dy-
namics For this reason, in the past, the signal level of the sensor was increased; signal levels of 5V and/or
10V are usual. However, for many applications the interference immunity is not sufficient. The solution is a
digital sensor electronics whose basic mechanical construction is represented in the following sectional view.

Electronics with transformer

Housing turning transducer
(Stator)

SG
Shaft

Transformer turning trans-

ducer with electronics

Modern torque sensor with integrated electronics

Located on the shaft is a - at the diameter reduced - spot to which the SG-bridge is applied. The rotating part
of the transformer turning transducer and the rotating electronics is attached on the shaft as well. The fixed
part of the transformer turning transducer and a further electronics is located in the housing. For the connec-
tion of the sensor a connector plug is implemented in the housing.

The integrated electronics has a microprocessor both in the stator and in the rotor with a corresponding
memory buffer. The measured value consumption occurs on the rotor by means of SG, the signal is immedi-
ately amplified and digitalized there. This digital signal then proceeds into a processor which prepares the
signal for the transfer to the stator in the form of a serial word with checksum. In the stator the data signal is
prepared and moved subsequently in a processor for a serial RS 485 interface.
By the use of processors, data like serial number, calibrating value, measuring range, calibrating date etc.
can be stored and read out on demand from the shaft as well as from the stator.

The supply of the sensor takes place by a power supply unit, checked by the processor which can also im-
pose a calibrating control for the check-up of the sensor. A very high reliability of the measuring device is a-
chieved by the digitalization of the measurement signal directly on the point of origin and the storing and
read-out of the sensor data.
.
Evolution and future of torque measuring technology

Rot.transformer

Supply- Oscillator DC
DC/DC
voltage 4 MHz AC
SG
Supply and
Takt und Control signals
Steuersignale

Filter for
Calibrat.- control signals
-processor
control Amplifier

Rot.transformer

Signal adaption
Signal- Signal-
analog or -processor
output Cond.
digital

Serial data transmission

A/D-converter
12 bit

A
Rot. angle- Signal-
output Cond.
(Option) B Rot.angle (Option)

Stator Rotor
Block diagram for a digital measurement signal transfer with integrated processors
Evolution and future of torque measuring technology

4 Areas of application for torque sensors

Today in many fields we cannot imagine to proceed without torque sensors anymore.
Here is a small choice of areas of application.
.

Application fields for torque sensors

extract
Production
Development Other
Education Quality assurance
Testing Applications
Product monitoring
Electro motors Test stands Control, regulation Wind force plants
Characteristics Reel test stand Tightening moment Performance
Performance Electro motors of screw caps Torque
Torque Combustion engines
Transmissions Alignment Bore tower
Combustion engines Generators Bearing pre-load Torque in
Characteristics Fans Spring pre-load bore rods
Performance Pumps Axial displacement
Torque Positioning drives
Measuring units Screw technique Locking characteristics
Torque sensor in Tightening moment of valves
versatile Loosening moment
meas. configurations Agriculture
Sliding roof Examination of function Torque controlled
Window lifter Crank torque machines
Generator
Rheology Pump Ships
Rheometer Pressure intensifier Ship shafts
Fan
Torque sensors built in Conveyor belt
automobiles Electro motors
Combustion engines
Bearing friction
Shrink fit
Sealings (friction)

Rheology
Rheometer

Test stands for

Endurance tests
Hand-held tools
Household appliances
Automobile
combustion engines

As you can see, torque sensors are inserted in all fields from training to product design, production, quality
assurance up to production monitoring. Even in agriculture, torque sensors can be found in the machinery.
For the traceability certificate of measurements, reference torque sensors are inserted more and more in or-
der to check the appliance of production directly on site.
Evolution and future of torque measuring technology

4.1 Application case motor test bench

For engines and driven hand-held
brake torque measurement speciman tool applications, a torque sensor
and a load unit is required. The
average performance data in the
continuous operation are compre-
hended there. These data give in-
formation about the correct func-
tion of the components, for exam-
ple about the proper contribution
of the poles in the electrical motor.
However, information about con-
Basic set-up for motor test stand trolling characteristics of the drive
can also be determined by dy-
namic load.

Test stand for electro motors

4.1.1 Application case test stand for comb.engine

brake torque measuring system combustion engine

Here the sensor is coupled to the brake di-

rectly. The coupling of the combustion engine
takes place by a joint shaft. As a result, the
alignment of the speciman is simplified essen-
tially. Furthermore the oscillations of the en-
gine are not transmitted onto the sensor so
strongly. As you can recognize, there is a
bursting and shock proof protection positioned
around the sensor and the joint shaft for
safety purposes, which is closed during op-
eration from above, of course.

Torque sensor with coupled joint shaft

Evolution and future of torque measuring technology

5 Future of torque sensors

The SG technique will be the supporting strength for torque sensors in the future. By the electronics becom-
ing smaller and electrically more stable, the sensors can be implemented to higher spring rates which leads
to improved dynamics of the measurement. This is being achieved in a manner that at the same measuring
accuracy, the measurement signals become smaller through the higher electric stability of the amplifiers.
On the other hand, the improved measurement signal conditioning can however be implemented for a higher
accuracy of the testing equipment layout as well.
The future also belongs to the intelligent sensors with stored measured technical data, through which the
measurements become more and more secure and the data for quality assurance can be called directly from
the sensor.