Torque Measurement Benefits for the Automotive Industry

05/02/2023 1

Binsfeld Engineering Inc.Torque Measurement Benefits for the Automotive Industry

Brian Carr & Mitch McDonald231-334-4383

[email protected]@binsfeld.comwww.binsfeld.com

Binsfeld Engineering Inc., Maple City, MI USA

www.binsfeld.com

mailto:[email protected]


http://www.binsfeld.com/

05/02/2023 Binsfeld Engineering Inc., Maple City, MI USA www.binsfeld.com

2

Topics Covered

• Common Problems Involving Torque/RPM

• Different Approaches & Why Strain Gages?

• How Strain Gages & Telemetry Work

• Turning Data Into Beneficial Actions

• Documented Case Studies from Clients


3

Why Measure At All?

• To determine true torque and load acting on rotating parts, like drive shafts of motors

• Does the equipment match the design specifications?

• That information leads to preventive maintenance or optimization

• For example, is a resonant torque event causing broken half shafts on a vehicle during R&D? (More later…)


4

Why Strain Gages & Telemetry?

• Gage factor sensitivity

• Ease of installation

• Can measure axial or bending strain

• Configure multiple gage to minimize effects of temperature


5

Downside to Dynamometers

• Less cost-effective

• Size prevents testing in confined spaces

• Inability to transport to remote, on-site locations

• Positive: Accuracy

Heavy duty engine dynamometer, UC Riversidehttp://cichlid.cert.ucr.edu/about/hddl.asp


6

Load Cell & Moment Arm Drawbacks

• Measures force, not torque, makingdata acquisition and analysis painstaking

• Limited by space due to cumbersome equipment

• Positive: Cost-effective

Armature and load cell to measure torque, Wright State University.


7

How About Inline Rotary Sensors?

• Costly

• Torque limitations

• Costing shaft modifications,especially for large diameter shafts

• Positive: Withstands high RPMs and G-Forces

Honeywell model 2110-2116 in-line torque sensor

05/02/2023 8

Review: Strain Gage Telemetry Advantages

Binsfeld Engineering Inc., Maple City, MI USAwww.binsfeld.com

• Measures live torque in real time

• Converts virtually any shaft into a torque sensor

• Installation requires no shaft modification

• Incorporates proven strain gage technology

• Seamless calibration and remote control

05/02/2023 9

Other Force Measurements


Able to transit any data for any property that can be sensed with Full Bridge or “simulated” Full Bridge Sensor:

• Torque (Most Common)• Bending • Axial Force (Tension and Compression)• Pressure• Temperature• Acceleration

05/02/2023 10

Strain Gage Telemetry Main Components


• Receiver

• Transmitter

• Remote Control

• Battery Housing

• Strain Gage

05/02/2023 11Binsfeld Engineering Inc., Maple City, MI USAwww.binsfeld.com

05/02/2023 12

How Strain Gage Telemetry Works


• Transmitter energizes Strain Gage• Strain Gage mV signal output amplified (Strain/Torque)• Transmitter receives and digitizes signal from Strain Gage • Transmitter transmits data to Receiver via RF Carrier• Receiver produces digital and analog signals• Amplifies sensor signal & transmits from Rotating Shaft• Output signal is a true representation of torque/strain by Strain Gage• System does not create sensor data

05/02/2023 13

Pre-Installation Preparation & Information


• Torque Strain Calculator; calculates expected micro strain distortion based on User Data. (Shaft dimensions and material, Torque)

• Use calculated strain value to adjust Transmitter Gain

• Torque Range Calculator; calculates Full Scale Torque based on the 10 Volt output of the Receiver. (User input of shaft dimensions and material, Gage Factor and Transmitter Gain)

• Important: accurately run through calculators before system installation

http://www.binsfeld.com/torquetrak/torque-strain-calculator.html

http://www.binsfeld.com/torquetrak/torque-strain-calculator.html

http://www.binsfeld.com/tt10k_range.swf

05/02/2023 14

Strain Gage Installation


• Bench Test System (recommended)

• Calculate Torque Strain and Full Scale Values• TT10K Technical Information• Aids in transmitter set up

• Determine location for system components• TT10K LP option

• Shaft surface preparation• Critical to proper strain gage adhesion and function• Sand and clean using proper tools and chemicals• Strain Gage Application kit (recommended)• Training videos; Video Link

http://www.binsfeld.com/torquetrak/torquetrak-10k/technical-info.html

http://www.binsfeld.com/torquetrak/training-aids/training-videos.html

05/02/2023 15

Strain Gage Installation Cont.


• Strain Gage Installation • Perpendicular to shaft axis

• Use proper adhesive• M-Bond (Cyanoacrylate)

• Tape and Teflon Strips

• Apply uniform pressure to entire area, avoid bubbles(Reference training videos andUser’s Manual pages 39-42)

05/02/2023 16

Wiring the Strain Gage


• Clean and prep solder pads

• Review wiring diagram

• Wire length to Transmitter

• Apply proper soldering procedures

• Protect gage with M-Coat JA• Test Gage before application

• Nominal Resistance Values(Reference Training videos and User’s Manual pages 42-43)


17

Application – SAE Baja Buggy

• Opportunity: Tuning, Research & Development

• Equipment: Drive-Shaft

• Solution: Real-time Monitoring of RPM & Torque


18

Application - Automotive Stamping Press

• Opportunity: Condition Monitoring & Design Validation

• Equipment: Stamping Press Transfer Drive

• Solution: Operating loads exceeded design, press manufacturer held accountable


19

Application - Transit Mixer Truck

• Opportunity: Validate new front engine power take-off

• Equipment: Rotating shaft/hydrostatic pump

• Solution: Torque reversals indicated necessity of duty cycle

05/02/2023 20Binsfeld Engineering Inc., Maple City, MI

USAwww.binsfeld.com

Certifications

ISO 9001:2008 American Bureau of Shipping Design Assessment

05/02/2023 21Binsfeld Engineering Inc., Maple City, MI

USAwww.binsfeld.com

About Binsfeld Engineering Inc.

• Founded in 1971 (near Traverse City, Michigan & where we currently reside)• Incorporated in 1978• Early business dominated by field consulting; measuring torque on rotating systems• By 1985, offered own line of torque telemetry systems (via strain gage)• 1990, developed first rotary temperature transmitter. Became known as TempTrak • 1999, TorqueTrak 9000 Introduction; Awarded “Product of the Year”• TorqueTrak 9000 evolved into present TorqueTrak 10K & 10K-LP (Low-profile)• 2002, TorqueTrak Revolution Introduction. Continuous torque and power monitoring • 2015, TorqueTrak TPM2 Introduction. Continuous torque and power monitoring with digital output • 2015 & Beyond: New TorqueTrak 20K development and introduction

http://www.binsfeld.com/temptrak/

http://www.binsfeld.com/torquetrak/

05/02/2023 22

Technical Support Contacts

Binsfeld Engineering Inc.#231-334-4383#1-800-524-3327

www.binsfeld.com

Brian Carr, U.S. Sales Manager231-334-4383 [email protected]

Bob Holden, International Sales231-334-4383 [email protected]

OpDaq Systems418-727-5753

www.opdaq.com


http://www.binsfeld.com/



http://www.opdaq.com/

Date post:	21-Mar-2017
Category:	Automotive
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