Torque Sensors - sensitec

TorqueSensorsMeasurementTechnology for TestRigs, Drives, ProcessMonitoring andQuality Assurance

Torque measurement applicationsDr. Staiger Mohilo‘s core competency isstrain gage technology for sensors forstatic and dynamic measurement. Closeongoing collaboration with research andindustry ensures continuous developmentof measurement technology and sensor designs.Noncontact digital signal transmissionfrom rotor to stator, integrated signalconditioning, interfaces such as CAN busand RS-232C, and normalized analog andfrequency outputs make integration intoexisting test systems easier for the user.Electric motor testingThe mechanical and electrical characteristics,thermal design, overload capacity andall technical data of electrical machinery aresubjected to intensive testing. The determinationof efficiency and power factor inparticular impose tough demands on theaccuracy and flexibility of a test system.Torque sensors play a central role.Accurate measurement of torques appliedto rotating drives and components is animportant criterion for effective productdevelopment and reliable quality assurancein production and assembly. Kistler’s versatileuniversal torque sensor, Type 4503A…,opens up a multiplicity of applicationsacross this sector.Production processmonitoringAccurate measurement of torques appliedto rotating drives and components is animportant criterion for evaluating manufacturingefficiency and quality assurancein production and assembly.These days process monitoring demandscomprehensive, traceable acquisition ofmeasurement results from torque sensorsystems.Examples include:• Automated screw connection processes• Viscosity monitoring• Measurement of friction coefficients inproduction control4 www.kistler.com

Research and developmentThe development of internal combustionengines and gearing, and test rig simulationas a means of investigating drive trains, requirea robust, high-precision torque sensor.A short, highly torsionally rigid design isalso needed to map dynamic load cyclesonto a realistic operating profile. The torquemeasuring flange, Type 4504A…, has beenspecially tailored to these requirements.Product testingEach and every assembly step in the productionof safety components is monitoredwith sensors. Automobile suppliers can onlyguarantee their components will work properlyby testing their production as a reliablemeans of avoiding the customer sufferingfailures.Testing ignition switches withtorque sensorsThe operation of mounted ignition switchescan be tested at the production stage withthe aid of torque sensors. The torques requiredto turn their spring-loaded componentsmust remain within specified tolerances.www.kistler.com 5

Ideal solution to any measurement challengeTorque sensors correctly mountedIt is vital to ensure the measurement setupis correct when mounting torque sensors.The choice of suitable couplings dependson whether the sensor is to be overhung,just provided with torsional restraint, ormounted with its own flange, base or retainingbracket. Kistler provides itscustomers with advice that ensures eachsetup is successful from the outset.Torque measuring systemThe performance of the measuringsystem as a whole is what counts whenmeasurements are performed on test rigs,for process monitoring or product testing.Mounting example: Torque sensor, Type 4503A… with mounting base•••••Precise and reliable sensor systemsMounting versatilityUser friendlinessTraceable measurement dataCost-effective operationThe new supply and evaluation unit,Type 4700A…, provides the key measurementdata at a glance. Standard USB andRS-232C interfaces allow easy acquisitionand evaluation on a PC of relevant datasuch as mechanical power, torque, speedor rotation angle.Fully automatic calibration system DKD-K-37701Supply and evaluation system, Type 4700A… (UMV3000)national normDr. Staiger MohiloDKD-Calibration labreference standardInternal calibration labWorking standard ormovement standardMeasuring and test equipmentof the companyProductCalibrationThe reference-standard torque measuringsystem with electric motor drive representsthe state of the art in calibrationof torque sensors. It was developed inconjunction with the Torque Laboratoryof the "Fachlaboratorium Drehmoment,Physikalisch-Technische Bundesanstalt"in Braunschweig, Germany. Torques areapplied with automatically configurableweights that can be moved along a loadlever. This system extends the usual staticcalibration to now allow quasi-continuouscalibration of torque sensors over their entiremeasuring range. Dr. Staiger-Mohilo hasbased its computer-controlled calibrationprocess on DIN ISO 9001 in order to offerusers of torque sensors comprehensive,measuring machine generated calibrationdocumentation that dovetails seamlesslywith their DIN ISO requirements.The Calibration Laboratory has been accreditedby the German Calibration Service(DKD) since Spring 2004. A factory calibrationcertificate and a DKD calibration certificatecan be provided.www.kistler.com 7

Range and typical measuring chainsMeasuring chains with rotating torque sensorsMeasuring Connecting AmplifyingAnalyzing4501A...KSM 007186KSM 4701A...4503A... KSM 018642 4700A...4504A...KSM 012497KSM 021468SupplySignal/controlType Sensor Measuring range in lbf-ftfixed rotating –0.074 0.740 7.4 74 7404501A…(0143SD)Torquesensor4.42 … 740 1)4502A…(0170MS)Mini-Smarttorquesensor0.37 … 740 1)4503A…(0260DM)Dual rangetorquesensor0.15 … 3,690 1) 150 … 7,400 1)4504A…(0325DF)Measuringflange9329A… to9389A…Reactiontorquesensor0.74 … 740 2)2)Piezoelectric sensors offer a resolution to a range of milli-newton – independent of the measuring range.8 www.kistler.com

Measuring chains with piezoelectric reaction torque sensorsMeasuring Connecting AmplifyingAnalyzing5073A1...5030A...9339A9329A ... 9389A1631C29339A9329A ... 9389A1631C25875A...5863A1...5863A2Max.speedSignaloutputSignal transmission Bearings Connection7,400 slip ring non-contact square hexagonalshaftflange< 3,000 rpm ±2 mV/V 12,000 rpm ±5 VDC 50,000 rpm0100 ±40 kHz0or ±5 VDC0or ±10 VDCand RS-232C 15,000 rpm100 ±40 kHz060 ±20 kHz10 ±5 kHz0 ±10 VDCand RS-232C––2,942 …–135 pC/lbf-ft(dependingon size)cablewww.kistler.com 9

MeasuringTorque sensorsSlipring torque sensors, 1.5 … 740 lbf-ftWType 4501A…LHTechnical dataType 4501A…Measuring range lbf-ft 1.5 / 8.8 / 18.4 / 46.5 / 125 / 370 / 740(Rated torque)Maximum torque1.5 x rated torqueAlternating torque0.7 x rated torqueAccuracy class % 0.2Output signal mV/V ±2(Rated value)Speed measurement pulses/rev. 2 x 360Nominal speed rpm ≤3,000 (depending on version)Balancing grade Q –Operating temperature range °F 40 … 120(Rated temperature range)Case materialAluminum, hard anodizedL in 1.73 … 2.87W in 1.10 … 2.87H in 2.05 … 3.54Degree of protectionIP40Electrical connections6-pin or 12-pin Binder connectorDrehmoment-SensorenMini-Smart torque sensor, 0.4 … 740 lbf-ftPropertiesUniversal torque sensor. Compact,various shaft connections.Areas of applicationDesigned specifically for use inscrew connection. Typical applicationsinclude the testing of built-innutrunners or torque measurementwith hand screw driving tools. Forbrief, intermittent operation at lowspeeds.AccessoriesFemale cable connector6-pinType KSM00082212-pinType KSM000703Connecting cable Type KSM007186Type KSM010382Type KSM018315see data sheet for further detailsData sheet 4501A_000-596HType 4502A…WLTechnical dataType 4502A…Measuring range lbf-ft 0.4 / 0.7 / 1.5 / 4.4 / 8.9 / 13.3 / 36.9 / 46.5 / 73.8 / 111 / 118 /(Rated torque) 184 / 221 / 370 / 740Maximum torque1.5 x rated torqueAlternating torque0.7 x rated torqueAccuracy class % 0.2Output signal VDC ±0 … 5(Rated value)Speed Measurement pulses/rev. 2 x 360 or 60Nominal speed rpm

MeasuringTorque sensorsDual range sensor with noncontact transmission, 0.2 … 3,685 lbf-ftHType 4503A…LDTechnical dataType 4503A…Measuring range lbf-ft 0.2 / 0.4 / 0.7 / 1.5 / 3.7 / 7.4 / 15 / 35 / 75 / 150 / 370(Rated torque) / 740 / 1,475 / 3,685Maximum torque1.5 x rated torqueAlternating torque0.7 x rated torqueAccuracy class % 0.1 or 0.05 (depending on version)Output signal VDC ±0 … 5 or ±0 … 10 V(Rated value) kHz or 100 ±40 and RS-232CSpeed measurement pulses/rev. 60 or 2 x 360Nominal speed rpm

MeasuringTorque sensorsReaction torque sensor, ±0.74 lbf-ft up to –740 … 7,400 lbf-ftDTechnical data Type 9329A Type 9339A Type 9349A Type 9369AMeasuring range lbf-ft –0.74 … 0.74 –7.4 … 7.4 –18.4 … 18.4 –148 … 148MzCalibrated measuring ranges lbf-ft 0 … 0.74 0 … 7.4 0 … 18.4 0 … 1480 … –0.74 0 … –7.4 0 … –18.4 0 … –1480 … 0.074 0 … 0.74 0 … 1.84 0 … 14.80 … –0.074 0 … –0.74 0 … –1.84 0 … –14.8Sensitivity pC/lbf-ft ≈–2942.5 ≈–623.8 ≈–311.9 ≈–176.3HD in 0.79 1.18 1.42 2.13H in 1.02 1.34 1.65 2.36Weight g 50 137 243 800Operating temperature range °F –4 … 175 –40 … 250 –40 … 250 –40 … 250Type 9329ATechnical dataType 9389AMeasuring range lbf-ft –740 … 740Calibrated measuring ranges lbf-ft 0 … 7400 … –7400 … 740 … –74Sensitivity pC/lbf-ft ≈–135.6D in 3.94H in 5.12Weight g 6,720Operating temperature range °Fx –40 … 250General technical dataDegree of protection (EN 60529)ConnectionIP65 with connected cableIP67 with cable Type 1983AD… and molded connectorKIAG 10-32 neg.AmplifyingPropertiesCompact reaction torque sensorready for mounting, flexible adapter,centering seat.Areas of applicationMeasurement of a torque actingabout the axis of the sensor, torquesetting and testing of threadedconnections, calibration of handtorque wrenches, torsional testingof springs, measurements on frictionclutches and electric motors, andtesting of rotary switches (producttesting).AccessoriesMounting flangeData sheet 9329A_000-463Type 9580A…IndustryICAM - Industrial Charge Amplifier for Applications in ManufacturingTechnical dataType 5073A…No. of channels 1, 2, 3, 4Measuring range pC ±100 ... ±1 000 000Output signal V 0 ... ±10Supply VDC 18 ... 30Sensor connectionBNC (neg.)Temperature range °F 32 ... 140 (noncondensing)InterfaceRS-232CDegree of protection (EN 60529) IP60PropertiesIndustrial charge amplifier housed ina rugged metal case. Outstandingfor ease of operation and faithfultechnical data over a very widemeasuring range.Areas of applicationSuitable for applications with nearlyall piezoelectric sensors.AccessoriesSee data sheetData sheet 5073A_000-52412 www.kistler.com

ConnectingConnecting cablesConnecting cables for sensorsTechnical data Type KSM 007186Connection6-pin, neg. – 6-pin, pos.Length m 5Diameter in 0.2Degree of protection (EN 60529) IP40Technical data Type KSM 010382Connection6-pin, pos. – free endsLength m 5Diameter in 0.2Degree of protection (EN 60529) IP40Technical data Type KSM 018315Connection12-pin neg. – free endsLength m 5Diameter in 0.2Degree of protection (EN 60529) IP40Technical data Type KSM 012497Connection12-pin neg. – free endsLength m 5Diameter in 0.2Degree of protection (EN 60529) IP40Technical data Type KSM 021971Connection7-pin neg. – free endsLength m 5Diameter in 0.2Degree of protection (EN 60529) IP40Technical dataType 1631C…ConnectionKIAG 10-32 pos. – BNC pos.Length m 0.5 / 1 / 2 / 3 / 5 / 10 / 20Diameter in 0.08 (PFA)Degree of protection (EN 60529) IP65 – IP40See data sheet KSM_000-615 for other cablesConnectorsConnectors/female cable connectorsTechnical data Types KSM 000822, 000517, 000703Connection6-, 7-, 12-pin neg.Degree of protection (EN 60529) IP40See data sheet KSM_000-615 for other connectors/female cable connectorswww.kistler.com 13

AmplifyingIndustryMeasurement amplifiers for strain gage sensorsTechnical dataType 4701A…No. of channels 1Input (strain gage) mV/V 0.5 … 3.0 (full or half bridge)Frequency range (–3 dB) kHz ≈0 … 1Output signal V ±5 or ±10Supply VDC options: 24 unstabilized (±10 %)10 … 15 stabilized and filteredInput signal Connector strain gage options: gland with soldering terminals6-pin connectorDegree of protection (EN 60529) IP40 ≈ IP54 IP40 (with connector), IP54 (with gland)PropertiesIndustrial measuring amplifier withrobust metal case. Amplification andzero adjustment are set with fixedresistors and potentiometers.Areas of applicationThis amplifier is designed for industrialapplications and intendedfor panel mounting. Universal measurementamplifier for strain gagesensors. Suitable for torque sensors,Type 4501A… .AccessoriesCable Type KMS 007186Cable Type KMS 010382Data sheet 4701A_000-621Control and monitoring unitsSupply and evaluation system for torque sensorsTechnical dataType 4700A…No. of channels 1Input for torqueStrain gage mV/V 0.5 … 3.5 (full bridge, 4-/6-wire)Active VDC ±5 … ±10Frequency kHz ≤300Frequency range (–3 dB) kHz 0.001 … 5Input for speed/rotation angleTracks A, B and Z kHz ≤300BNC neg. connectorsSensor supplies 24 V stabilizedDMS 5 V unipolar5 V stabilized±12 V stabilizedInput signal Connector 25-pin D-Sub female connectorOutput signals3 channels V ±10 (9-pin D-Sub neg. connector)BNC neg. connectorDigital control8 digital inputs8 digital outputs25-pin D-Sub neg. connectorInterfaces RS-232C, USB 2.0PropertiesUniversal measurement amplifier forconnecting passive and active forceand torque sensors. It is possible toevaluate torque / speed or torque /rotational angle measurements. Themechanical power is calculated andindicated by the unit. The unit alsohas digital inputs and outputs andcircuitry for measuring extreme valuesand saving measurement curves.Areas of applicationThe unit is ideal for use in productioninstrumentation and in the testand laboratory environment.AccessoriesConnection cable Type KSM018535Type KSM018537Type KSM018538Type KSM018642Data sheet 4700A_000-62014 www.kistler.com

AccessoriesCouplingsMiniature coupling, torsionally rigid, with single flexibility, clamping hubTechnical data Type 966……25 …37 …50 …62 …75Rated torque lbf-ft 0.29 1.15 4.55 18.22 26.7Maximum torque lbf-ft 0.40 1.62 6.37 25.52 37.39Compliance, axial in 0.03 0.03 0.03 0.03 0.03Compliance, radial in 0.028 0.028 0.028 0.028 0.028Compliance, angular ° 2 1.5 1 0.7 0.7Torsional spring constant 10 6 N·m/rad 3.89 25.986 39.768 103.572 161.76Maximum speed min -1 64,000 44,000 36,000 28,000 24,000Mass moment of inertia 10 -6 kg·m 2 1.83 11.1 28.56 78.61 159.4Miniature coupling, torsionally rigid, with dual flexibility, clamping hubTechnical data Type KK 965……25 …37 …50 …62 …75Rated torque lbf-ft 0.29 1.15 4.55 18.22 26.7Maximum torque lbf-ft 0.40 1.62 6.37 25.52 37.39Compliance, axial in 0.03 0.03 0.03 0.03 0.03Compliance, radial in 0.028 0.028 0.028 0.028 0.028Compliance, angular ° 2 1.5 1 0.7 0.7Torsional spring constant 10 6 N·m/rad 3.89 25.986 39.768 103.572 161.76Maximum speed min -1 64 000 44 000 36 000 28 000 24 000Mass moment of inertia 10 -6 kg·m 2 2.33 14.01 37.99 104.28 203.55Bellows coupling with clamping hubTechnical dataType BK2……15 …30 …60 …80 …150Rated torque lbf-ft 11 22 44 60 110Total length in 2.32 / 2.60 2.72 / 3.03 3.27 / 3.66 3.70 / 4.17 3.74 / 4.21Compliance, axial in 0.04 / 0.08 0.04 / 0.08 0.06 / 0.08 0.08 / 0.12 0.08 / 0.12Compliance, radial in 0.006 / 0.008 0.008 / 0.01 0.008 / 0.01 0.008 / 0.01 0.008 / 0.01Torsional spring constant 10 6 N·m/rad 0.02 / 0.015 0.039 / 0.028 0.076 / 0.055 0.129 / 0.085 0.175 / 0.110Maximum speed min -1 10,000 for precision-balanced versionMass moment of inertia 10 -6 kg·m 2 70 / 80 140 / 150 230 / 260 650 / 670 2,500 / 3,200Technical dataType BK2……200 …300 …500 …800 …1500Rated torque lbf-ft 148 221 368 590 1,105Total length in 4.1 / 4.6 4.4 / 4.9 5.2 / 5.7 5.5 6.5Compliance, axial in 0.07 / 0.12 0.1 / 0.14 0.1 / 0.14 0.14 0.14Compliance, radial in 0.01 0.01 0.01 0.01 0.01Torsional spring constant 10 6 N·m/rad 0.191 / 0.140 0.450 / 0.350 0.510 / 0.500 0.780 1.304Maximum speed min -1 10,000 for precision-balanced versionMass moment of inertia 10 -6 kg·m 2 4,500 / 5,400 8,500 / 10,500 17,300 / 19,600 24,300 49,200www.kistler.com 15

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