Operation Manual for Torque Sensors
Contents
1. 11 11 lez RR TIT ee ee eee 11 11 1 Proprietary CaliDration ccccccccccssssseeccceeeeeeeeeseeceeeeeeseeeeseceeeeeeseeeeeseeeeeesessaaaaeeeeeeeessaageeeseeeees 11 11 2 BY 4 BE F 1 0 c 1 1 0 8 ee 11 11 3 mim iD O res E E ere ee eee 11 12 Brel NO A A E 11 13 Bri AD ENTE TS 11 E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 3 of 11 B LORENZ MESSTECHNIK GmbH Vx aat pax 07172 873022 1 Read First 1 1 Safety and Caution Symbols Caution Injury Risk for Persons Damage of the Device is possible CE Note Important points to be considered 1 2 Intended Use Torque sensors are intended for the measurement of torques This measurand is further suitable for control tasks The valid safety regulations should be absolutely respected The torque sensors are not safety components in the sense of the intended use The sensors need to be transported and stored appropriately The assembly commissioning and disassembling must take place professionally 1 3 Dangers The torque sensor is fail safe and corresponds to the state of technology 1 3 1 Neglecting of Safety Notes At inappropriate use remaining dangers can emerge e g by untrained personnel The operation manual must be read and understood by each person entrusted with the assembly maintenance repair operation and disassembly of the torque sensor 1 3 2 Remaining2. 7 AA IOOl VETSIOM ASSEMDIY acers csn tessvates tbv cu win susan bote HU avo td o don ilta Genel ductos vbi wd gat UON ERG CN 8 SEMI e e EE oia Ee i a e AE UU T mmm 8 oa E EU i a a E E E neers E E E A E E E 8 S GAE a E A E E ee ee eee ee 8 S9 MONON GOMMCC OM os sssini r a ea eetan osii ia aai 8 5 4 Running of Measuring Cables cccccsssccccccssssececccseseeeeecceaseceeeeeeeeeeeeseaaeceeesseaacessssagseeesssaageeeess 8 SEM UNR RETE m 9 6 1 late AGUNG MERETUR I manseieemetsossanccodsiaoseests 9 62 U eieuke Mee 9 63 Static Quas Slate Eo ToU i EET T m 9 cA Dynamic roe MEE Te 9 6 4 1 BC MNT DES 9 642 INalurd Resonants qursmecuurisezmtiasbecyit buneu ut damrdadiearnautdvaneuusnsneinet anini aieiai Sa Pa a t egal XS iian 9 oo NER R 9 Bo DISTRO ANGS V Al ADE MERIT TET 9 Fo uncle e M 10 7 1 Maintenance Schedule cccccccccccseesseeeeeeeeecaeseceeeeeesaaesesseceeeesssueaseeeeeeeesssuaesseeeeeeeessaaaseeeeeeess 10 L OUDE ae 109 MEINTE um 10 o ISCO UN emm 10 9 Transportation and Storage cccccccccccsssseeeceeeeeceeeeeeeeeeeseeeeeeeeeeeeeessuaeseeeeeesseeeaeeeeeeeeessaaeeeeeseeeeeesaaas 10 D TRANS OO AO asuesnecennntccisentcaesamimvanaiaialanatosisyaddt ental din tuniaadeail E xd UNE Do M 11 SE MM iicet eee eee een ene eee ee eee eee ee 11 10 ESO OS Ales
3. E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 9 of 11 LORENZ MESSTECHNIK GmbH 72 5 Rona 7 Maintenance 7 1 Maintenance Schedule Control of cables and connectors xpa J o o 0 Calibration lt 26 months Jo o Control of fixation flanges shafts d xpa JJ Have bearings exchanged by Lorenz 20000 hrs Messtechnik GmbH operating time 7 2 Trouble Shooting This chart is used for searching for the most frequent errors and their elimination Possible Cause Trouble Shooting No signal No sensor excitation e Outside of permissible range e Connect excitation e Cable defect e e No mains supply e Evaluation electronics defect Sensor does not react to torque No power supply e Outside of permissible range e Connect supply e Cable defect e No mains supply e Cable defect Hepair cable Connector connected wrong e Connect correctly oignal has dropouts Axial position rotor to stator e Align rotor outside of tolerance Cable defect e Repair cable Zero point outside of tolerance Distorted flanges e Check evenness of flange surfaces Wrong torque indication e Re calibrate Oscillations Alignment of shaft not correct e Align correctly Unbalance e Balance the corresponding parts Decommission All sensors must be dismantled professionally Do not strike sensor housings with tools Do not apply bending moments on the sensor e g throug
4. B LORENZ MESSTECHNIK GmbH 7s Fax 07172 193730 22 Operation Manual for Torque Sensors For Type DR 2477 E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 1 of 11 LORENZ MESSTECHNIK GmbH 72 5 onus Imprint Manufacturer Place Lorenz Messtechnik GmbH D 73553 Alfdorf Valid for Torque sensor type DR 2477 Copyright O 2006 Lorenz Messtechnik GmbH Alfdorf Reprint Interdiction Reprints even in extracts only with written authority Modification Technical changes reserved References in this Text 1 6 Warning Notes Page 4 Attention must be paid to the accident prevention regulations of the trade associations Coverings and casings are necessary before operating the sensor This is also valid for commissioning maintenance and trouble shooting Duties of the coverings and casings are Protection from detaching parts Protection from contusion and shear Prevention from reaching rotating parts Prevention from being tangled up and or getting caught by parts Coverings may Not grind Not rotate Coverings are also necessary outside of operating and motion travel areas of persons These demands can be modified if other sufficient safety devices are available During operation the safety precautions must be operative By vibrations damages can occur at the device 4 1 3 Alignment of the Measurement Arrangement Page 6 For further refer
5. g acetone no foreign particles may adhere to them The hub must fit corresponding to the connection Ss During the assembly the sensor must be supported to protect if from falling down E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 6 of 11 LORENZ MESSTECHNIK GmbH 72 5 Exam Connections with Clamping Piece The indications of the clamping piece manufacturer must be considered The clamping piece must be able to transfer the arising torques safely Ss Caution During the assembly inadmissibly large forces may not act on the sensor or the couplings At small torques lt 20 N m connect the sensor electrically during the assembly and observe the signal the measurement signal may not exceed the limit values 4 2 1 Torque Sensors below 20 N m E Sensors with nominal torques below 20 N m are very sensitive to overload therefore these sensors need to be handled with greatest caution 1 Connect the sensor electrically during the assembly and observe the measuring signal the limit values may not be exceeded in any case 2 Align the arrangement before the parts are connected firmly 3 Assemble the sensor at the low torque resistance side first then at the stationary side this avoids impermissibly large torques from acting on the sensor 4 QCounter hold by hand so that impermissibly large torques or disturbance variables can not act on the torque sensor 4 2 2 T
6. Dangers The plant designer the supplier as well as the operator must plan realize and take responsibility for safety related interests for the sensor Remaining dangers must be minimized Remaining dangers of the torque measurement technique must be pointed out Human mistakes must be considered The construction of the plant must be suitable for the avoidance of dangers A danger analysis for the plant must be carried out 1 4 Reconstructions and Modifications Each modification of the sensors without our written approval excludes liability on our part 1 5 Personnel The installation assembly commissioning operation and the disassembly must be carried out by qualified personnel only The personnel must have the knowledge and make use of the legal regulations and safety instructions 1 6 Warning Notes Attention must be paid to the accident prevention regulations of the trade associations Coverings and casings are necessary before operating the sensor This is also valid for commissioning maintenance and trouble shooting Duties of the coverings and casings are Protection from detaching parts Protection from contusion and shear Prevention from reaching rotating parts Prevention from being tangled up and or getting caught by parts Coverings may Not grind Not rotate Coverings are also necessary outside of operating and motion travel areas of persons These demands can be modified if other sufficient safety devices ar
7. Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 7 of 11 LORENZ MESSTECHNIK GmbH 9 55 Ea wre 4 4 Foot Version Assembly The sensor can be installed as a bearing block A double jointed coupling must be mounted on each shaft end By this inevitable axis offsets which can also appear during the period of operation are being balanced If no couplings are used very large transverse forces can occur in the bearings of the sensor as well as in the bearings on drive and output which will limit their life span very strongly Further large bending moments will emerge in the shaft At small torques 20 N m connect the sensor electrically and observe the signal the measurement signal may not exceed the limit values Shafts must be cleaned with solvent e g acetone before the assembly No foreign particles may adhere to them Shift couplings on shafts use entire clamping length of the coupling and align shafts Absolutely assure that the data of the couplings axis offset angular offset tension compression are not exceeded Torque sensor Drive Double jointed coupling Double jointed coupling Output 5 Electrical Connection 5 1 Pin Connection Also see test certificate The firmly connected cable has free ends Excitation GND OV Excitation 12 28 VDC Signal 5 V 10 V Signal GND OV 5 2 Cable Only use a shielded cable with preferably small capa
8. city We recommend measuring cables from our product range They have been tested in combination with our sensors and meet the metrological requirements 5 3 Shielding Connection In combination with the sensor and the external electronics the shield forms a Faraday Cage By this electro magnetic disturbances do not have any influence on the measurement signal 5 4 Running of Measuring Cables Do not run measuring cables together with control or heavy current cables Always assure that a large distance is kept to engines transformers and contactors because their stray fields can lead to interferences of the measuring signals If troubles occur through the measuring cable we recommend to run the cable in a grounded steel conduit E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 8 of 11 B LORENZ MESSTECHNIK GmbH xax Fax 07172 99700 22 6 Measuring 6 1 Engaging The warming up period of the torque sensor is approx 5 min Afterwards the measurement can be started CE The warming up period of the torque sensor is approx 5 min 6 2 Direction of Torque Torque means clockwise or clockwise torque if the torque acts clockwise when facing the shaft end In this case a positive electrical signal is obtained at the output Torque sensors by Lorenz Messtechnik GmbH can measure both clockwise and counter clockwise direction 6 3 Static Quasi Static Torques otatic and o
9. e available During operation the safety precautions must be operative By vibrations damages can occur at the device E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 4 of 11 B LORENZ MESSTECHNIK GmbH Vx aet pax 07172 873022 2 Term Definitions 2 1 Terms Measuring Side Mechanical connection of the torque sensor in which the torque to be measured is applied Usually this side has the smallest moment of inertia Drive Side Mechanical connection of the torque sensor on the opposite side of the measuring side usually with the largest moment of inertia At static torque sensors the housing is fastened on this side Low Torque Resistance Side The shaft of the arrangement drive load which can be turned considerably smaller with torque than the nominal torque of the torque sensor M lt lt Mnenn 2 2 Definition of the Pictograms on the Torque Sensor The measuring side of the torque sensor is designated as follows Measuring side C3 or M e More information can be found on the data sheet if needed 3 Product Description The sensor measures static and dynamic torques The mounting position of the torque sensor is horizontally Caution it is to be differentiated between measuring side and drive side see data sheet of the sensor http www lorenz sensors com 3 1 Mechanical Setup The sensors consist of a torsion shaft with free round shaft ends The tors
10. eeeeeeeeesseeeeecesesseeeeseeeeeeesseeeaeeeeeeseessaeeas 4 1 3 2 Remaining Dangers ssssssssssssssssesseeeeee nennen nnne nnne nnn nennen nnns nennen earn nsa nnns 4 1 4 Reconstructions and Modifications eeeesessssesssissssseseeeeeeen nennen nnne nnn nnn 4 088 7 010 t 4 1 6 Warning BUICK 4 2 Term Definitions 2 0 eee ccc eeeccccseccceeeeeceeeeeseeecsaeeseucecsaueeseaeeecaueeesaeeesaeessaeeeseaeeesaeeeseueeesageeessaeeessaeeesaaees 5 idee ene eee ee eee eee eee ee 5 2 2 Definition of the Pictograms on the Torque Sensor ccccccccecceeseeeecseeeeeeeseaeeeceeesaeaeeeeeseaaaeeeees 5 S POUC IG SG HOU OI ee E E E A eamecetumnancaas 5 al Mecane ao G TERT 5 e Feic o e eee Lm 6 4 Mechanical Assembly sssrinin Ea aT aE REE E EiS 6 Al a OODI e EE A NE E ENE EE 6 4 1 1 Misalignment Possibilities of Single Jointed Couplings sseeeeeeeeesssssss 6 4 1 2 Double Jointed Couplings sessi nnn nnne nnn nnns n nnns 6 4 1 3 Alignment of the Measurement ArrangeMment ccccccseeeeeceeseeeeeeeeeeseeseeesaeeeeeeeeeeeesaaneesens 6 2288 t E E A 6 4 2 1 Torque Sensors below 20 Nm ssssssssssssssesseenn nennen nnne nnn nnns nnna rnnt na annees 7 4 2 2 Torque Sensors from 20 N m and above sssssssessssssssessennnn nennen nennen nnn nnns nnn 7 ZO Ir FCCHOAUIIMOM ASS SIMON M n
11. ences see coupling manual 4 2 General Page 6 S Before the assembly shafts must be cleaned with dissolver e g acetone no foreign particles may adhere to them The hub must fit corresponding to the connection E During the assembly the sensor must be supported to protect if from falling down m Caution During the assembly inadmissibly large forces may not act on the sensor or the couplings 4 2 1 Torque Sensors below 20 N m Page 7 Sensors with nominal torques below 20 N m are very sensitive to overload therefore these sensors need to be handled with greatest caution 4 3 Freefloating Assembly Page 7 In this installation case double jointed couplings can not be used for both sides Risk of Breakage 6 1 Engaging Page 9 L Warming up period of the torque sensor is approx 5 min 6 4 2 Natural Resonances Page 10 An operation of the device in natural resonance can lead to permanent damages E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 2 of 11 LORENZ MESSTECHNIK GmbH 72 5 VAR Contents De Se e 4 1 1 Safety and Caution SYMbOIS cccccccccssseseeeceeeeeceaeeeeeeeeeeeeeseeesseeceeeeeeseeeeseeeeeessseeeaeeeeeeeeesssaaaeess 4 Te ended USE eee ee ee ee eee ee ee ee 4 Mise DNO S E 4 1 3 1 Neglecting of Safety Notes cccccccccscssssseseeeeeeeeeaeee
12. h levers The torque sensor must be supported to avoid falling down during the dismantling 9 Transportation and Storage The transportation of the sensors must occur in suitable packing For smaller sensors stable cartons which are well padded are sufficient e g air cushion film epoxy crisps paper shavings The sensor should be tidily packed into film so that no packing material can reach into the sensor ball bearings Larger sensors should be packed in cases E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 10 of 11 LORENZ MESSTECHNIK GmbH 75 5 Exams 9 1 Transportation Only release well packed sensors for transportation The sensor should not be able to move back and forth in the packing The sensors must be protected from moisture Only use suitable means of transportation 9 2 Storage The storage of the sensors must occur in dry dust free rooms only Slightly lubricate shafts and flanges with oil before storing rust 10 Disposal The torque sensors must be disposed according to the valid provisions of law For this see our General Terms and Conditions www lorenz sensors com 11 Calibration At the time of delivery torque sensors have been adjusted and tested with traceable calibrated measuring equipment at factory side Optionally a calibration of the sensors can be carried out 11 1 Proprietary Calibration Acquisition of measurement poi
13. ion shaft applied with two strain gauge full bridges is bedded in a housing through ball bearings For the signal transmission and or the supply of the strain gauge full bridges a rotating transformer according to the principle of a transformer is arranged in the sensor For supply and measuring signal conditioning electronics are integrated in the stator and the rotor Cable connection Electronics in the stator EJ SNANNAAN SALSAS Drive side DAN O Meas side es oe VIILZLLAZLMLLLLLLLLLLLLLXLLL LD Rot transformer with electronics SG E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 5 of 11 LORENZ MESSTECHNIK GmbH 72 5 Exams 3 2 X Electrical Setup The electronics integrated in the sensor consists of two parts The first part is in the stator and has following tasks Stabilization of the supply voltage Electric supply of the rotor electronics through the rotating transformer Preparation of the measurement signal from the rotor Readout of the torque measurement signal to the cable connection The second part of the electronics is placed in the rotor of the torque sensor and has following functions Supply of the SG full bridge with d c voltage Preparation of the electrical torque measurement signal Transmission of the measurement signal to the stator 4 Mechanical Assembly For the assembly of a torque sensor in a shaft line we alwa
14. nts and issuing of a calibration protocol Traceable calibrated measuring equipment is being used for the calibration The sensor data are being checked during this calibration 11 2 DKD Calibration The calibration of the sensor is carried out according to the guidelines of the DKD The surveillance of the calibrating laboratory takes place by the DKD At this calibration the uncertainty of measurement of the torque measuring instrument is determined Further information can be obtained from Lorenz Messtechnik GmbH 11 3 Re Calibration The recalibration of the torque sensor should be carried out after 26 months at the latest Shorter intervals are appropriate e Overload of the sensor After repair After inappropriate handling Demand of high quality standards Special traceability requirements 12 Data Sheet See www lorenz sensors com 13 Literature Dubbel Taschenbuch f r den Maschinenbau Springer Verlag E Mail info lorenz sensors com Technical changes reserved 090234c doc Internet www lorenz sensors com Page 11 of 11
15. orque Sensors from 20 N m and above The hub must fit corresponding to the connection 4 3 Freefloating Assembly The sensor is installed between two single jointed couplings and contributes to the balance of an inevitable axis offset between the two mechanical connections If no couplings are used very large transverse forces can affect the sensor In addition large forces occur on the bearings in drive and output which limit their life span very strongly Shafts must be cleaned with solvent e g acetone before the assembly No foreign particles may adhere to them Shift couplings on shafts use entire clamping length of the coupling and align shafts Absolutely assure that the data of the couplings axis offset angular offset tension compression are not exceeded The housing must be protected from twisting e g by a flexible connection The cable connection may not be used for this The cable connection must be placed loosely form of goose neck so that it can follow the light movements of the stator Torque sensor Drive Single jointed coupling Single jointed coupling Output Jf Flexible connection for Cable connection housing fixation In this case with both single jointed couplings the torque sensor forms a double jointed coupling A single jointed coupling can only balance axial and angular misalignments In this installation case double jointed couplings can not be used for both sides Risk of Breakage E
16. r quasi static torque is a slowly changing torque The calibration of the sensors occurs statically on a calibration device The applied torque may accept any value up to the nominal torque 6 4 Dynamic Torques 6 4 1 General The static calibration procedure of torque sensors is also valid for dynamic applications Note The frequency of torques must be smaller than the natural frequency of the mechanical measurement setup The band width of alternating torque must be limited to 70 96 of the nominal torque 6 4 2 Natural Resonances Estimate of the mechanical natural frequencies C fo Natural Frequency in Hz J4 Jo Moment of Inertia in kg m J C Torsional Rigidity in Nm rad J Further methods for the calculation of natural resonances are corresponding purchasable programs or books e g Holzer Procedure Dubbel Taschenbuch f r den Maschinenbau Springer Verlag L An operation of the device in natural resonance can lead to permanent damages 6 5 Speed Limits The maximum speed indicated in the data sheet may not be exceeded in any operating state 6 6 Disturbance Variables By disturbances measured value falsifications can occur by e Vibrations Temperature gradients Temperature changes Arising disturbance variables during operation e g imbalance Electrical disturbances Magnetic disturbances e EMC electromagnetic disturbances Therefore avoid these disturbance variables by decoupling of vibrations covers etc
17. ys recommend to use couplings which can be misaligned 4 4 Couplings We recommend multi disc couplings for our torque sensors Couplings must be able to balance an axial radial or angular offset of the shafts and not allow large forces to act on the sensor The assembly instructions of the respective coupling manufacturer must be considered 4 1 1 Misalignment Possibilities of Single Jointed Couplings u mad C oti Angular Misalignments Axial Misalignments Note Radial misalignments are only possible in the combination of single jointed coupling torque sensor as adapter single jointed coupling Thus with both single jointed couplings the torque sensor forms a double jointed coupling Radial Misalignments 4 1 2 Double Jointed Couplings Double jointed couplings are used for the balance of inevitable angular axial and radial misalignments 4 1 3 Alignment of the Measurement Arrangement Precisely alignment of the couplings reduces the reaction forces and increases the durability of the couplings Disturbance variables are minimized as well Due to the multitude of applications an alignment of the coupling with a straight edge in two levels vertical to each other is sufficient However in drives with high speed an alignment of the coupling shaft ends with a dial gauge or a laser is recommended For further references see coupling manual 4 2 General Ss Before the assembly shafts must be cleaned with dissolver e
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