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Binsfeld TorqueTrak 10K-LP, User Manual

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Binsfeld TorqueTrak 10K-LP User Manual Download Page 31

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Appendix B: Calibration Calculations 

 
The equations in this Appendix define the relationship between the 
input signal to the TX10K Transmitter (typically from a strain gage) 
and the Full Scale output voltage of the TorqueTrak 10K System.  
The calculations are based on parameters of the device being 
measured (e.g. shaft diameter), sensor parameters (e.g. gage 
factor) and Transmitter Gain setting. 
 
Section B1 is specific to torque measurements on round shafts 
(full bridge, 4 active arms). 
 
Section B2 applies to axial strain (tension/compression) 
measurements on round shafts (full bridge, 2.6 active arms). 
 
Section B3 is for use with a single grid (1/4 bridge). 
 
1  µe  is  distortion  of  the  shaft  surface  1  x  10

-6

  in/in.    For  more 

technical  information  regarding  the  relationship  between  shear 
strain  and  torque,  see  the  excellent  technical  article 

TN-512 

published by Vishay

. 

Summary of Contents for TorqueTrak 10K-LP

Page 1: ...TorqueTrak 10K LP Torque Telemetry System User s Guide 869501 9_F ...

Page 2: ......

Page 3: ...12 Figure 4 RM10K Remote Control 13 Product Safety 16 Installation Procedure 16 Field Testing 17 Bench Testing 19 Calibration 21 Warranty and Service Information 22 FCC Rules Part 15 Computing Devices 23 Appendix A TorqueTrak 10K Specifications 24 Appendix B Calibration Calculations 29 B1 Torque on Round Shafts 30 B2 Axial Strain on Round Shafts 35 B3 Single Grid 1 4 Bridge 37 Appendix C Error Cod...

Page 4: ...nique simulated transmitter inputs Simple keypad and LCD display for easy user interface TX10K Transmitter High signal to noise ratio for excellent resolution Low temperature coefficient for accuracy from 25 to 85 C Wide power supply input range from 6 to 25VDC Power Standby mode to extend battery life Two on board shunt calibration values Status Indicator light to assist in troubleshooting Circui...

Page 5: ...na Magnetic Base with 25ft Cable RM10K Remote Control 110VAC 12VDC or 220VAC 12VDC Wall Plug Transformer 5 ft DB9 Cable 10 ft 4 Conductor Ribbon Cable BS900 Bridge Simulator Screwdriver 9V Battery Connector 9V Lithium Batteries 2 1 Roll of 1 Fiberglass Reinforced Strapping Tape Butyl Rubber Sheet Teflon Film kit TT10K LP User s Guide TT10K Equipment Case Calibration Certificate ...

Page 6: ...he left and in graphical form on the right Figure 1 The numeric value corresponds to the Voltage Output signal in millivolts For example an output signal of 8 450V would be displayed as 08450 The bar graph provides a visual representation of the output signal level Each position on the bar graph represents approximately 2V Both the numerical and graphical indicators are averages of the received si...

Page 7: ...e Power Input Voltage Output and Com digital output share a common or ground connection Specifically the outside ring of the Power Input the jack of the Voltage Output and pin 5 of the Com output are all internally connected Care must be taken in connecting the RX10K to external components in order to eliminate ground loop problems Such ground loop currents can cause errors in the output signals a...

Page 8: ...hannels and their corresponding frequencies Along with the channel selection value a bar graph indicating the relative RF signal strength being received is displayed The more units the better the signal strength ten is maximum Input The Input parameter allows the user to simulate certain inputs from the TX10K These can be used to check the operation and settings of the RX10K even without a transmi...

Page 9: ...On the existing input from the TX10K becomes the input zero Before adjusting the Gain apply the AutoZero to the input signal In this way the zero 0V output will not change when the Gain setting is adjusted When the AutoZero is off Input AutoZero Off no offset correction is applied to the output signal To turn the AutoZero On press and hold the ADJUST key for 2 seconds To turn the AutoZero Off pres...

Page 10: ... Gain is set based on the microstrain e range expected during a given test see table below strain values assume a Gage Factor of 2 0 Transmitter Gain Setting Full Scale Strain Full Bridge e 500 4000 1000 2000 2000 1000 4000 500 8000 250 16000 125 Full Scale Strain corresponds to a display reading of 10000 an analog Voltage Output value of 10 VDC and a digital data output of 10000 The System Gain c...

Page 11: ... anywhere within the output range This adjustment affects the display output the Voltage Output signal and the digital RS 232 output signal The Output Offset value is applied to the signal after the Gain adjustment therefore the Gain adjustment may affect the zero output signal User Default The RX10K parameters can be returned to their default settings Holding down the ADJUST key while powering up...

Page 12: ... Apply Gain 8 Apply Output Offset 9 Send signal to display voltage output and digital output TX10K LP S Transmitter The TX10K LP S Transmitter is encased in a small rugged potted plastic housing The TX10K LP S also features a Status Indicator light an Infrared Receiver lens and a screw terminal block for making power and sensor input connections Figure 3 TX10K LP S Transmitter Infrared Receiver St...

Page 13: ...ndicator Light When the TX10K is powered up and done initializing it is in normal operating mode transmitting actual data from the sensor and the Status Indicator is on solid An error is indicated when the light is flashing flickering or off as described below Indication TX10K Status Off continuously No power applied power polarity is reversed battery is dead or the transmitter is in Standby mode ...

Page 14: ...ge to the transmitter can occur if operated outside its specified power input voltage range RM10K Remote Control The handheld RM10K Remote Control allows the user to configure the TX10K Transmitter even while it is installed The RM10K keypad operates similar to a common TV remote control emitting an infrared signal through the window on the front of the unit Simply point the RM10K at the Infrared ...

Page 15: ...lity of inadvertently changing the configuration of the TX10K by accidentally pressing a key on the RM10K It also reduces the chance of changing the configuration of other transmitters in a multiple transmitter installation The RM10K also has a high infrared power mode This mode is useful when access to the TX10K is difficult or dangerous Line of sight distances of 10 feet 3 meters or more are fea...

Page 16: ...porarily enables high infrared power mode TRANSMITTER STANDBY Switches the TX10K into a low power Standby mode to conserve the battery No signal is transmitted while in Standby mode The Status Indicator light on the TX10K turns off The TX10K ignores all commands from the RM10K except TRANSMITTER ON Disconnecting and reconnecting the 9V battery or activating TRANSMITTER ON brings the TX10K out of S...

Page 17: ...the Status Indicator on the TX10K will flash only once indicating the command was received but not carried out SENDING Light The SENDING light will come on for about 1 second when a key is pressed This indicates the RM10K is sending a signal It is not an indication that the TX10K has received the signal The Status Indicator on the TX10K or the display on the RX10K can be monitored to confirm succe...

Page 18: ...ts are strapped to a rotating shaft If sufficient care is not taken to properly secure these components or accessories connected to them they can be flung from the shaft causing damage to the components or to property or persons in the vicinity Use more than enough tape 10 or more wraps is not too much Installation Procedure The TorqueTrak 10K System is designed for ease of use The procedure for a...

Page 19: ...e the components to the shaft The open end of the tape should follow shaft rotation For extra protection glue the end of the tape down When finished with your testing cut the tape and remove the components Avoid the risk of being struck by an improperly secured object flung from the machine by standing clear during operation NOTE 1 This method of securing the transmitter and battery holder is for ...

Page 20: ...ip the RX10K power switch to On while holding down the ADJUST key NOTE This resets the RX10K parameters to their default settings Simply turn On without holding any keys if previously set parameter configurations are desired 7 Turn on the TX10K with the RM10K if needed Confirm that Status Indicator light is on solid Slowly scroll through each RX10K channel until it matches TX10K channel setting to...

Page 21: ...RX10K display to Gain parameter screen Set the System Gain to scale and or calibrate output based on calculations as demonstrated in Appendix B Check calibration by using the RM10K to command the TX10K to transmit REFERENCE 1 and or 2 to the RX10K 12 Connect appropriate recording device to either the analog Voltage Output terminals or digital Com DB9 connector Check the zero and adjust using the O...

Page 22: ...toZero parameter screen Apply AutoZero with BS900 in center or zero 0 position Press and hold ADJUST key for 2 seconds until bottom line reads Input AutoZero On 7 Switch BS900 to the positive position RX10K output should be close to 2V 02000 and the bar graph indicator should move one segment to the right of zero 0 8 Switch BS900 to the negative position RX10K output should be close to 2V 02000 an...

Page 23: ... source i e wall socket Flip the RX10K power switch to On while holding down the ADJUST key 2 Allow the RX10K to warm up for 15 minutes 3 Connect a calibrated high accuracy voltmeter to the Voltage Output terminals 4 Scroll RX10K display to Input parameter screen Press the ADJUST key to scroll through the simulated inputs and check the outputs Input Output FS 10 000 010 VDC Zero 0 000 005 VDC FS 1...

Page 24: ...or abnormal conditions of operation or handling This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to any implied warranty of merchantability or fitness for a particular purpose or use Binsfeld Engineering Inc will not be liable for any special indirect incidental or consequential damages or loss whether in contract tort or otherwise NOTE ...

Page 25: ...ful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications The user is cautioned that changes and modifications made to the equipment without the express approval of the manufacturer could void the user s authority to oper...

Page 26: ...efficient2 0 004 R C max 0 85 C amb Shunt resistor Reference 1 437400Ω 0 1 25 ppm C Shunt resistor Reference 2 87370Ω 0 1 25 ppm C Simulated torque strain 350Ω bridge GF 2 0 Shunt resistor Ref 1 100 microstrain e Shunt resistor Ref 2 500 microstrain e G force 2000 G s max continuous Operating temperature range 30 to 85 C 22 to 185 F Dimensions 0 64 x 1 02 x 2 01 16 mm x 26 mm x 51 mm Weight 1 1 oz...

Page 27: ...6 Active Arms TX10K Gain Setting Full Scale Strain e Full Scale Input mV System Gain V V Min 0 25x Nom Max 4 0x 500 6154 20 125 500 2000 1000 3077 10 250 1000 4000 2000 1538 5 500 2000 8000 4000 769 2 5 1000 4000 16000 8000 385 1 25 2000 8000 32000 16000 192 0 625 4000 16000 64000 Sensor Input Range Bridge 1 Active Arm TX10K Gain Setting Full Scale Strain e Full Scale Input mV System Gain V V Min ...

Page 28: ...iver Analog voltage output signal Nominal range 10 V Maximum range 12 V Analog output connection 5 way binding posts Analog output impedance 50Ω System Gain adjustment 0 25 to 4 0 x Transmitter Gain Offset adjustment 10 V Display 2 line x 20 character high contrast LCD w backlight Power input 10 to 18 VDC 300mA max 110 or 220VAC adapter included Antenna input connection SMA Power input connector 2...

Page 29: ...ection 6 7 8 9 PC COM Port Settings Bits per second 115200 Data bits 8 Parity none Stop bits 1 Flow control none Sample Protocol The output sample rate is 2400 samples per second There are 4 bytes sent for each sample 1 Start byte ASCII SOH code hex 01 2 Sample data low byte 3 Sample data high byte 4 Stop byte ASCII CR code hex 0D The sample data is sent as a 16 bit signed integer Dout Vin x Asys ...

Page 30: ...drift2 0 005 FS C max 0 70 C RF Channel Frequencies Table RF Channel Frequency MHz RF Channel Frequency MHz 1 902 62 9 914 62 2 904 12 10 916 12 3 905 62 11 917 62 4 907 12 12 919 12 5 908 62 13 920 62 6 910 12 14 922 12 7 911 62 15 923 62 8 913 12 16 925 12 Note For best performance use Channels 1 8 when operating at high temperatures NOTES All specifications subject to change 1 Measured with 350...

Page 31: ...er sensor parameters e g gage factor and Transmitter Gain setting Section B1 is specific to torque measurements on round shafts full bridge 4 active arms Section B2 applies to axial strain tension compression measurements on round shafts full bridge 2 6 active arms Section B3 is for use with a single grid 1 4 bridge 1 µe is distortion of the shaft surface 1 x 10 6 in in For more technical informat...

Page 32: ...ral equation is Where E 206 8 x 103 N mm2 Legend of Terms Di Shaft Inner Diameter in zero for solid shafts Do Shaft Outer Diameter in E Modulus of Elasticity 30 x 106 PSI steel GF Gage Factor specified on strain gage package GXMT Telemetry Transmitter Gain user configurable typical is 4000 for 500 microstrain range N Number of Active Gages 4 for torque TFS Full Scale Torque ft lb TXconst Transmitt...

Page 33: ...490 1 ft lb volt Step 2 Scale the Full Scale Output If desired the Full Scale voltage output of the TX10K can be scaled so that it corresponds to a convenient torque value e g 100 ft lb volt As stated earlier the System Gain can be adjusted from to 4 times the Transmitter Gain The equation below defines the Scale Factor Z Legend of Terms Z Scale Factor 0 25 to 4 0 TFS Full Scale Torque ft lb TREF ...

Page 34: ...ays to perform a calibration of the installation a deadweight calibration or shunt calibration Deadweight Calibration The most precise method is to perform a deadweight calibration This involves suspending a known mass a known horizontal distance from the center of the shaft This is not always practical but does take into account all possible deviation in the system actual material properties vers...

Page 35: ...mulates 500 µe when using a 350Ω strain gage with a Gage Factor of 2 0 Alternatively precision resistors can be placed in parallel with one arm of the bridge to simulate a torque load The Tech Info section on our website www binsfeld com has a helpful Torque Strain Calculator to assist in determining the strain a given resistor value simulates The equation relating strain and shunt resistance is s...

Page 36: ...e output matches this value The adjustment is typically small 0 5 The system is now ready to measure torque with the desired output scaling NOTE When the Gage Factor is not 2 0 the actual Full Scale Strain and Simulated Strain values are affected proportionately In the example above with a Gage Factor of 2 08 Full Scale Strain is technically 480 7 µe not 500 However the Simulated Strain is likewis...

Page 37: ...meter in zero for solid shafts Do Shaft Outer Diameter in E Modulus of Elasticity 30 x 106 PSI steel GF Gage Factor specified on strain gage package GXMT Telemetry Transmitter Gain user configurable typical is 4000 for 770 microstrain range PFS Full Scale Force tension or compression lb TXconst Transmitter constant 2 5 volts VFS Full Scale Output of System 10 volts Poisson s Ratio 0 30 for steel V...

Page 38: ...ed 2 25 inches GF Gage Factor from gage package 2 045 GXMT TX10K Gain setting 4000 145 x 106 lb in2 2 25 in 2 PFS 89 739 lb 2 045 4000 so 10 V output from the RX10K indicates 89 739 lb of force or 8974 lb volt For information on output scaling and calibration see section B1 ...

Page 39: ...ified on strain gage package GXMT Telemetry Transmitter Gain user configurable typical is 4000 for 2000 microstrain range TXconst Transmitter constant 2 5 volts VFS Full Scale Output of System 10 volts Example GF gage factor from gage package 2 045 GXMT TX10K gain setting 4000 16 FS 1956 x 10 6 inches inch 2 045 4000 so 10 V output from the RX10K indicates 1956 microstrain or 196 microstrain volt ...

Page 40: ... The output signal of the RX10K is greater than the maximum level Tx Rx Data Error The signal from the TX10K is not being received properly by the RX10K NOTE The output signals of the RX10K will go to negative full scale 12000mV Tx Power Low Error The power supply voltage level of the TX10K is too low Tx Power High Error The power supply voltage level of the TX10K is too high Rx Power Low Error Th...

Page 41: ...e use a clean area of the tissue to eliminate contamination 3 Rinse shaft this time by squirting with M Prep Neutralizer 5A Wipe the gaging area dry with a clean tissue wiping in only one direction and using clean area of tissue with each wipe Do not allow any solution to dry on the surface as this may leave a contaminating film which can reduce bonding Surface is now prepared for bonding MARKING ...

Page 42: ...age attached to the tape POSITIONING THE GAGE 6 Using the small triangles located on the four sides of the gage place the taped gage on the shaft perpendicular with the shaft axis aligned with your guide marks If it appears to be misaligned lift one end of tape at a shallow angle until the assembly is free to realign Keep one end of the tape firmly anchored Repositioning can be done as the PCT 2M ...

Page 43: ...idity NOTE The next three steps must be completed in sequence within 3 5 seconds Read through instructions before proceeding so there will be no delays Have Ready M Bond Cyanoacrylate Adhesive 2 5 piece of teflon tape Tissues MOUNTING THE GAGE 9 Lift the leading edge of the tape and apply a thin bead of adhesive at the gage end where the tape meets the shaft Adhesive should be of thin consistency ...

Page 44: ... with a solder dot It is helpful to polish the solder tabs e g with a fiberglass scratch brush or mild abrasive before soldering Trim and tin the ends of the 4 conductor ribbon wire Solder the lead wires to the gage by placing the tinned lead onto the solder dot and pressing it down with the hot soldering iron Note For single stamp torque gages a short jumper is required between solder pads 2 and ...

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