Driveshaft Torque and Speed Sensor With Integrated Battery
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Solution Overview
Problem
Existing torque and angular velocity measurement systems for driveshafts lack integration with electronic data collection systems, are not suitable for field tests, and require external mounting, which can damage the shaft and cause balance issues.
Innovation Solution
A compact, detachable sensor design with a protective container and integrated battery that wirelessly transmits data, allowing assembly without altering the driveshaft design, and includes a strain gauge for torque measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external mounting systems are used for torque measurement, then measurement capability is provided, but the shaft integrity is damaged and balance issues occur
Solution Approach 1:
The sensor system is integrated directly into the driveshaft structure, merging the measurement function with the shaft itself. The strain gauges are mounted on the shaft surface and electrically connected through the shaft material, eliminating the need for external mounting hardware that would cause balance issues and potential damage.
Solution Approach 2:
The driveshaft structure serves multiple functions: it transmits mechanical power and simultaneously acts as the mounting substrate for the sensor system. The shaft's own structural elements are utilized for sensor attachment and electrical connection, making the shaft itself a multi-functional component.
2Measurement precision
If integrated sensor systems are implemented, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The sensor system is divided into distinct functional modules: strain gauge elements for torque measurement, separate angular velocity sensors, signal conditioning circuits, and wireless communication components. This segmentation allows each module to be optimized independently while simplifying the overall integration process.
Solution Approach 2:
Signal conditioning circuits and wireless communication modules act as intermediaries between the physical measurement elements (strain gauges, angular velocity sensors) and the data collection system. These intermediary components simplify the interface requirements and reduce the complexity of direct integration with external systems.
3Reliability
If protective sealing is added to protect electronics from harsh conditions, then reliability under harsh conditions improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The electronic components and sensor elements are nested within a hierarchical sealing structure. The strain gauges and sensors are mounted on the shaft surface, followed by a first sealing layer, then electronic components are added, and finally an outer protective housing provides additional sealing. This nested arrangement protects electronics from harsh conditions while maintaining a systematic assembly process.
4Productivity
If wireless data transmission is implemented, then uninterrupted data collection in field conditions is enabled, but energy consumption increases
Solution Approach 1:
The wireless data transmission operates periodically rather than continuously. Data is collected by the strain gauges and angular velocity sensors, then transmitted wirelessly at scheduled intervals to the data collection system. This periodic transmission mode enables uninterrupted field data collection while significantly reducing battery energy consumption compared to continuous transmission.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables uninterrupted data collection under harsh conditions, maintains shaft integrity, and prevents balance issues during high-speed operations.
Implementation Method 1
The torque measuring element (12) (strain gauge) is located on the carrier body (9)
Implementation Method 2
at least a magnet and at least a hall sensor, wherein one of said magnet and hall sensor is connected onto either the rotating elements of the driveshaft and the other to a fixed point
Data Source
Figure 1~2
Figure 3
AI summary
A torque and angular velocity sensor (20) for use in measuring torque and angular velocity in driveshafts (30), characterized by comprising a carrier body (9) which enables assembly of the torque and angular velocity sensor (20) to the driveshaft (30), a circuit (11) which measures angular velocity and torque, a protective container (6) which is glued (2) to the carrier body (9) to protect the circuit (11) from external effects, and a battery referencing (4) to position the battery (5) and the circuit (11) in the protective container (6).