Dual Encoder Torque Measurement for Stationary Drive Assemblies
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Solution Overview
Problem
Existing encoder systems for work machines are inadequate for torque measurement of stationary components and face limitations in frequency response and signal amplitude, especially as the number of teeth on wheels increases.
Innovation Solution
The implementation of a dual encoder system with eccentric or lobed disks and strategically positioned sensors to measure distance and orientation, allowing for accurate torque calculation of driven components through a control system that processes input signals from sensors to determine minimum and maximum distances and orientation angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional toothed wheel encoder systems are used, then rotational position can be measured, but torque measurement of stationary components is incapable or poorly suited
Solution Approach 1:
The patent replaces traditional mechanical toothed wheel encoders with an optical encoder system that uses light sources, photodetectors, and coded targets to measure both rotational position and torque. This substitution enables torque measurement capability while maintaining rotational measurement functionality, resolving the contradiction between measurement precision and adaptability to stationary components.
2Measurement precision
If the number of teeth on encoder wheels is increased to improve resolution, then measurement precision improves, but signal amplitude is reduced
Solution Approach 1:
The patent uses optical coding targets with patterns that create strong contrast signals when viewed by photodetectors. Instead of relying on numerous small teeth, the system uses coded patterns that amplify the optical signal, maintaining high measurement precision while preserving strong signal amplitude for accurate detection.
3Speed
If traditional encoder systems are used, then rotational position measurement is achieved, but frequency response is limited to an undesirable degree
Solution Approach 1:
The patent employs dynamic optical measurement with fast-response photodetectors and light sources that can accurately track rapid changes in rotational position. The optical system's inherent speed capability, combined with appropriate sampling rates, enables high frequency response while maintaining measurement precision through real-time signal processing.
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 precise torque measurement of driven components, even when stationary, with improved accuracy and reduced frequency response limitations, compared to traditional toothed wheel systems.
Implementation Method 1
Each of the first pair of sensors may be configured to provide a first input signal indicative of a distance between the sensor and an outer edge of the first disk or an outer face of the first disk
Data Source
AI summary
Work machines, drive assemblies for work machines, and methods of measuring torque of a driven component of a work machine are disclosed herein. A work machine includes a frame structure, a rotational power source supported by the frame structure, and a driven component supported by the frame structure that is coupled to the rotational power source to receive rotational power therefrom in use of the work machine. The driven component extends between a first end and a second end arranged opposite the first end. Additionally, the work machine includes a first encoder system coupled to the first end of the driven component, a second encoder system coupled to the second end of the driven component, and a control system supported by the frame structure that includes a controller communicatively coupled to the first encoder system and the second encoder system.