Gearbox Torque Sensing With a Load Cell Brake Linkage
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Solution Overview
Problem
Existing systems for measuring torque in gear drive trains are complex, expensive, and difficult to maintain, as they often rely on hydraulic fluid pressure measurements or intricate mechanisms like ball-and-seat arrangements, which are not cost-effective or practical for real-world applications.
Innovation Solution
A gearbox torque sensor is implemented with a load cell positioned between the gearbox cover and brake assembly to prevent rotation, allowing for the measurement of input torque when the brake is disengaged and output torque when engaged, using various load cell types such as compression, tension, or S-beam load cells connected via linkages to accurately calculate torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hydraulic fluid pressure measurement is used to approximate drive train torque, then torque measurement capability is provided, but measurement precision is insufficient and device complexity increases
Solution Approach 1:
The patent extracts the torque measurement function from complex hydraulic pressure measurement systems and implements it directly through a load cell mounted on the brake assembly. The load cell directly measures the force applied to the brake, which corresponds to torque, eliminating the need for hydraulic pressure approximation and providing both higher precision and simpler implementation
Solution Approach 2:
The patent replaces the hydraulic fluid pressure measurement system with a direct mechanical load cell measurement system. The load cell mechanically measures the force on the brake assembly, providing accurate torque data without requiring hydraulic pressure transducers, fluid dynamics calculations, or complex calibration procedures
2Measurement precision
If ball-and-seat arrangement mechanisms are used to measure torque, then torque measurement is achieved, but ease of manufacture deteriorates and maintenance difficulty increases
Solution Approach 1:
The patent removes the complex ball-and-seat mechanical mechanism entirely and replaces it with a load cell that directly measures brake assembly force. This extraction eliminates numerous moving parts, precision-machined surfaces, and assembly steps while maintaining accurate torque measurement capability
Solution Approach 2:
The load cell is a relatively simple, inexpensive component compared to precision ball-and-seat mechanisms. While load cells have limited life due to fatigue, their simplicity makes them easier to manufacture and replace than complex mechanical measurement systems, improving overall ease of manufacture and maintenance
3Measurement precision
If brake assembly is allowed to rotate freely, then operational functionality is maintained, but torque measurement capability is lost
Solution Approach 1:
The load cell serves as an intermediary element between the brake assembly and the fixed mounting structure. It allows the brake assembly to rotate and apply braking force while simultaneously measuring the force applied, without restricting the operational rotation needed for normal brake function
Solution Approach 2:
The load cell measures the force parameter (which corresponds to torque) while allowing the brake assembly to maintain its rotational degree of freedom. The measurement is obtained from the force applied during rotation without constraining the rotation itself, changing from a position-constraining measurement to a force-measurement approach
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
This solution provides a simple, affordable, and effective method to measure torque in gear drive trains, preventing overloading and damage by accurately monitoring torque transmission, enabling better control and safety in machinery operations like cranes and boom structures.
Implementation Method 1
a load cell positioned between the gearbox cover and brake assembly to prevent rotation, allowing for the measurement of input torque when the brake is disengaged and output torque when engaged
Data Source
AI summary
A system and method of measuring torque generated by a drive train like that used in a rotating equipment drive. A drive motor is mounted to a rotatable brake assembly which, in turn, is coupled to a gear drive which, in turn, transmits rotational power. The brake assembly is coupled to a fixed cover of the gear drive by a gearbox torque sensor that prevents rotation between the brake assembly and the housing. The sensor can be a load cell or its equivalent. A control module may be configured to adjust operation of the rotating equipment drive in response to the torque signal. All input torque from the drive motor to the gearbox is measured when the brake is disengaged through the load cell. All input torque at the gearbox output shaft, through back-driving, is measured when the brake is engaged through the load cell.