Torque Motor with Embedded Sensors for Test Bench Accuracy
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Solution Overview
Problem
Conventional test benches for mechanical components face challenges with drive motors and sensors, including high costs, complex installation, frequent maintenance, and reduced accuracy due to externally mounted sensors, which compromise test time, reproducibility, and longevity.
Innovation Solution
An integrated torque motor with embedded sensors for precise torque and angle measurement, eliminating the need for external sensors and providing a compact, scalable design with extended service life and reduced maintenance, enhancing test efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If externally mounted sensors are used for torque and angle measurement, then the test bench can perform measurements, but the sensors are susceptible to malfunctions, complex to install, and make the design significantly more expensive
Solution Approach 1:
The patent integrates torque sensors and angle sensors directly into the motor structure, merging the drive function with measurement function. This eliminates external sensor mounting, reducing installation complexity and improving reliability by protecting sensors from external damage.
Solution Approach 2:
The motor shaft and motor housing serve as intermediaries that inherently provide measurement capabilities. The torque sensor is integrated into the shaft, and the angle sensor is integrated into the housing, using the motor's own structural elements as measurement platforms.
2Power
If conventional DC or AC motors are used as drives, then the required torque, dynamics and speed can be achieved, but the bearings wear out early and require frequent replacement
Solution Approach 1:
The motor is specifically designed for test bench applications with self-optimizing features. The bearing preload is automatically maintained through the integrated sensor system and control algorithm, which compensates for wear and maintains optimal operating conditions, extending service life.
Solution Approach 2:
The patent implements dynamic parameter adjustment through integrated sensors that monitor motor current, torque, and position. The control system continuously optimizes operating parameters to minimize bearing loads and extend service life while maintaining required performance.
3Reliability
If standard frequency converters with specially wound AC motors are used, then all requirements for measuring and testing fields are met, but the motors are a compromise and not explicitly designed for test benches
Solution Approach 1:
The motor is designed as a multi-functional unit that simultaneously provides drive function, torque measurement, and angle measurement. This universal design eliminates the need for separate measurement components and creates a purpose-built solution for test benches.
Solution Approach 2:
The motor is segmented into functional modules: drive winding, torque sensor integration, angle sensor integration, and control electronics. This modular segmentation allows for simplified manufacturing and assembly while maintaining high measurement accuracy.
4Adaptability or versatility
If multiple separate components are assembled to create a test bench, then the required functionality can be achieved, but the components must be well coordinated and the design effort and costs increase
Solution Approach 1:
The patent merges drive and measurement functions into a single integrated motor unit, eliminating the need to coordinate multiple separate components. This reduces design complexity while maintaining full test functionality through the motor's built-in sensor system.
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
The integrated solution reduces test duration, lowers maintenance costs, and improves measurement accuracy by integrating sensors within the motor, offering a cost-effective, efficient, and reliable testing solution with extended service intervals and energy savings.
Implementation Method 1
specially wound AC motors with standard frequency converters are usually used
Implementation Method 2
The torque sensors include strain gauges
Implementation Method 3
The absolute position and/or the relative position of the test object are recorded with one or more rotary encoders
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a test bench motor in the form of a torque motor (1) comprising a stator (5), a rotor (6), a drive shaft (7), associated bearings (11, 12), an adapter flange (8) connected to the drive shaft for receiving a test object, sensors (9, 10) for measuring torques, and sensors (16) for measuring rotational ripple, characterized in that the sensors (9, 10, 16) are arranged inside the motor (1) and are thus protected from any external mechanical influences, such as impacts. The invention further relates to the use of the test bench motor for functional and/or load-bearing capacity testing of rotating mechanical components.