Torque Sensor Assembly for Driveline Strain Isolation
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Solution Overview
Problem
Current mechanical powertrain systems lack an inexpensive and accurate method to measure individual torques within drivetrain components, affecting efficiency and longevity, as existing solutions fail to effectively isolate non-torque related strains such as thermal expansion, vibration, and acceleration.
Innovation Solution
A torque sensor assembly comprising a holder, sleeve, and strain sensors attached to the driveline component, which filters non-torque related strains through strategic placement and configuration, allowing for accurate torque measurement by correlating strain with torque applied, using a signal analyzer and controller network for data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain sensors are used to measure torque in driveline components, then torque measurement capability is provided, but non-torque related strains (thermal expansion, vibration, acceleration) interfere with measurement accuracy
Solution Approach 1:
The measurement system is segmented into multiple independent strain sensors positioned at specific locations on the driveline component. By dividing the measurement function across multiple sensors, the system can isolate torque-related strain from non-torque related strains through differential measurement techniques, thereby improving torque measurement accuracy while filtering out interfering factors.
Solution Approach 2:
Strain sensors are strategically positioned at specific locations on the driveline component where torque-induced strain is maximized while non-torque related strains are minimized. The holder structure provides localized support and positioning to ensure sensors are placed at optimal locations for selective strain measurement, enhancing measurement precision by exploiting local strain characteristics.
2Measurement precision
If existing torque sensing devices are implemented, then torque measurement is achieved, but the devices are expensive and complex to install
Solution Approach 1:
The holder structure serves multiple functions: it positions the strain sensors accurately, provides mechanical support, and facilitates installation on the driveline component. This multi-functional design reduces the number of separate components needed, simplifying the overall device structure and reducing installation complexity while maintaining measurement accuracy.
Solution Approach 2:
The holder acts as an intermediary component between the strain sensors and the driveline component. It simplifies the installation process by providing a pre-fabricated mounting structure that can be attached to the driveline component, thereby reducing installation complexity and cost while ensuring proper sensor positioning for accurate torque measurement.
3Measurement precision
If strain sensors are attached directly to the driveline component, then torque measurement is possible, but the sensors are exposed to harsh environmental conditions
Solution Approach 1:
The holder structure serves as a protective intermediary between the strain sensors and the harsh environmental conditions in the driveline. It shields the sensors from direct exposure to extreme temperatures, vibrations, and other adverse conditions while maintaining the sensors' ability to detect strain, thereby improving both reliability and measurement precision.
Solution Approach 2:
The holder structure is designed to protect strain sensors from harsh environmental conditions before the sensors are exposed to operation. By providing pre-installation protection through the holder structure, the system cushions the sensors against thermal expansion, vibration, and other environmental factors that could compromise sensor durability and reliability.
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 and cost-effective torque measurement within mechanical powertrain systems by isolating non-torque related strains, improving monitoring and control of powertrain components, and enhancing the longevity and efficiency of drivetrain components.
Implementation Method 1
The strain sensor is attached to a sleeve inner surface of the sleeve and used to sense a strain in the driveline component
Data Source
AI summary
A torque sensor assembly is used with a driveline component. The torque sensor assembly includes a holder, a sleeve, and at least one strain sensor. The holder includes a side wall that has a holder outer surface and a holder inner surface. The holder outer surface is corresponding to and attached to an aperture of the driveline component. The sleeve is corresponding to and attached to the holder inner surface. The strain sensor is attached to a sleeve inner surface of the sleeve and used to sense a strain in the driveline component.