Torque Test Device Using Vertical Torque Arm and Load Cell
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Solution Overview
Problem
Conventional torque test devices for electric actuators have a limited range of allowable torsion angle due to the use of leaf springs, requiring precise alignment of the shaft, adapter, and torque sensor, which restricts the measurement range and can lead to overtorque and overcurrent issues.
Innovation Solution
A torque test device design that includes a potentiometer, a torque arm, a rod with a load cell, and a spring system, where the torque arm is disposed vertically to the shaft, eliminating the need for precise alignment and allowing measurements beyond 90 degrees, using a control unit to calculate torque and elastic modulus based on rotation angle, force, and displacement data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a leaf spring is used to measure torque, then the device structure is simple, but the allowable torsion angle range is limited
Solution Approach 1:
The device is divided into independent functional modules: a torque arm for force application, a rod with load cell for force measurement, and a spring system for displacement measurement. This segmentation allows each component to operate within its optimal range while collectively achieving a wider measurement range of 90 degrees or more, resolving the contradiction between structural simplicity and measurement range.
Solution Approach 2:
The rod acts as an intermediary component connecting the torque arm and the spring system. It transmits the rotational motion and force from the torque arm to the spring system, enabling the decoupling of the measurement functions. This intermediary mechanism allows the system to achieve large rotation angles without requiring the entire structure to be flexible, thus expanding the allowable torsion angle range while maintaining structural integrity.
2Measurement precision
If a torque sensor and adapter are used, then torque measurement precision is high, but precise alignment of shaft, adapter, and torque sensor axis is required
Solution Approach 1:
The patent replaces the traditional torque sensor with a combination of a load cell and spring system. Instead of directly measuring torque through a torque sensor requiring precise alignment, the system measures the force applied by the torque arm using a load cell and calculates torque based on the known geometry and spring displacement. This substitution eliminates the need for precise alignment of the shaft, adapter, and torque sensor axis, while maintaining measurement precision through mathematical calculation.
Solution Approach 2:
The rod serves as an intermediary that transfers the torque measurement function from a directly aligned torque sensor to a load cell positioned at the end of the rod. This intermediary arrangement decouples the measurement point from the rotation axis, allowing the load cell to measure force without requiring precise alignment with the shaft or torque sensor axis, thereby simplifying the alignment requirements while preserving measurement accuracy.
3Adaptability or versatility
If the torsional rigidity of the leaf spring is small, then the device can measure torque at certain rotation angles, but nonlinear behavior occurs at large torsion angles
Solution Approach 1:
The system dynamically adjusts the measurement approach based on the rotation angle. The torque arm and rod configuration allow the system to operate in different regimes: at smaller angles, the spring system provides linear restoration, while at larger angles up to 90 degrees or more, the geometry of the torque arm and rod maintains accurate torque calculation through the relationship between force, arm length, and angle, preventing nonlinear behavior and ensuring data reliability across the full range.
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 a wider operational rotation range, reduces the risk of overtorque and overcurrent, and allows for precise torque measurement without the need for precise alignment of components, enhancing the reliability and accuracy of torque testing.
Implementation Method 1
a spring system having one end coupled to the rod and the other end coupled to a second bracket, and disposed vertically to the shaft of the electric actuator
Implementation Method 2
a potentiometer having one end fixed by a first bracket, and disposed at an end of a shaft of the electric actuator
Implementation Method 3
a spring system having one end coupled to the rod and the other end coupled to a second bracket
Data Source
AI summary
The provided device is a torque testing tool for electric actuators, employing a potentiometer, load cell, and spring system to measure torque. It surpasses conventional leaf springs with its wider operational rotation range. The setup includes a potentiometer fixed at the electric actuator's shaft end, a vertically positioned torque arm, a rod connected to the torque arm with a load cell, and a spring system attached to the rod and a second bracket, all vertically aligned with the actuator's shaft. A control unit processes force data from the load cell and rotation angle data from the potentiometer to accurately calculate the electric actuator's torque. This innovative design ensures precise torque measurement, offering enhanced efficiency and versatility for various applications relying on electric actuators.