External torque sensor design providing wireless and real-time data customized for drivetrain

Abstract

In this study, a torque sensor design that can be used in both laboratory and field tests simulating road conditions of drivetrain of the vehicles is explained. Mechanical design of the sensor has been carried out via finite element method (FEM). Material of the torque sensor and the relevant heat treatment were determined. Electronic measurement circuit design and its setup have been carried out including amplifier, filter, ADC and data transmission features which are suited for full bridge connection. Verification and calibration tests have been performed with respect to DIN-51309. As a result of the studies, it was determined that the measurement accuracy of the system in the torque range of 250 ÷ 2500 Nm was 0.5%. The effect of noise-induced deviations was found 0.05% for the precision value. Consequently, a verified universal torque sensor has been developed for any drivetrain application under torsional effect with the given specifications. It is hoped that this sensor might become a common feature on any and every drivetrain for advanced monitoring of the drive components.