Accelerating Advanced Automotive Testing Using Torque Transducers

The automotive industry has long demanded excellence in torque measurement, as transducers provide essential data crucial for engineering, design, testing, and performance monitoring of all types of vehicles.

Interface is a long-time preferred supplier to the auto industry of rotary and reaction torque sensors. Why? Accuracy and durability are central to the selection decisions, as well as the broad line of sensors, which vary by capacity and configuration. The industry is also changing. Advanced testing requirements for torque transducers that support innovation and facilitate the transition from concept to production are driven by the industry’s shift toward increasing motor performance, fuel-efficient designs, Electric Vehicles (EVs), advanced safety systems, and the integration of Autonomous Vehicle (AV) technologies.

These industry and market demands call for highly accurate and dependable force and torque measurement solutions. Interface force measurement devices are crucial for vital testing in both commercial and industrial vehicle design and manufacturing, ensuring safety and reliability.

Torque transducers are seeing a significant increase in use. While foundational applications, such as engine head bolt tightening, lug nut assembly, and vacuum pump testing, remain crucial, the growing emphasis is on the high-speed, high-power density demands of EV components and the precise, dynamic control of ADAS/AV systems. Interface provides a wide range of rotary and reaction torque solutions to suit this diverse testing landscape, from small designs for easy integration to advanced wireless technologies for maximum efficiency.

Interface Automotive Torque Solutions from Reaction to High-Speed Rotary

The range of torque testing in the automotive sector has never been wider, spanning low-torque quality checks on the assembly line to high-speed dynamometer testing of powerful motors. Interface is meeting this demand by supplying a variety of high-accuracy solutions that encompass both reaction and rotary torque transducer technologies. This breadth includes:

• Reaction Torque Transducers are primarily used for static applications, such as fastening, tightening, and assembly. These static transducers ensure precise quality control.
• Rotary Torque Solutions for dynamic testing of rotating components, featuring advanced options like miniature, lightweight torque transducers for easy integration into compact test rigs, and wireless torque transducer capabilities that eliminate the need for cables, providing more convenient and efficient testing. They are commonly used in motor test stands, dynometers, component fixture tests, and for testing any moving component.

 The revolutionary AxialTQ™ Rotary Torque Transducer line, an advanced product specifically created for the automotive industry, exemplifies this evolution in dynamic testing.

The AxialTQ is now utilized across a vast spectrum of testing environments, from traditional to next-generation components, including:

• Internal Combustion Engine (ICE) Lab Testing and End-of-Line (EOL) Testing
• Drivetrain Lab Testing
• Automotive Accessory Lab Testing
• Electric Vehicle (EV) Motor EOL and EV Lab Testing

NEW! Listen to our new InterfaceIQ Podcast discussion on torque transducers.

High-Focus Applications in Automotive Torque Measurement

While traditional automotive applications utilize reliable rotary torque transducers, such as the T33 Spindle Torque Transducer, for quality control on assembly lines, the most demanding and rapidly evolving areas are centered around electric powertrains, dual-motor systems, and ADAS/Autonomous testing.

 EV Motor and Powertrain Testing

Electric vehicle motors operate at significantly higher rotational speeds and have much higher power densities compared to their Internal Combustion Engine (ICE) counterparts. EV manufacturers need a highly accurate torque measurement system to test the torque and speed of their electric motors, ensuring optimal instant peak torque performance. The AxialTQ™ Wireless Rotary Torque Transducer is a precise system designed for this purpose. Mounted on a test bench, it accurately detects the motor, measuring and calculating torque and rotational speed (RPM) in real-time. This system is crucial for achieving and verifying the necessary instant peak torque performance.

Dual-motor dynamometer testing is utilized in electric and hybrid vehicles. Two AxialTQ™ Wireless Rotary Torque Transducers can be installed on both ends of a dual-ended dynamometer, enabling simultaneous, high-accuracy testing and data collection of two motors. Read more in our Dual Motor Dynamometer application note. 

Autonomous and ADAS System Testing

Another vital and rapidly expanding application requiring advanced torque transducers is testing the performance of Advanced Driver Assistance Systems (ADAS). ADAS and autonomous systems depend on various sensors to measure and control the vehicle’s dynamics. Torque transducers are used to measure and monitor forces and moments related to steering, braking, and suspension systems, all of which are controlled or assisted by ADAS technology. The data collected helps engineers verify the precise, real-time control these systems need for safe and dependable operation. This application often requires small, lightweight torque transducers for easy integration into complex assemblies and dynamic vehicle testing setups.

 Tire Force and Moment Measurement

The dynamic control capabilities of tires are central for both high-performance and safety-critical vehicle operations, particularly in the context of advanced driver assistance systems and autonomous features. Tire production companies stress-test their products to research dynamic control. This requires measuring both the torque (rotational force) and lateral force (sideways force) of the tire simultaneously under dynamic conditions.

The AT105 Contactless Force and Torque Transducer is specifically designed for this purpose, enabling the measurement of tire lateral force and torque during stress tests. The data provides valuable insight for optimizing tire design to enhance vehicle control and stability.

Interface Torque Transducer Technology for Advanced Automotive Testing

Interface provides the essential tools that modern automotive testing labs require to meet these evolving requirements. Interface torque transducers are crucial for innovation in the automotive sector, as they provide the specialized accuracy, speed, and form factors necessary to test the next generation of vehicles. Interface helps accelerate the shift to these advanced platforms by offering crucial dynamic and static testing solutions.

The AxialTQ provides the high-speed and high-accuracy measurement capabilities needed to validate the performance and efficiency of EV motors and powertrains. Simultaneously, high-accuracy reaction sensors and miniature designs enable the precise dynamic measurement of steering and braking components, which is critical for ensuring the functional reliability and safety of autonomous systems.

TIP: Check out the Interface AxialTQ Wireless Rotary Torque Transducer System with In-Line Magnetic Encoder Kit and Single or Double Flex Couplings complete system.

This commitment to advanced measurement extends across the testing spectrum. While supporting high-stakes dynamic testing, Interface also provides solutions that streamline operational efficiency, such as wireless capability that simplifies test rig integration by eliminating cumbersome cables.  Interface torque transducers ensure the necessary precision and data integrity required to move new automotive concepts quickly and safely from design to market.

To find the right product for specific application needs, manufacturers and test engineers should refer to Interface’s Torque Transducer Selection Guide. Additionally, explore our case study, ‘Accelerating Automotive Excellence with Interface Testing Lab Solutions.’

Interface showcases our expanding range of torque transducers, as well as wireless systems, multi-axis sensors, and instrumentation at the Automotive Testing Expos each year in Asia, Europe, and the United States. If you are unable to meet with us in person at these events, please don’t hesitate to contact our experienced application specialists.

BONUS!

How to Select a Torque Transducer Training