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AxialTQ Technical White Paper Details Comparative Testing

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Recently, Interface put together a full comparison of our AxialTQ™ Torque Transducer measurement systems versus a competitor’s system that offers a DIN120, 1kNm capacity transducer. To view the complete details, read the new Interface technical white paper A Comparison of Torque Measurement Systems, authored by Jay Bradley, Interface Electrical Engineering Manager.

Here is a brief overview covering the crucial results of the comparison testing.

About AxialTQ Torque Transducer

Since 2018, the AxialTQ has redefined the category of torque measurement systems in terms of function, accuracy, and customizable compatibility. It’s a must have torque transducer for anyone working to minimize uncertainty when measuring anything that turns. It is specifically designed for the expanding torque measurement needs in fields that include the automotive industry, as well as the aerospace and industrial automation sectors.

At the heart of AxialTQ’s innovation is the rotor and high-precision sensing element technology, which when combined with the electronics component, produces industry-leading accuracy. This product is also fully customizable due to its ability to use simultaneous analog and digital outputs. This is key, as it enables real-time control and data collection. The flexible capability of the stator and output module mounting offers an infinite number of configurations to meet any application needs.

AxialTQ was designed and engineered by Interface in direct collaboration with end-users who shared their wish-lists for operational priorities, user profiles, design specifications, feature preferences, and real-world field challenges they wanted a solution to resolve.

The unique decision to implement an axial gap, as opposed to the industry standard radial gap, means there is minimized concern that the shaft, rotor and stator will make contact, significantly reducing the possibility of damaging the system.

Installation Overview

AxialTQ features a 120° stator coil giving it the ability to be mounted in several different orientations. While the full stator loop of the competing system must be carefully aligned with the rotor. AxialTQ’s large axial gap of up to 6mm and radial gap of up to 12mm also allows for small misalignments or rotor movement. The competing system has a small radial gap of 1mm and ±2mm when installed, providing less flexibility and durability. The stators of both the AxialTQ and the competing system have multicolor status LEDs that indicate proper alignment and data transmission.

Performance Testing and Validation

The tests found that both systems performed well and met their respective operating specifications. Some of the dynamic testing was performed only once due to time constraints. This testing also has a greater uncertainty of measurement because of the test setup.

In this comparison we tested the installation process, as well as performance for the following specifications:

  • Zero balance stability
  • Shunt calibration stability and repeatability
  • Measurement repeatability
  • Measurement non-linearity
  • Measurement hysteresis
  • Axial force crosstalk
  • Zero balance over operating temperature
  • Axial gradient temperature performance

Overall, both systems performed in line with specifications. Areas in which the AxialTQ stood out included change in zero-balance readings, performance in operating temperature ranges, and in the in-house spin testing cycles.

Configuration Advantages

Unlike the competing system, the AxialTQ has one analog voltage or current output, two analog frequency outputs, and a digital serial output which are all active and independently scalable and filtered. This means that by applying different scaling to two different outputs, the AxialTQ can operate like a dual range sensor.

Durability

AxialTQ also has a significant advantage in durability. The large axial (up to 6mm) and radial (typically 12 mm) gaps between the rotor and stator make it highly unlikely that the rotor will contact the stator because of harmonic vibration, torque pulse or some other event. Both the rotor and stator coils of the AxialTQ are fabricated from 0.125in (3.18mm) thick FR4, with any conductors located at least 0.05in (1.27mm) from the edge. If damaged, these coils are easily replaced in the factory.

AxialTQ is innovative alternative to current systems and includes creative solutions to overcome some of the challenges that diminish performance in these systems as well. To learn more about go to our AxialTQ product page.

Additional Resources

Recap of Latest Spin on AxialTQ Webinar

AxialTQ Engine Dynamometer Application Note

The AxialTQ Dynamometer

AxialTQ for Anything That Turns and Needs Testing

Recap of Latest Spin on AxialTQ Webinar

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Interface recently hosted a new webinar in our ForceLeaders series that highlighted the revolutionary AxialTQ product.  The event reviewed the bearingless wireless rotary torque transducer design and detailed component specifications, why test engineers prefer the AxialTQ, and use cases for this precision measurement system.

If you were not able to attend the Latest Spin on AxialTQ event, you can watch the entire recording online here.

The revolutionary AxialTQ was first introduced in 2018. The design originated from the popular HRDT product that utilized a rotor stator gap design as a single component. After hundreds of users, we started the product engineering exercise to see how we could advance the soon-to-retire HRDT and evolve it into something that would perfectly fit current market conditions.

As technologies were changing testing protocols and requirements, such as for electric motors, alternative energy hardware, space vehicles and industrial machine automation, we wanted to add new functionality. Jay Bradley and the Interface engineering team began the process by looking at DIN size optimization, shorter stators, additional coupling options, advanced software configurations and simple “drop-in” replacement parts with a modular design.

After thousands of design hours and testing, Interface released the AxialTQ. The specialized product is a unique combination of accuracy, reliability and ease of use that redefines the standard torque measurement device in terms of function and durability.

Engineers prefer the new AxialTQ because of the time-proven sensing element with longer active area providing greater measurement sensitivity while being less vulnerable to shock loads.  The high-resolution digital electronics are state-of-the art. Uniquely, the large gap design up to 6 mm axial and 12 mm radial minimizes contact damage which is important at high-speed testing. It has 120-degree partial loop antenna on the stator to make installation easier.

Specialized design features of AxialTQ make it a great fit for test and production applications.

  • Crash-proof design for maximum reliability
  • Industry-leading gap to prevent damage to rotor stator at full speed
  • Simultaneous analog and digital outputs, enables real-time control and data collection
  • Interchangeable stators and output modules minimize parts inventory
  • Versatile design and wide range of configurations to match any application
  • Hardware is self-configuring
  • New advanced software with added features and logging capabilities
  • Rotor and stator coils designed using printed circuit boards for durability

The AxialTQ rotor sensing element and electronics are the heart of the system. It has a rugged design for all types of torque measurement applications.  It comes in 8 torque capacities. The status assembly matches to the rotor DIN size and is interchangeable with equipment DIN size rotor assemblies, increasing usability.  The USB digital output module has galvanic isolation on all outputs and has standard IP65 ingress protection.  It enables real-time control and accurate data collection.

Keith Skidmore shared several use cases during the presentation, including engine dynamometers, motor test stands and other automotive production line applications.

The AxialTQ is designed for testing anything that spins. It’s ideal in testing and production of hydraulic motors, EVs, helicopters, aircraft, and drones, along with windmills and industrial fans.  It’s great for testing forklifts, off-road and utility vehicles as wells as tractors and watercraft.  AxialTQ is also generally used for measuring torque on industrial motor assemblies, pumps, appliances, braking systems, and motor vehicle accessories.

Watch the entire webinar below to hear Keith and Jay share tips, specifications, frequently asked questions and how to get the most out of your torque measurement applications.

Learn more about AxialTQ here.

The Next Generation of Torque Measurement Devices is AxialTQ

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This was a big year for Interface’s force measurement solutions at the Automotive Testing Expo held October 23-25, 2018 in Novi, Michigan, just west of Detroit. For it was at this world’s leading trade fair for automotive test, evaluation and quality engineering professionals, that we chose to proudly introduce our innovative AxialTQ™ Torque Measurement System.

As a company with more than 50 years of engineering expertise in force measurement, we were eager to share the details of AxialTQ with the world.  The response we’ve received from show attendees and current customers has been phenomenal. AxialTQ redefines the category of torque measurement systems in terms of function, accuracy and reliability, and it’s a must for anyone working to minimize uncertainty. AxialTQ is specifically designed for the expanding torque measurement needs in the automotive industry, as well as the aerospace and industrial sectors.

At the heart of AxialTQ’s innovation is the rotor and high-precision sensing element technology, which when combined with the electronics component, produces industry-leading accuracy. This product is also fully-customizable due to its ability to use simultaneous analog and digital outputs. It enables real-time control and high accuracy data collection giving the user the best of both worlds. The flexible capability of the stator and output module mounting offers an infinite number of configurations to meet any application need.

AxialTQ was developed in direct collaboration with end-users who shared their wish-lists for operational priorities, user interface, design, features, real-world field issues and more. The unique decision to implement an axial gap, as opposed to the industry standard radial gap, means there is minimized concern that the shaft, rotor, and stator will make contact, significantly reducing the possibility of damaging the system.

Interface’s AxialTQ is available in eight torque capacities and five DIN sizes. Additionally, there will be three accuracy classes, EX, LX and HX. The benefits of each class can be found here.

We believe AxialTQ is critical in helping to address the demand for a more accurate, reliable, customizable and easy-to-use force measurement device, and Interface is proud to be leading the way. To find out more about Interface and AxialTQ, you can connect with us by phone, email or live chat here. We’d love to hear from you.

By Jake Shaffer, senior product manager, Interface