Torque Transducers and Couplings are the Perfect Pairing

Torque transducers require couplings to enhance precision and reliability in performance. The pairing ensures accurate measurements. The coupling enables the torque transducer to precisely measure torque while maintaining a secure mechanical connection to the rotating components. This facilitates data collection, analysis, and control, leading to improved performance, efficiency, and reliability when using a torque transducer in various test and measurement applications.

Couplings are designed to provide a strong and secure connection between the shafts, ensuring efficient torque transmission while minimizing stress and wear on the components. They come in distinct types and designs, each suited for specific applications and operating conditions.

For example, rigid couplings provide a solid and inflexible connection between the shafts, allowing for precise torque transmission but offering little or no flexibility to compensate for misalignments. Whereas flexible couplings are designed to accommodate small misalignments and angular offsets between the shafts. They use flexible discs to provide some degree of flexibility, dampen vibrations, and reduce stress on the connected components.

Interface Torque Transducer Models T2, T3, T4, T5, T6, T7, T8, T11 and T25 offer a range of product-specific coupling options. It is important to note that couplings are not universal, and your best options are always the couplings designed for the specific model, thus the perfect pairing. To demonstrate the range of options, here is a quick list of coupling designs:

  • Floating Mount Keyed Single Flex Couplings
  • Pedestal or Foot Mount Keyed Double Flex Couplings
  • Floating Mount Clamping Ring Single Flex Couplings
  • Pedestal or Foot Mount Clamping Ring Double Flex Couplings
  • Floating Mount Shrink Disk Single Flex Couplings
  • Pedestal or FootMount Shrink Disk Double Flex Couplings
  • Floating Mount Single Flex Couplings
  • Pedestal or Foot Mount Double Flex Couplings

A torque transducer coupling is a specific coupling designed to facilitate the connection and torque measurement between a torque transducer and a rotating shaft, providing accurate and reliable torque data. Whenever you are selecting an Interface torque transducer, be sure to request or add the Interface couplings that are designed for that specific transducer model. It is especially important to review the couplings features that pairs with your specific transducer. They are designed to work together, and you risk any problems or potential transducer failure.

Torque Transducers Require Couplings for Accuracy and to Safeguard Your Investment

Without a coupling, the torque transducer cannot be mechanically connected to the rotating shaft or component. As a result, it will not be able to measure the torque being transmitted through the shaft. This means you will lose the ability to accurately monitor and analyze torque in the system.

Using couplings is a standard requirement when using a torque transducer. They provide the mechanical connection, transmission and reduce misalignments, which all contributes to accurate and reliable torque measurements with torque transducers.

A coupling provides a means of mechanically connecting the torque transducer to the rotating shaft or component from which torque is being measured. It ensures a secure and reliable connection between the transducer and the system under test. In the absence of a coupling, the torque transducer may not be securely attached to the rotating shaft. This can lead to relative movement or slippage between the transducer and the shaft,

The coupling enables the transfer of torque from the rotating shaft to the torque transducer. As the shaft rotates, the torque is transmitted through the coupling to the transducer, which measures and converts it into an electrical signal for further analysis or control.

A coupling helps to compensate for small misalignments between the shaft and the transducer. Without a coupling, any misalignment between the two components can put additional stress on the transducer and the shaft, potentially causing premature wear, increased friction, or even catastrophic failure.

Couplings can also provide vibration damping properties by design, as they absorb or dampen vibrations and shocks that may be present in the system. This helps to protect the torque transducer from excessive mechanical stresses and safeguards torque measurements. Without a proper coupling, the transducer may also be susceptible to excessive vibrations or shocks, increasing the risk of mechanical failure.

Torque Transducer and Couplings Applications

If you are looking at a torque transducer use case, assume there are couplings that are part of the application. To point out common examples of testing programs that utilize couplings with high-performance torque transducers, the first place to start is in the automotive industry. In the automotive industry, high-performance torque transducers with couplings are used for various testing purposes. For example, during the development and testing of engines, transmissions, and drivetrain components, torque transducers coupled with the rotating shafts allow for precise measurement of torque and power output. Torque measurement data is crucial for performance analysis, efficiency optimization, and durability testing.

Torque transducers with couplings are extensively utilized in the engineering, testing, and use of industrial automation, machinery and equipment. Manufacturing processes that involve rotating components, such as pumps, compressors, and turbines, are using torque transducers coupled with the shafts to provide measurements of torque. Accuracy in data helps monitor the efficiency of the machinery, detect deviations, and ensure standard operation. All of this contributes to preventative maintenance.

There are many R&D use cases where torque transducers with couplings are required. We often see torque transducers and couplings used in material testing and structural analysis. In the renewable energy sector, wind turbines and hydroelectric generators use torque transducers and couplings.

These examples the coupling enables the torque transducer to accurately measure torque while maintaining a secure mechanical connection to the rotating components.  To explore more about couplings, be sure to tune into our recorded torque transducers webinar.

Additional Resources

Couplings 101

Torque Transducer Selection Guide

Miniature Torque Transducers 101

Choosing the Right Torque Transducer

Fuel Pump Optimization & Rotary Torque

A Comparison of Torque Measurement Systems White Paper

Rover Wheel Torque Monitoring

Torque Measurement Primer

Testing Lab Essentials Webinar Recap

Interface recently hosted an in-depth discussion about one of our favorite topics, testing labs. Our focus in this technical webinar centered on test lab devices, instrumentation, industry testing lab challenges and considerations, along with best practices. We also took a deep dive into different testing lab applications and how to modernize your test lab.

Force measurement experts Elliot Speidell and Jeff Boyd delivered an engaging and knowledgeable seminar, Testing Lab Essentials: Today + Tomorrow.  Bringing decades of first-hand experience, they were able to provide product examples, tips, recommendations and lessons learned in working with testing lab professionals across industries, from automotive to medical devices.

Initial discussions in the event covered test lab basics, including types of products should be in every lab that performs testing of force, torque, and weight. The quick summary, force, torque and weight measurement devices including load cells and torque transducers of various models, calibration grade equipment and published standards, test stands, data acquisition systems and safety equipment.

One of the first steps in assessing any lab is the type of measurement equipment on hand to perform various testing requirements. Transducer selection criteria includes mechanical connection and load application, force magnitude and loading condition, cycle count, form factor restrictions, environmental conditions, additional measurements needs, such as multiple axis.

Testing labs often require different types of load cells depending on the type of products being tested and the applications in which the load cells will be used. Here are some common types of load cells used in testing labs:

  • Compression load cells: Used to measure the compressive force applied to an object. They are commonly used in materials testing to measure the strength of materials such as concrete, metals, and plastics.
  • Tension load cells: Used to measure the tensile force applied to an object. They are commonly used in materials testing, such as in tensile strength testing of metals and other materials.
  • Shear load cells: Used to measure the shear force applied to an object. They are commonly used in materials testing, such as in shear strength testing of materials.
  • Multi-axis load cells: These load cells are capable of measuring forces in multiple directions and are commonly used in structural testing applications.
  • Torque transducers: Used to measure torque or twisting forces. They are commonly used in automotive testing, industrial machinery, and other applications where rotational forces are important.
  • Fatigue-rated load cells: These load cells are designed to withstand high-cycle fatigue testing and are commonly used in materials testing and durability testing of products.
  • Low profile load cells: These load cells are designed to fit into tight spaces and have a low profile, making them ideal for use in small-scale applications.
  • High-capacity load cells: These load cells are designed to measure large forces and are commonly used in heavy machinery and structural testing.

Instrumentation is central to any testing lab environment. The three most common types of instrumentation found in test lab includes:

  • Indicators: Indicators are used to convert the input signal to a local displayed value.  Often they will have features like, peak capture, alarms, and analog outputs.
  • Signal Conditioners: Signal conditioners are used to convert (amplify) one type of electrical signal into another. 
  • DAQ: Data acquisition systems are used to collect and analyze data from measurement devices. These systems may include software, hardware, and data processing equipment.

In a series of follow-up InterfaceIQ Blog posts we will detail other topics covered in this information packed discussion, including modernization, load frames and test stands, do and don’t tips, plus frequently asked questions.

Watch the complete webinar here:

Interface Helps to Power the Electric Vehicle Market Forward

Any time innovation is introduced into the market, it takes many years to iterate and realize the full potential of the technology. In today’s automotive marketplace, electric vehicles (EV) are reaching a point where the technology and capabilities are fully realized and is primed for an outbreak on mass scale. In fact, a recent IEA report found that more than 10 million cars on the road in 2020 were electric, estimated to be 2% of the market.

There are currently 370 models of electric vehicles sold today, with the number growing. To facilitate the further growth of the EV market, Interface continues to play a pivotal role in supplying force and torque test and measurement systems that meet the demands for superior testing requirements of all components used to make these vehicles. The automotive market, and especially EVs, are subjected to extremely strict regulations. Therefore, test and measurement are critical for every part for safety, reliability, durability, and overall vehicle performance.

Interface saw the rise in the electric vehicle market long before is the exponential adoption and growth and started early in investing in the development of force measurement technologies designed specifically to support testing of EVs. Our products we’re already well-known within the automotive industry because of our ability to deliver superior quality and high accuracy solutions that auto manufacturers and testing labs rely upon.

One of the most important developments in our lineup of EV compatible testing equipment was the introduction of AxialTQ™ torque transducer system in 2018. The AxialTQ system was engineered in direct collaboration with end-users who shared operational priorities, user interface, design, features, real-world field issues and more. The AxialTQ torque measurement system redefines the torque transducer category in terms a crash-proof design for maximum reliability, versatile model for application flexibility, simultaneous analog and digital outputs, real-time control and data collection and interchangeable stators and output modules that minimize parts inventory. You can see it in action in this video, AxialTQ Engine Dynamometer Application Note.

The rotor sensing element and electronics are the heart of the system which will be offered in 8 torque capacities in 5 DIN sizes. With the flexible capability of stator and output module mounting, the AxialTQ system offers vast configurations capabilities to meet any application need, especially for testing of EV motors. Watch the latest webinar, The Latest Spin on AxialTQ, to learn more about this dynamic auto testing transducer.

Torque Measurement for Electric Vehicles

When an electric vehicle manufacturer needed a torque measurement system for their electric vehicle, they contacted us to inquire about a solution designed for the unique needs of EV motors. These motors run at significantly higher rotational speeds than their internal combustion engine (ICE) counterparts and have much higher power densities due to the small size and light weight. The preferred system would be used to test the torque and speed of their electric motors to achieve and ensure optimum instant peak torque performance.

Interface provided its AxialTQ Wireless Rotary Torque Transducer to provide the highest quality torque measurement. This product was delivered with the AxialTQ Output Module and the provided AxialTQ Assistant Software, that is installed on a test bench. This allows data results to be calculated and collected in real-time. Using AxialTQ, the customer ran tests to sense the electric vehicle’s motor with high accuracy. It both measured and calculated the electric vehicles torque and rotational speed (RPM), while collecting data. Results are then be reviewed on the customer’s PC or laptop with the included AxialTQ Assistant Software. Using this solution, the customer was able to achieve their required instant peak torque.

This is just one of the many test and measurement solutions Interface provides to automotive manufacturers and makers of electric vehicles components.  Interface will be showcasing additional products used for auto testing at the next Automotive Test Expo.  You can see a highlight of some of these products in this highlight video of popular Interface automotive testing products.


Advancing Auto Testing with Interface Measurement Solutions

Driving Force in Automotive Applications

Auto Industry Applications

Automotive and Vehicle

Torque Measurement for Electric Vehicles

Test and Measurement for Electric Vehicles