Torque Sensing: Any Time & Everywhere 2016 · • Torque – Bending – Axial Load • Most affordable Active Sensor Kit • Wide measurement range • Ideal for safety applications

Version 2.7 www.tam-sensors.com

Torque Sensing: Any Time & Everywhere

2016Measure Torque

easily and affordably

Non-Contact Active Sensors

Torque And More GmbH • Münchener Str. 33, D-82319 Starnberg • Tel: +49 8151 368 981 30 • www.tam-sensors.comPage 2

About Torque and More

M ünchener S tr.

Moo

s

Str

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Petersbrunner

Str.

Lake Starnberg

Page 3Torque And More GmbH • Münchener Str. 33, D-82319 Starnberg • Tel: +49 8151 368 981 30 • www.tam-sensors.com

Table of Contents

Products, Services, Solutions:

Standard Sensors and Sensor Kits Custom Specific Sensor Solutions

Manufacturing & Manufacturing SupportModules & Licenses

Contents:

Active Sensors Measuring Torque - Bending - Axial Load ....... 4Standard Sensor Kits .......................................................... 9A3-P High Performance Active Torque Sensor Kit ................ 22Height Sensors for Air-Springs .......................................... 23


Sensor Kits and Sensor Products

Sensor Kits and Sensor Products• Active-2 Sensor Kit• Active-3 Sensor Kit• Application Specific Sensing Module• Custom Sensing Modules• Ferro-Detector


Application for Active Sensors

Applications for Active Sensors• Pumps and Compressors• Chassis Load Sensing• Transmission Shaft• Power Tool Drive Shaft• E-Bike / Pedelecs• Gearboxes• Test Benches• Vehicle Chassis and Cranes

Height Sensor for Air-Spring, Suspension and Seats• Commercial Truck• Passenger Cars• Railroad • Processing & Tooling


Application “Limitless”

“Limitless” use and Applications • Measuring Torque – Bending – Axial Load• Measuring from static and dynamic objects• Any ferromagnetic object of any size• Insensitive to dirt, humidity, vibrations• Will not age; Overload Resistant

Julius Beck(Project Manager)


A3 Sensing Modules for different shaft diameters

A2 Sensor Kits A3 Sensor Kits

Active 2 Master Active 2 SHORT Active 3 Advanced Active 3 Meter(Target Release Date 2.Q. 2016) (Target Release Date 2.Q. 2016)

Versatile & Programmable

Gearbox &Power Tools

Performance &Features

Overload Monitoring

Features and Functions• Small Sensing Module• Fully user

programmable• Settings:

20 parameters • Built-in Display• Parameter storage (3)• Windows-PC-Soft-

ware

• Low Cost Solution• Compact Electronics• Hardware Interface

Options• Reduced Signal Noise• Settings: Gain, Offset

• Short Sensing Module• Reduce Air Gap Sensitivity• Built-In Data Logger• <1 mV signal noise• MicroSD card storage• USB Interface for

Windows PC

• Low Cost Solution• Reduced Air-Gap

Sensitivity• Compact Electronics• On-board

data storage• Reduced Signal Noise • Settings: Gain, Offset

Target usage, Target application

• Any shaft diameter• Research activities• Material analysis• Easy-to-use, auto-

matic adaption• Industrial Applications• Wind-Turbine

• Any shaft diameter• Space restricted

applications• Power-Tools• Gearbox application• Operates at default

settings

• Remote Application• Distant Communication• Precision Measurements• Equipment Monitoring• Demanding Jobs• Marine Application• Renewable Energy

• Fast installation• Over-Torque

monitoring• Mobile applications• Engine Monitoring• E-Bike / Pedelecs

MICRO(M 18x30)

SHORT(M 30x30)

STANDARD(M 30x70)

Sensing Modules


Active-2 and Active-3 Sensors

Measuring Torque Anywhere and InstantlyFeatures• Non-Contact• Works on ANY ferromagnetic Object / Shaft• No shaft magnetization required• Any shaft size (>3 mm diameter), no upper limit• Reliable Performance Not affected by Over-Load Not damaged by magnetic stray field Insensitive to water, oil, dust• Reduce sensitivity to air-gap changes• Insensitive to shaft speed• +5 Volt Analog Signal Output• USB Serial Digital Communication with PC• Optional: CAN Interface, 4-20 mA, IP67

Benefits• Out-of-the-box taking measurements immediately• Automatic and manual initialization • Bi-directional measurement range• Built-in data logger and signal filter• Sensor is reusable on as many different application as you like• Very wide range of material where it can be used


Active-Sensor Kits

Active-2 Sensor Kit: “A2-Master”• Torque – Bending – Axial Load• One Sensing Module fits all shaft sizes• Fully User Programmable Sensor System• Individual optimization to any application• Built-in display and programming buttons • Miniaturized Custom Specific Sensing Module• Shaft sizes from 3 mm upwards, no limits

Active-3 Sensor Kit: “A3-Meter”• Torque – Bending – Axial Load• Most affordable Active Sensor Kit• Wide measurement range• Ideal for safety applications

(over load detection)• Compact electronic design• Shaft sizes from 15 mm upwards, no limits

Active-3 Sensor Kit:“A3-Advanced”

• Torque – Bending – Axial Load Sensor• Short / Compact Sensing Module• Low Signal Noise• MicroSD Card Reader• Built-in Data Logger function• Reduced sensitivity to air gap changes • Optional: CAN Hardware Interface• USB Interface for Windows PC• Using “Advanced-Algorithm TAM ASIC”


Active Torque, Bending & Axial Load Sensor

Low Cost, Economical, Practical• Easy to apply; No Shaft Processing• Applicable to any ferromagnetic shaft material and any size (>2mm)• Lowest Overall Cost: No Shaft Processing required

Robust, Reliable• Cannot be damaged by over-torque or strong magnetic fields• Increased reliability as there are no moving parts• Insensitive to dirt, shaft coating, rust, oil vapour, mechanical shocks

Functionality• High measurement resolution• User programmable measurement range• Bidirectional measurement range

Features• A2: Sensing Modules can be built to fit very small spaces• A3: Low signal noise; Affordable; Analog and USB I/O• A3-A: Built-in air-gap (distance) compensation; MicroSD Data Logging

Versatile• Torque Measurement (bidirectional, any shaft speed)• Bending Measurement (high sensitivity)• Axial Load Measurement (easy to apply)

“Active” Sensing Technologies


Unique Benefits

Active Sensor “can do” what “others can’t”The robustness and the easy way of applying an “Active” Sensor from Torque And More are just two of the unique features of this innovative sensing technology. The Active Sensors can be re-used in different applications nearly limitlessly, working with any ferromagnetic Test-Object, and are cost effective.

• Plug-and-Play and Non-Contact Sensor System Placing the Sensing Module at a stable location nearest to the Test-Object, switching-on, one-time initialising, and measuring immediately.

• Works with any ferromagnetic steel (can be easily tested with a permanent magnet) Note: Lowest possible measurement hysteresis and best performance will be achieved when the Test-Object has been hardened.

• No changes are needed at the Test-Object (shaft or tube)

• The Test-Object does not need to be magnetised No pre- or post-processing required of any kind

• Applicable to any shaft sizes, no upper limit Starting with 3 mm diameter (A2) and 15 mm (A3) upwards

• Torque Sensor performance will not age Maintenance free; No moving parts; No telemetry required

• Torque Sensor will not be damaged by over-torque

• Insensitive to dust, humidity, oil, dirt, mechanical shocks, ….

• Sensing Module is being placed only from one side onto the Test-Object (shaft) Easy retrofitting in already existing applications

• Simple logistics and lowest overall costs


Active-2 “Master” Sensor Kit

Active-2 Sensor KitThe A2 Master Kit is always supplied with a standard, flat front faced Torque Sensing Module suitable for ANY shaft diameter ranging from 3 mm upwards (no upper diameter limit). Custom Specific designed Sensing Modules are available and have to be ordered separately.

The Active-2 Master is a complete Sensor System stored in its own carrier case. The A2 Master Kit can be powered by a regulated +9 to +12 Volt supply or by the included Universal Power Supply. The Sensing Module comes with a 3 meter connection cable and can be replaced by a Custom Specific Sensing Module (optional order). When having ordered the USB interface the A2 Master can be connected to a Windows operated PC and communicate with the TAM Dashboard software. Here the user can change a large number of sensor parameters and also activate special functions.


Features and Functions

Active-2 “Master”The Sensor Electronics has its own 16 x 2 OLED Text Display and 5 setting buttons that allow the user to modify and display the settings and features of this sensor system. When ordering an USB interface then the sensor electronics can also communicate with the specially developed Windows PC dashboard software. This allows the user to operate and to use the Active Sensor Kit by two different communication interfaces: 1. Using the built-in text display and setting buttons, 2. Using a Windows based PC interface.

Software Programmable FeaturesThe controller software for the built-in 16 x 2 character display is menu driven and can be operated by the user using the 5 setting buttons that are mounted on the front and back panel of the electronics housing.

• Taking real-time measurements and displaying Forces and Sensor Distance simultaneously

• Zero Offset reset• Enforcing system initialization (optimising all sensor setups)• Operational frequency• Field generator amplification• Receiver sensitivity• Receiver filter settings• Sensor System Calibration• Analog output signal: Measured Force or Sensor Distance• Display the installed software version• Setting the measurement units (Newton, Newton Meter, …)• Save and Restore individual sensor system settings• Display all used setting values

User Setting Buttons The user can scroll through the different setting options by using the front panel mounted Up-and-Down buttons. Reachable from the back panel are the buttons: ESC (escape), Menu, and Enter.


Features and Functions

Analog Signal Output All the measurements taken are shown at the 16x2 Text Display and, simultaneously, will be provided in high resolution and in real-time through the single channel Analog output interface (BNC connector at the back panel). The user can decide to view either the mechanical forces (“Force-Output”) measured by the sensor system, or the distances (“Distance-Output”) measured between the Test-Object Surface and the Sensing Module front face.

The Analog signal output has the 0 to +5 Volt standard. When set into “Force-Output”, then, when measuring no torque or no bending forces the signal output will be at +2.50 Volt. When set into “Distance-Output” then a low voltage represents a very small or no distance between the Sensing Module front face and the Test-Object Surface, while a larger voltage represents an increased distance between the Test-Object and the Sensing Module. The measurements are showing absolute values. In average, a change of 1 Volt is equivalent to a change of 1 mm in distance (air-gap).


A2 Torque Link PC Dashboard Software

Torque Link PC Dashboard SoftwareWhen using the built-in USB interface (has to be ordered separately) the user has access to a much wider range of features and functions. However, it is important to understand that the fastest Torque Measurements with the highest possible signal resolutions is available through the built-in analog signal interface (BNC connector). The user defines which communication interface will be used (built-in 16 x 2 text display, or PC Dashboard interface Torque Link) by flipping a switch at the sensor electronics. All the sensor settings and programmable sensor features are accessible from one PC screen (no longer need to scroll through the system menu). The additional features and functions available through the Torque Link software are:

• 2 channel Oscilloscope• Data Logger (pre-set number of measurements will be taken and stored)• Data Logger to Excel File conversion• Advanced digital programmable signal post-processing for Data Logger

measurements

2 Channel OscilloscopeThe User can decide about showing either Torque or Distance measurements, or both simultaneously at the PC screen in real time. For Some typical examples are: Showing in real-time the Torque Measurements taken and the Distance Sensor Measurements at the same time (2 channel display). Another example may be to show the unfiltered and the digitally filtered Torque and Distance measurements (2 channel display) to identify more easily correlations between a non-centric running Test-Object (shaft) and the measured Torque Forces.Be aware that the real-time measurement signal bandwidth is limited when using the USB signal interface.

Data LoggerThe user can define the number of measurements that will be taken and the rate with which they will be taken before these measurements will then be stored in a PC format file. This file can then be opened by the Microsoft excel spread sheet software for further analysis and manipulation.



Current Measurement Value:In [V] or [Nm] after calibration

Initialisation:After Initialization, the sys-tem measures immediately

System Settings:Configure measurement range, change sample rate and fine tune other settings for optimal sensor performance.

Default Values:Restore default system set-tings if necessary.

Oscilloscope like Display:Visualisation of measure-ments in real-time.

Legend:Choose whichsignal to display.

Connection:Quickly and easily estab-lish a connection between TorqueLink and the elec-tronics box.

Integrated Data Logger:Log measurements for later analysis.


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Active-3 “Meter” Sensor Kit

Active-3 “Meter” Sensor KitIn the “Standard” configuration the A3 “Meter” Kit is supplied with a Torque Sensing Module for a shaft diameter range of 20 mm to 32 mm. Other standard Sensing Modules are available and can be selected when ordering the A3 Meter Kit.

The Active-3 “Meter” Kit is a complete Sensor System stored in its own carrier case. The A3 “Meter” Kit can be powered by a regulated +9 Volt supply or by the included Universal Power Supply. The supported Sensing Module is tooled for a specific shaft diameter and comes with a 3 meter connection cable. Other A3 Sensing Modules can be connected to the Sensor Electronics at any time. With the built-in USB interface the A3 “Meter” can be connected to a Windows operated PC to adjust signal gain and to retest the offset.

You have the option to order application-specific

sensor modules that match the diameter of

your test object.


Active-3 “Advanced” Sensor Kit (A3-A)

Active-3 “Advanced” Sensor Kit (A3-A)One of the biggest performance improvements is a reduced distance sensitivity (from 0.5 mm to 1.5 mm air-gap) of this high performing Active Sensor System. The A3-A is optimal for applications with non-centric running or slightly wobbling shafts. The A3-A Sensor is insensitive to changes in the operating temperature and comes with a built-in data-logger (including MicroSD storage).

The Active-3 “Advanced” Kit is a complete Sensor System stored in its own carrier case. The Sensor Electronics can be powered by a regulated DC Voltage +9V to +12V or by the included mains AC 230 Volt module (German Plug). When ordering the A3-A Sensor Kit, the user can chose between three different Sensing Modules: Types 1, Type 2, and Type 3. The A3 Sensing Module has a curved front face (Type 1 and 2) or flat front face (Type 3) and has to be ordered to match the diameter of the targeted Test-Object (shaft size). The measurement results are available from the 0 to +5 Volt analog signal output, the USB interface, and the MicroSD memory card (included). Our power supplies use the Europlug (Type C) socket.


A3 “Meter” Torque Link PC Dashboard Software

Initialisation:After

Initialization, the

system m

easures imm

e-diately

System Settings:

Configure the

settings for

optimal sensor perform

ance

Connection:Quickly and easily estab-lish a connection betw

een TorqueLink

and the

elec-tronics box.


Sensor Principle

Sensor PrincipleThe physical path of magnetic flux lines that are travelling through a ferromagnetic Object will be influenced by the mechanical forces that act onto the object.

The Sensing Module of an “Active” Sensor is be placed close to the ferromagnetic Test-Object from where the measurements (e.g Torque) have to be taken. The Sensing Element inside the Sensing Module is emitting a small and alternating magnetic field that will penetrate the surface of the Test-Object. The returning magnetic response (from the Test-Object) is then received by the Sensing Element and passed-on for further processing in the Sensor Electronics.

The alternating magnetic field that is passing through (and beneath) the Test-Object surface will be influenced by the mechanical forces that are applied to the Test-Object. The mechanical forces will alter some of the specifications and characteristics of the alternating magnetic field. These alterations are detected by the Sensing Element and then converted into a 0 (zero) to +5 Volt analog signal output. When using the default system settings, and when no mechanical forces are applied to the Test-Object (example: 0 Nm Torque), then the signal output will be + 2,50 Volt.


A3-P High Performance Active Torque Sensor Kit

A3-P High Performance Active Torque Sensor KitThe Active Torque Sensor Kit A3-P will be available mid-2016 and can be used to measure Torque, Bending, or Axial Load Forces from any ferromagnetic shaft (min. diameter applies).

This next generation non-contact Active Sensor System is detecting and measuring mechanical stress in ferromagnetic materials (after calibration) in mV/MPa or mV/(N/mm2). Through a Windows-PC USB interface the user can set critical sensing parameters like: Zero-Point, Signal Gain, Data Logger Sample Rate, and Signal Filter.

An on-board data logger stores the measurements onto a MicroSD memory card in real-time. The sampling rate are user definable and range from 1000 S/s to 1 S/day. A battery buffered RTC (real-time-clock) records the time at which the measurements were taken.

The A3-P Sensor Kit comes in its own case and includes everything to take measurements immediately: Standard Sensing Module (predefined shaft diameter range), Sensor Electronics, Connection cable, Mains power supply, Mounting material, Software (USB stick), Ferro Detector, USB-Isolator for low-noise measurements and User Manual.

The included battery powered Ferro-Detector assists the user in qualifying the material-suitability for the Active-3 Sensing Technology. The included USB Isolator eliminates the risks of a PC ground loop and enables low noise measurements.

FEATURES• Bi-directional measurement• Range: <10-4 MPa

to >1000 MPa• Analogue and USB interface• Very low

signal noise• Automatic system

initialisation• Single supply:

+9V to +36V• Shaft diameter:

Optional >15 mm to ∞

• Windows-PC dashboard software

SensingModule

FerroDetector

USBIsolator


Height Sensor for Air Spring, Suspension and Seats

Height Sensor for Air Spring, Suspension and Driver Seats

The company Torque And More has developed a Height Sensor system for an smart Air Spring. The Height Sensor is fully integrated into the Air Spring and replaces the traditional levelling sensor. The well known disadvantages of the traditional levelling sensor are eliminated and new advanced features include:

• Signal Resolution of 0,1 mm• Improved Performance and Repeatability• Overall System Cost Reduction• Easy Installation – Fewer Part Numbers• More robust system• After Sales Business Protection • Manipulation Proof• Applicable with/without bumpers

Lutz MayCEO

“We can measure where nobody else can”

Torque And More GmbHMünchener Str. 3382319 StarnbergGermany

[email protected]: +49 8151 368 981 30Fax: +49 8151 368 98 299Web: www.tam-sensors.com

ABOUT USWe are experts in the field of de-veloping, testing and producing sophisticated and market leading magnetic principle based sensing technology. Our key applications for the global markets include: automotive, industry, renewable energy, power tools and con-sumer products. Founded in Germany, TAM is a research, testing, and produc-tion management Company that is 100% privately owned. TAM works together with automotive certified production partners.

WHAT OUR CUSTOMERS SAY ABOUT US:

How to Contact Us:Mailing Address:

Torque And More GmbH Phone: +49 8151 368 981 30Münchener Str. 33 Fax: +49 8151 368 982 99 82319 Starnberg Sales: [email protected] Web: www.tam-sensors.com

“We mounted our sensor to our steering shaft. The sensor works very well indeed. It is very sensitive to torque variations, exceeding our requirements.”

Research Scientist | Automotive Company (NL)

“Wir haben Ihre Firma stets in guter Erinnerung. Die von Ihnen gelieferten Sensoren passen und funktionieren einwandfrei und haben zum Erfolg des Projektes beigetragen.

Vielen Dank für Ihren Support und Ihre Hilfe.”Technical Sciences | Large Steel Company (GER)

“Your support was quite useful and I appreciate and thank you for it. With the correct sensor alignment, the system works very well.” Engineer | Industrial Equipment Factory (UAE)

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Documents

Torque Sensing: Any Time & Everywhere 2016 · • Torque – Bending – Axial Load • Most affordable Active Sensor Kit • Wide measurement range • Ideal for safety applications