Kistler 4551A Owner's manual

System

Description

KiTorq Torque

Measuring Flange

Type 454xA...

Type 455xA...

ä

002-566e-03.23

Foreword

002-566e-03.23 Page 1

Foreword

This system description applies to the torque measuring

flange system that consists of the type 455xA... KiTorq

Rotor torque measuring unit and the type 454xA... KiTorq

Stator torque evaluation unit.

Keep this system description for future reference. It should

be available at the point of use.

Information in this system description is subject to change

at any time, without notice. Kistler reserves the right to

improve and modify its products in the course of technical

advancement, without any obligation to inform any

persons or organizations of such changes.

Original language of this System description: German

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

phone +41 52 224 11 11

[email protected]

www.kistler.com

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 2

Contents

1.Introduction ................................................................................................................................... 7

1.1FCC compliance statement ................................................................................................... 8

2.General description of the KiTorq System ...................................................................................... 9

2.1KiTorq stator torque evaluation unit ..................................................................................... 9

2.2KiTorq rotor torque measuring unit ...................................................................................... 9

3.Transmission ................................................................................................................................ 10

4.Speed/Angle measurement .......................................................................................................... 11

4.1Speed measuring system for Type 4550A… ....................................................................... 11

4.2Speed measuring system for Type 4551A… ....................................................................... 11

4.3Diagram – Maximum possible output pulses ...................................................................... 12

5.Terminology Calibration .............................................................................................................. 13

5.1Terminology ....................................................................................................................... 13

6.Typical setup of a KiTorq torque measuring linkage .................................................................... 15

7.Vibrations .................................................................................................................................... 16

8.Evaluation of the torque ............................................................................................................... 17

9.Running the measurement cable .................................................................................................. 18

9.1Connection diagram torque measuring flange .................................................................... 19

10.Standard calibration and special calibration ................................................................................. 20

11.Important notes Type 455xA… .................................................................................................... 21

11.1For your safety ................................................................................................................... 21

11.2Electromagnetic compatibility (EMC) .................................................................................. 21

11.3Tips for using this assembly manual ................................................................................... 22

11.4Note on the disposal of electronic devices .......................................................................... 22

12.Typical properties torque measuring unit .................................................................................... 22

13.Brief instructions for commissioning Type 455xA… .................................................................... 23

13.1Mechanical setup ............................................................................................................... 23

13.1.1Mounting the torque measuring unit on the counterflange ................................... 24

13.1.2Rotor screw connection/mounting screws Type 4550A… ..................................... 24

13.1.3Rotor screw connection/mounting screws Type 4551A… ..................................... 24

13.1.4Alignment of the Type 455xA... torque measuring unit (Rotor and Stator) ............ 25

13.1.5Application examples ............................................................................................. 26

13.2Metal-free space ................................................................................................................ 26

14.Standard calibration and special calibration ................................................................................. 27

Introduction

Page 3 002-566e-03.23

15.Important notes Type 454xA… ..................................................................................................... 28

15.1For your safety .................................................................................................................... 28

15.2Electromagnetic compatibility (EMC) .................................................................................. 28

15.3Tips for using the instruction manual .................................................................................. 28

15.4Note on the disposal of electronic devices ........................................................................... 29

16.Typical properties of the torque evaluation unit ........................................................................... 30

16.1Functional overview Type 4541A… .................................................................................... 30

16.2Functional overview Type 4542A… .................................................................................... 30

16.3Overview of signal processing Type 4541A… ..................................................................... 31

16.4Overview of signal processing Type 4542A… ..................................................................... 31

17.Assembly manual and alignment .................................................................................................. 32

17.1Mounting ............................................................................................................................ 34

18.Plug connections Type 4541A… ................................................................................................... 35

18.1Connector X1: 7 Pin built-in connector Type 4541A… ....................................................... 35

18.2Connector X2: 14 Pin built-in connector Type 4541A… ..................................................... 35

18.3Connector X3: 7 Pin built-in connector Type 4541A… ....................................................... 36

18.4Connector X4: 12 Pin built-in connector Type 4541A… ..................................................... 36

18.5Connector X1, X2 (PROFINET, EtherCAT, EtherNet/IP) Type 4542A… .............................. 37

18.6Connector X1 and X2 (PROFIBUS) Type 4542A… .............................................................. 38

18.7Connector X1 and X2 (CANopen) Type 4542A… ............................................................... 39

18.8Connector X3 Type 4542A… .............................................................................................. 40

18.9Connector X4 Type 4542A… .............................................................................................. 41

18.9.1Connector X4: 12 Pin built-in connector Type 4542A…......................................... 41

18.10Connector X5: USB Type 454xA… ...................................................................................... 42

18.11USB Interface Type 454xA… .............................................................................................. 42

18.12Tare button Type 454xA… ................................................................................................. 43

18.13Power LED Type 454xA… .................................................................................................. 43

18.14Communication LEDs PROFINET Type 4542A… ................................................................ 44

18.15Communication LEDs EtherCAT Type 4542A… .................................................................. 45

18.16Communication LEDs EtherNet/IP Type 4542A… ............................................................... 47

18.17Communication LEDs PROFIBUS Type 4542A… ................................................................ 48

18.18Communication LEDs CANopen Type 4542A… .................................................................. 49

19.Connection cable Type 4541A… .................................................................................................. 50

20.Connection cable Type 4542A… .................................................................................................. 52

21.Further connection cable Type 4542A… ....................................................................................... 55

22.Electrical and mechanical commissioning Type 454xA… ............................................................. 57

23.Calibration .................................................................................................................................... 59

23.1Torque evaluation unit (Stator) ........................................................................................... 59

23.2Generating the system certificate from the individual certificates ........................................ 59

24.Features ........................................................................................................................................ 61

24.1Tips for using these operating instructions .......................................................................... 61

24.2Nomenclature ..................................................................................................................... 61

25.Interface commands ...................................................................................................................... 62

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 4

25.1Conventions and syntax ..................................................................................................... 62

25.2Glossary of commands ....................................................................................................... 64

25.3Error messages ................................................................................................................... 67

25.4HyperTerminal® .................................................................................................................. 68

25.5System ............................................................................................................................... 72

25.5.1Identification (*IDN?) ............................................................................................ 72

25.5.2Event status register (*ESR?) ................................................................................. 73

25.6Measure ............................................................................................................................. 75

25.6.1Determine measured values (MEAS) ...................................................................... 75

25.6.2Clear peak value buffer (TRAC) ............................................................................. 76

25.6.3Switch scaling range (INP:GAIN:MULT) ................................................................ 77

25.6.4Control signal (INP:CONT) .................................................................................... 77

25.6.5Low pass filter for digital measured torque values (OUTP:TORQ:FILT) ................. 78

25.6.6Low pass filter for digital measured torque values measured speed values

(OUTP:SPE:FILT) ................................................................................................... 79

25.6.7Tare the torque outputs (OUTP:TARE) .................................................................. 80

25.6.8Tare the angle output signal (TRAC:ANG) ............................................................. 81

25.6.9Automatic tare of angle output signal (SYST:SPE:TURN) ....................................... 81

25.6.10Number of output pulses (OUTP:SPE:IMP) ............................................................ 81

25.6.11Synchronize measured values (INP:SYNC) ............................................................. 82

25.6.12Absolute/Relative angle measurement (SYST:SPE:MODE) ..................................... 82

25.7Primary voltage output (Plug X3) ...................................................................................... 83

25.7.1Configuration (OUTP:PRI:VOLT:CONF) ................................................................ 83

25.7.2Source (OUTP:PRI:VOLT:SOUR) ........................................................................... 84

25.7.3Scaling ranges (OUTP:PRI:VOLT[:EXT]:SCAL) ....................................................... 84

25.7.4Low-Pass filter (OUTP:PRI:VOLT[:EXT]:FILT) ........................................................ 85

25.7.5Taring (OUTP:PRI:VOLT:TARE) ............................................................................. 86

25.7.6Output swing magnitude (OUTP:PRI:VOLT:MAGN) ............................................. 87

25.7.7Output swing magnitude for control (OUTP:PRI:VOLT:CONT:MAGN) ................ 87

25.7.8Digital control input (INP:PRI:VOLT:CONT) .......................................................... 88

25.8Primary frequency output (plug X1) Type 4541A… ........................................................... 89

25.8.1Configuration (OUTP:PRI:FREQ:CONF) Type 4541A… ........................................ 89

25.8.2Scaling ranges (OUTP:PRI:FREQ[:EXT]:SCAL) Type 4541A… ................................ 90

25.8.3Low-Pass filter (OUTP:PRI:FREQ[:EXT]:FILT) Type 4541A… ................................. 90

25.8.4Taring (OUTP:PRI:FREQ:TARE) Type 4541A… ..................................................... 92

25.8.5Output zero point (OUTP:PRI:FREQ:ZERO) Type 4541A… .................................. 93

25.8.6Output swing magnitude (OUTP:PRI:FREQ:MAGN) Type 4541A… ..................... 93

25.8.7Output swing magnitude for control (OUTP:PRI:FREQ:CONT:MAGN) Type

4541A… ............................................................................................................... 94

25.8.8Output signal shape (OUTP:FREQ:MODE) Type 4541A… .................................... 94

25.8.9Output amplitude (OUTP:FREQ:AMPL) Type 4541A… ........................................ 95

25.8.10Digital control input (INP:PRI:FREQ:CONT) Type 4541A… ................................... 95

25.9Secondary output (Plug X4) ............................................................................................... 96

25.9.1Configuration (OUTP:SEC:CONF) ......................................................................... 96

25.9.2Source (OUTP:SEC:SOUR) .................................................................................... 97

25.9.3Output signal type (OUTP:SEC:ROUT) ................................................................. 97

25.9.4Scaling ranges (OUTP:SEC[:EXT]:SCAL) ................................................................ 98

25.9.5Low-pass filter (OUTP:SEC[:EXT]:FILT) .................................................................. 99

25.9.6Taring (OUTP:SEC:TARE) .................................................................................... 100

25.9.7Output voltage swing magnitude (OUTP:SEC:VOLT:MAGN) ............................. 101

25.9.8Output Voltage Swing Magnitude for Control (OUTP:SEC:VOLT:CONT:MAGN) 101

25.9.9Frequency output zero point (OUTP:SEC:FREQ:ZERO) ....................................... 102

25.9.10Output frequency swing magnitude (OUTP:SEC:FREQ:MAGN) .......................... 102

25.9.11Output frequency swing magnitude for control (OUTP:SEC:FREQ…) ................. 103

25.9.12Output amplitude (OUTP:FREQ:AMPL) .............................................................. 103

25.9.13Digital control input (INP:SEC:CONT) ................................................................. 104

Introduction

Page 5 002-566e-03.23

25.10Peripheral output (plug X2) Type 4541A… ....................................................................... 104

25.10.1Digital control input (INP:PRI:FREQ:CONT) ......................................................... 104

25.10.2Digital tare input (INP:TARP) Type 4541A… ........................................................ 105

25.10.3Digital scaling selection (INP:RANG) Type 4541A… ............................................. 106

25.10.4Digital scaling acknowledgment (OUTP:RANG:ACKN) Type 4541A… ................. 106

25.11Tare button and LED ......................................................................................................... 107

25.11.1State of the Tare Button (INP:TARB) .................................................................... 107

25.11.2State of the LED (OUTP:LED) ............................................................................... 107

25.12Fieldbus/Industrial Ethernet (general data) Type 4542A… ................................................ 108

25.12.1Fieldbus/Industrial Ethernet Type (OUTP:FBUS:TYPE) Type 4542A… .................. 108

25.12.2Physical plug type (OUTP:FBUS:HARD) Type 4542A… ....................................... 108

25.12.3Firmware version (OUTP:FBUS:VER) Type 4542A… ............................................ 109

25.13PROFINET Type 4542A… ................................................................................................. 109

25.13.1MAC address (OUTP:FBUS:PN:MAC) .................................................................. 109

25.13.2Device name (OUTP:FBUS:PN:NAME) Type 4542A… ......................................... 110

25.13.3IP address (OUTP:FBUS:PN:[IP | ADDR]) Type 4542A… ...................................... 110

25.13.4Subnet mask (OUTP:FBUS:PN:GATE) Type 4542A… ........................................... 111

25.13.5Gateway address (OUTP:FBUS:PN:GATE) Type 4542A… .................................... 111

25.13.6Define IP address (OUTP:FBUS:PN:[IP | ADDR]:PWUP) Type 4542A… ............... 111

25.13.7Define device name (OUTP:FBUS:PN:NAME:PWUP) Typ 4542A… ..................... 112

25.13.8Define subnet mask (OUTP:FBUS:PN:SUBN:PWUP) Type 4542A… .................... 113

25.13.9Define gateway address (OUTP:FBUS:PN:GATE:PWUP) Type 4542A… .............. 113

25.14PROFIBUS Type 4542A… ................................................................................................. 115

25.14.1Address (OUTP:FBUS:PB:ADDR) Type 4542A… .................................................. 115

25.14.2Baud rate (OUTP:FBUS:PB:BAUD) Type 4542A… ................................................ 115

25.15CANopen Type 4542A… .................................................................................................. 117

25.15.1ID (OUTP:FBUS:CAN:ID) Type 4542A… ............................................................. 117

25.15.2Baud rate (OUTP:FBUS:CAN:BAUD) Type 4542A… ............................................ 117

25.15.3TPDO refresh rate (OUTP:FBUS:CAN:PDO:RATE) Type 4542A… ....................... 118

25.15.4Status (OUTP:FBUS:CAN:MODE) Type 4542A… ................................................ 118

25.15.5Switch TPDO On and Off (OUTP:FBUS:CAN:TPDO) Type 4542A… ................... 119

25.16EtherCAT Type 4542A… .................................................................................................. 120

25.16.1MAC address (OUTP:FBUS:ECAT:MAC) Type 4542A… ...................................... 120

25.16.2Second station address (OUTP:FBUS:ECAT:SSAD) ............................................... 120

25.17EtherNet/IP Type 4542A… ............................................................................................... 121

25.17.1MAC address (OUTP:FBUS:EIP:MAC) Type 4542A… .......................................... 121

25.17.2IP address (OUTP:FBUS:EIP:[IP | ADDR]) Type 4542A… ...................................... 121

25.17.3Subnet mask (OUTP:FBUS:EIP:GATE) Type 4542A… ........................................... 122

25.17.4Gateway address (OUTP:FBUS:EIP:GATE) Type 4542A… .................................... 122

25.17.5Define IP address (OUTP:FBUS:EIP:[IP | ADDR]:PWUP) Type 4542A… ............... 122

25.17.6Define subnet mask (OUTP:FBUS:EIP:SUBN:PWUP) Type 4542A… .................... 123

25.17.7Define gateway address (OUTP:FBUS:EIP:GATE:PWUP) Type 4542A… .............. 124

25.18Buffer area ........................................................................................................................ 125

25.18.1Load and save settings (MEM:[LOAD | SAVE]) .................................................... 125

25.18.2Digital data sheet ................................................................................................. 126

26.PROFINET Type 4542A… ........................................................................................................... 128

26.1Cyclical input data (for sensor) Type 4542A… .................................................................. 128

26.2Cyclical output data (from sensor) Type 4542A… ............................................................. 131

26.2.1Status bytes Type 4542A… .................................................................................. 132

26.2.2Torque and measured value status Type 4542A… ............................................... 132

26.2.3Speed and measured value status Type 4542A… ................................................. 133

26.2.4Angle and measured value status Type 4542A… ................................................. 134

26.2.5Rotor temperature and measured value Type 4542A…........................................ 135

26.2.6GSDML-file Type 4542A… .................................................................................. 135

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 6

27.PROFIBUS Type 4542A… .......................................................................................................... 136

27.1Cyclical input data (for sensor) Type 4542A… ................................................................. 136

27.2Cyclical output data (from sensor) Type 4542A… ............................................................ 139

27.2.1Status bytes Type 4542A… ................................................................................. 140

27.2.2Torque and measured value status Type 4542A… .............................................. 140

27.2.3Speed and measured value status Type 4542A… ................................................ 141

27.2.4Angle and measured value status Type 4542A… ................................................ 142

27.2.5Rotor temperature and measured value status Type 4542A… ............................. 143

27.2.6GSD file Type 4542A… ....................................................................................... 143

28.CANopen Type 4542A… ............................................................................................................ 144

28.1Cyclical input data RPDO 1 (for sensor) Type 4542A… ................................................... 144

28.2Cyclical output data TPDOs (from sensor) Type 4542A… ................................................ 147

28.2.1TPDO 1 Torque Type 4542A… ........................................................................... 147

28.2.2TPDO 2 speed Type 4542A… ............................................................................. 149

28.2.3TPDO 3 Rotor temperature Type 4542A… ......................................................... 150

28.2.4TPDO 4 angle Type 4542A… .............................................................................. 151

28.2.5EDS File Type 4542A… ....................................................................................... 152

29.EtherCAT Type 4542A… ............................................................................................................ 153

29.1Cyclical input data (for sensor) Type 4542A… ................................................................. 153

29.2Cyclical output data (from sensor) Type 4542A… ............................................................ 156

29.2.1Status bytes Type 4542A… ................................................................................. 157

29.2.2Torque and measured value status Type 4542A… .............................................. 157

29.2.3Speed and measured value status Type 4542A… ................................................ 158

29.2.4Angle and measured value status Type 4542A… ................................................ 159

29.2.5Rotor temperature and measured value status Type 4542A… ............................ 160

29.2.6XML file Type 4542A… ....................................................................................... 160

30.Ethernet/IP Type 4542A… ......................................................................................................... 161

30.1Cyclical input data (for sensor) Type 4542A… ................................................................. 161

30.2Cyclical output data (from sensor) Type 4542A… ............................................................ 164

30.2.1Status bytes Type 4542A… ................................................................................. 165

30.2.2Torque and measured value status Type 4542A… .............................................. 165

30.2.3Speed and measured value status Type 4542A… ................................................ 166

30.2.4Angle and measured value status Type 4542A… ................................................ 167

30.2.5Rotor temperature and measured value status Type 4542A… ............................. 168

30.2.6EDS file Type 4542A… ........................................................................................ 168

31.Index .......................................................................................................................................... 169

Total pages 171

Introduction

Page 7 002-566e-03.23

1. Introduction

Thank you for choosing a quality product from Kistler.

Please read this system description carefully, so that you

can put the many properties of your product to optimal

use.

Kistler declines any liability, to the extent permissible by

law, if action is taken contrary to this system description, or

other products are used than those listed as accessories.

Kistler provides a wide range of metrology products and

overall solutions:

 Piezoelectric sensors for measuring pressure, force, torque,

strain, acceleration, shock, and vibration

 Strain gage sensor systems for measuring force and torque

 Piezoresistive pressure sensors and transmitters, with

corresponding measuring amplifiers

 Corresponding measuring amplifiers (charge amplifiers,

piezoresistive amplifiers, etc.), display units, and charge

calibrators

 Electronic control, monitoring, and evaluation units, and

application-specific metrological software

 Data transmission modules (telemetry)

 Electromechanical NC joining modules and load-

displacement monitors

 Test bench systems for electric motors and gears in the lab,

in production, and for quality assurance

Kistler also develops concepts for entire measurement

systems for special uses, such as in the automotive

industry, plastic processing, and biomechanics.

Our full catalog provides an overview of our product line.

Detailed data sheets area available for practically all of our

products.

For assistance with any special questions remaining after

studying these instructions, Kistler customer service is

available around the world with expert advice for

application-specific problems.

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 8

1.1 FCC compliance statement

This device complies with Industry Canada licence-exempt

RSS standard(s) and part 15 of the FCC Rules. Operation is

subject to the following two conditions:

(1) this device may not cause interference, and (2) this

device must accept any interference, including interference

that may cause undesired operation of the device.

Changes or modifications not expressly approved by the

party responsible for compliance could void the user's

authority to operate the equipment.

General description of the KiTorq System

Page 9 002-566e-03.23

2. General description of the KiTorq System

The torque measuring flange consists of a KiTorq Rotor

torque measuring unit, a KiTorq Stator torque evaluation

unit, and a calibration of the combined torque measuring

linkage. All rotors and stators in the KiTorq system are

based on the same technology, so they can be combined

with the same speed measuring option. The members of

the this technological family can be recognized by their

type identification. The torque measuring units are

identified by the type range from Type 4550A… to Type

4559A…, and the torque evaluation units are found in the

range from Type 4541A… to Type 4549A… .

2.1 KiTorq stator torque evaluation unit

The torque evaluation unit (stator) supplies power to the

torque measuring unit (rotor), and receives data and

measured values. The digital measured values are

processed and prepared for various outputs. Depending on

the design of the evaluation unit, various types of outputs

are available.

Depending to the speed option (N1/N2/N3), the torque

evaluation unit additionally offers an integrated

speed/angle measurement system for a speed

≤20 000 min-1. Speed respectively angle can be transfered,

together with a reference pulse (Z-Impulse), as TTL signal

or read out from the serial interface.

2.2 KiTorq rotor torque measuring unit

The torque to be measured is captured by the torque

measuring unit, using strain gages, then amplified and

digitized. Due to this basic technology, all rotors in the

torque measuring flange system have a very high

bandwidth.

Tor

q

ue evaluation uni

t

KiTorq Stator

Type 454x…

Tor

q

ue measuring uni

t

KiTorq Rotor

Type 455xA…

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 10

Strain

Gage

V

ADC

CPLD

EEPROM



ADC

DDS

DAC

FPGA

µC

DC

Torque evaluation unit

KiTorq Stator Type 454x...

Torque measuring unit

KiTorq Rotor Type 455x…

Voltage

Supply

Frequency

RS-232C

USB

Control Signal

Feldbus

DATA

POWER

3. Transmission

Transmission of power and data from the torque

evaluation unit to the torque measuring unit takes place via

inductive coupling (telemetry), across an air gap of ≤2 mm.

Frequencies from the ISM band between 115 … 130 kHz

are used for this purpose.

The torque evaluation unit automatically adapts the power

supply during operation to the axial and radial position of

the torque measuring unit, thereby securing it for all

operating points.

The feed frequency is PSK modulated for sending data to

the rotor. Depending on the feed frequency, the data rate

can be between 360 ... 406 bit/s.

The ISM band frequency 13,56 MHz is used for receiving

the measurement data. The measurement data are also

transmitted from the torque measuring unit to the torque

evaluation unit via inductive coupling as a PSK modulated

signal, at up to 1,4 MBit/s. In addition to the torque, the

rotor measurement data include the temperature, supply

voltage, and EEPROM (electrically erasable programmable

read-only memory) contents.

Fig. 1: Block diagram of a torque measuring flange

Speed/Angle measurement

Page 11 002-566e-03.23

4. Speed/Angle measurement

4.1 Speed measuring system for Type 4550A…

4.2 Speed measuring system for Type 4551A…

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 12

4.3 Diagram – Maximum possible output pulses

Terminology Calibration

Page 13 002-566e-03.23

5. Terminology Calibration

5.1 Terminology

There is a fundamental difference between adjusting and

calibrating. Calibration is only the measurement of

a system. The output signal that arises for defined loads is

registered. For adjustment, the output is affected by an

adjusting element while under a defined load. The torque

measuring flange is adjusted at the factory.

When a torque measuring flange is ordered for the KiTorq

system, the calibration of one or more outputs can be

selected. In this case, the torque measuring unit provided is

calibrated together with the supplied torque evaluation

unit. An individual certificate is also included for each stator

and rotor. This means that the torque measuring flange

can also be combined from individual orders for torque

measuring units (rotors) and torque evaluation units

(stators) and commissioned accordingly, and that

a component that fails during operation can be replaced

directly, without removing and recalibrating the entire

torque measuring linkage. The measurement uncertainty

and the certificate of the torque measuring flange are

derived, in this case, from a measurement uncertainty

analysis or calculation from the individual certificates for

the rotor and stator.

If the frequency output or a digital output is used for

evaluating the torque, then the calibration of the stator is

not required.

Kistler recommends regular calibration of the measurement

linkage and the individual components of the torque

measuring flange. To this end, there is a sticker on each

torque measuring unit and torque evaluation unit that

shows the next recommended calibration date. The next

calibration date can also be found on the certificate of the

torque measuring linkage.

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 14

The following illustration shows a simply setup for

a calibration system. Local gravity must be considered in

order to calculate the torque.

It is recommended that the calibration be performed by the

Kistler DAkkS laboratory. Available calibration types include

simple calibration, factory calibration (20 % load steps),

and DAkkS calibration per 51309 (3 mounting positions).

Further information about Kistler calibration services is

available in our Calibration brochure 960-077.

Tor

q

ue measuring flange,

such as Type 454xA...

KiTorq Stator and Type

4550A... KiTorq Rotor

Bearing for lever arm

(double bearing)

Extendable cou

p

ling

or articulated shaft

Lever arm

bearing

Locking

device

Lever arm

Weigh

t

(calibrated)

Drive

Lever arm

Typical setup of a KiTorq torque measuring linkage

Page 15 002-566e-03.23

6. Typical setup of a KiTorq torque measuring linkage

The illustration shows a typical setup of a measuring

linkage for determining torque. The torque acting on the

torque measuring flange is converted to a voltage or

a frequency. The torque measuring flange has a limit

frequency, which can be between 0,1 Hz and 10 kHz,

depending on its setting. In order to avoid aliasing effects,

a low-pass filter must be used prior to digitization. The limit

frequency of this filter must be selected depending on the

selected low-pass filter for the torque measuring flange

and the scanning frequency of the digitization.

The scanning rate must be at least twice the maximum

frequency to be measured (Shannon sampling theorem). In

order to retain good reproducibility of the signal shape,

however, a scanning rate of 3 … 10 times the maximum

frequency to be measured is recommended.

Examples:

In one application, a rotary vibration at a higher frequency

(2 kHz) is superimposed on a torque curve having a lower

frequency (100 Hz). The sampling rate is 10 kHz.

In order to size the filter, the highest frequency to be

measured is used. In this case it is 2 kHz. The limit

frequency of the input filter must be greater than the

2 kHz in any case. It must also, however, be much less

than the scanning rate. At a scanning rate of 10 kHz,

a filter with a 2 or 3 kHz limit is recommended. If the

scanning rate is much greater, such as 100 kHz, the filter

can also be set higher. In order to measure the rotation

vibration, the filter in the sensor is set to an appropriately

high limit frequency. In order to measure the superimposed

torque curve, the limit frequency of the filter in the sensor

is lowered.

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 16

In order to prevent aliasing effects, a low-pass filter

should always be used before digitization. The limit

frequency is determined substantially by the scanning

rate; the limit frequency should be at least one third of

the scanning rate.

7. Vibrations

The installation of a torque measuring flange in a machine

train changes the vibration behavior by adding rigidity.

Under certain conditions, a rotary vibration can be excited

in the system by the drive controller or the test specimen

behavior.

If undesired vibrations occur in the torque signal for an

application, they can be suppressed or prevented by

various means.

Measures:

 Change the control parameters of the drive

 Change the rigidity of the system (e.g. by replacing the

coupling)

 If the vibration is above the maximum frequency of the

torque to be measured, the vibration can be suppressed

using a low-pass filter. Care must be taken, however, that

the vibration can lead to destruction of the torque

measuring flange if resonance occurs. This is because the

torque can be well above the limit torque but will not be

captured in the output signal, due to the low-pass filter.

Evaluation of the torque

Page 17 002-566e-03.23

8. Evaluation of the torque

In order for the output signal (voltage or frequency) of the

torque measuring flange to be displayed as a torque, the

measuring amplifier used must perform a correlation

between the output signal and the torque value. This is

generally a two-point evaluation. This means that the

output signal (characteristic value) that is present at the

nominal torque is entered into the amplifier. The

intermediate values result from a linear correlation.

Depending on the calibration and measuring amplifier

used, various possibilities are available.

Nominal characteristic value entry:

The nominal characteristic value can be found on the data

sheet for the sensor.

Entering the calculated characteristic value:

Every KiTorq torque measuring flange includes a certificate

for the KiTorq Rotor torque measuring unit and the KiTorq

Stator torque evaluation unit. The characteristic value can

be calculated from these documents.

Entering the characteristic value for the measuring linkage

calibration:

If the torque measuring linkage has a current calibration

certificate, the characteristic values can be taken directly

from the certificate.

Entering the interpolated value for the measuring linkage

calibration:

If a factory calibration certificate (FCC) is available, the

value for the measuring amplifier can be calculated from

the interpolation equation. This equation can be found on

the FCC. This is a regression line that is derived from all

points of the ascending sequences of the calibration.

The best result is obtained by entering the interpolated

characteristic value.

For a DAkkS calibration, a quadratic and a cubic function

and provided in addition to the linear regression line,

depending on the class. Entering these coefficients can

further increase the precision of the system. At this time,

however, there are very few measuring amplifiers on the

market that allow entry of these coefficients.

Exam

p

le:

KiTorq Torque Measuring Flange, Type 455xA...

002-566e-03.23 Page 18

9. Running the measurement cable

 Do not run in parallel with high-current or control cables.

 Do not run near strong electromagnetic fields, such as

transformers, welders, contactors, motors, etc. If this

cannot be avoided, run the measurement cable in

a grounded steel shield conduit.

 At high speed probe frequencies, use of the X3 plug is

recommended in order to minimize coupling of the speed

and the torque signal.

 Avoid excess lengths of cable. If this is not possible, do not

coil the excess length into a closed ring. Keep the induction

area as small as possible.

Fig. 2: Running the measurement cable

Risk of interference with the measurement signal

due to electromagnetic fields A bifilar run reduces the active induction area.

Measurement cable Cable raceway Measurement cable Cable raceway



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