Torque Sensor Troubleshooting

Torque sensors are used to detect different rotating or non-rotating mechanical components on the perception of torsional torque. It converts the physical change of torque into precise electrical signal output, and has the characteristics of high reliability, fast frequency response, high precision and long life.

Because the torque sensor can measure many kinds of rotational speed, torque and mechanical power, its application is very wide, and the main uses are as follows:

  • Can be used in process and process industries.
  • Can be used to detect sewage treatment systems.
  • Can detect the output power and torque of rotating power equipment such as engines, electric motors and internal combustion engines.
  • Can detect the power and torque of automobiles, railway locomotives, airplanes, ships and tractors and other machinery.
  • Can be used to make viscometers.
  • Can detect the power and torque of water pumps, fans, torque wrenches, etc.

Therefore, its figure is almost everywhere.

Below we specifically collect the problems encountered in the use of torque sensors, and summarize the corresponding processing methods. You may find the most frequent errors and their elimination.

Error 1: No signal

Possible cause 1: no sensor excitation
Elimination 1: connect excitation

Possible cause 2: Outside of permissible range
Elimination 2: check excitation

Possible cause 3: no mains excitation
Elimination 3: connect excitation

Possible cause 4: cable defect
Elimination 4: repair cable

Possible cause 5: wrong connected signal output
Elimination 5: connect output correctly

Possible cause 6: evaluation electronics defect
Elimination 6: repair / change

Error 2: sensor does not react to torque

Possible cause 1: shaft is not clamped
Elimination 1: clamp correctly

Possible cause 2: no sensor excitation
Elimination 2: connect excitation

Possible cause 3: no mains excitation
Elimination 3: connect excitation

Possible cause 4: outside of permissible range
Elimination 4: check excitation

Possible cause 5: cable defect
Elimination 5: repair cable

Possible cause 6: wrong connected connector
Elimination 6: connect output correctly

Error 3: Signal has dropouts

Possible cause 1: Carbon dust in the sensor
Elimination 1: clean sensor

Possible cause 2: Axial position of rotor to stator outside of tolerance
Elimination 2: send to manufacturer

Possible cause 3: cable defect
Elimination 3: repair cable

Error 4: Zero point outside of tolerance

Possible cause 1: strong lateral forces
Elimination 1: reduce lateral forces

Possible cause 2: shaft mounted distorted
Elimination 2: Mount correctly

Possible cause 3: distorted shaft string
Elimination 3: Release from desertion

Possible cause 4: cable defect
Elimination 4: repair cable

Possible cause 5: distorted flanges
Elimination 5: check evenness of flange surfaces

Possible cause 6: shaft overloaded
Elimination 6: send torque sensor to manufacturer

Error 5: Wrong torque indication

Possible cause 1: calibration is not correct
Elimination 1: re-calibrate

Possible cause 2: sensor is defect
Elimination 2: send to manufacturer

Possible cause 3: torque shunt
Elimination 3: eliminate shunt

Error 6: Shaft drags

Possible cause 1: shaft drags in stator
Elimination 1: align shaft

Possible cause 2: strong lateral forces
Elimination 2: reduce lateral forces

Error 7: Vibrations

Possible cause 1: alignment of shaft is not correct
Elimination 1: Align correctly

Possible cause 2: unbalance
Elimination 2: balance the corresponding parts

In addition to solving the problems encountered during the use of the torque sensor at any time, to ensure the normal operation of the torque sensor, special care must be taken in the later maintenance and maintenance.

Maintenance of rotary torque sensor:

  1. Grease the bearings at both ends of the torque sensor every other year. When adding grease, only open the bearing caps at both ends, add grease to the bearings, and then install the end caps.
  2. It should be stored in a dry, non-corrosive environment with room temperature ranging from -20°C to 70°C.

Precautions for rotary torque sensor:

  1. When installing, do not operate with electricity, and do not directly hit or collide with the rotary torque sensor.
  2. The fastening bolts of the coupling should be tightened, and a protective cover should be added to the outside of the coupling to avoid personal injury.
  3. The output of the signal line shall not be connected to the ground, short-circuited to the power supply, and the output current shall not be greater than 10mA.
  4. The shielding layer of the shielded cable must be connected to the common terminal (power ground) of the +15V power supply.

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