SENSORS & SENSING SYSTEMS FEATURE High precision torque sensors from


Kistler have been deployed on a test bench at Moog’s development centre which is designed to determine the efficiency of pumps


of 500Nm, 2,000Nm and 3,000Nm. Thanks to the rigid design and


Testing times for pump efficiency


Moog commissioned FMB Blickle to install a new test bench for hydraulic pump development


n many industries – including automotive and aerospace, forming processes, plastics processing and the renewable energy sector – sophisticated testing and simulation procedures are essential. Here, they can boost the efficiency of drives, and therefore of complete systems such as pumps, resulting in lower energy consumption and cutting costs. At its development site in Böblingen,


I “After setpoints for


pressure, flow rates and speed have been defined for the test object, efficiency is calculated on the basis of the actual torque measured”


Moog develops and produces hydraulic pumps for use across the world in sectors such as plastics processing and metal forming, and for wind turbines. To optimise its processes for determining pump efficiency in the future, the company commissioned FMB


Blickle to install a new test bench


for hydraulic pump development. The objects


under test are piston pumps that are powered by the electrical drive in the test bench. After setpoints for pressure, flow rate and speed have been defined for the test object, efficiency is calculated on the basis of the actual torque measured. Dynamic stressing of the specimens


during testing can place an additional load on the power train. To achieve clear


measurement results in all tests, a sturdy sensor that could also measure accurately was needed. There were, however, several other requirements for the sensor technology – the ability to read out the torque signals digitally via an EtherCAT interface; the client wanted the option of using multiple measuring ranges so that different pumps could be tested with minimum loss of time, i.e. without converting the test bench; and straightforward inventory management for spare parts was also a prerequisite. Following a thorough review of


solutions available, it was decided that sensor technology from Kistler would meet the demands. Karl-Heinz Rebstock, head of


automation technology at FMB Blickle, commented: “Kistler’s sensor technology meets our specifications in their entirety. As well as high accuracy and an EtherCAT interface, Kistler offers many other benefits – including the possibility of covering different measurement ranges thanks to the stator with several rotors.”


TORQUE MEASUREMENT For this application, the client selected three KiTorq type 4550A torque measuring flanges with measuring ranges


 DESIGN SOLUTIONS | MAY 2016 19


high resolution of the sensors, pump components can be tested and adjusted with great precision. Of additional benefit, each of the measuring flanges is equipped with an integrated EtherCAT interface, ensuring problem-free transmission of measurement data, even during operation in contaminated environments (especially where oily air or severe temperature fluctuations are present). With this interface, there is no longer any need for other external interface modules in the switch cabinet, saving installation space and further outlay on cabling. Measurements for different pumps are also possible thanks to the option of a second measuring range. This feature saves even more time and money because it reduces the need to convert the test bench, the company explains. The design of the test bench delivers


additional added value: the short rotor allows major savings on space and costs. In addition, the sensor is simple and economical to install and operate thanks to its ringless stator design. Rebstock added: “These sensors play


a valuable part in ensuring that Moog’s development centre in Böblingen will maintain its optimal standing on the global market as time goes on.”


Kistler www.kistler.com


The KiTorq 4550A is used to determine torque, speed or rotation angle


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