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FEATURE TEST SYSTEMS


Torque transducers on test rig help check advanced electric and hybrid powertrains


Wireless rotary torque transducers from sensor manufacturer, Sensor Technology, are at the heart of a test rig to develop next generation technologies for electric and hybrid vehicle powertrains


efficiency electric motor and power electronics technology delivers class- leading electrified powertrains and propulsion systems. In order to test and characterise the


W


ith expertise in the electric motors and electronics used across the key


powertrain technologies, AVID Technology relies on Sensor Technology’s torque transducers as part of an automated approach to motor characterisation. Climate change, urban air quality and


the rising cost of energy have become the defining issues of the 21st century. With energy consumption and exhaust emissions from vehicles and transport being significant contributors to these issues, governments across the world are driving moves to secure a future where the air is safe to breathe and transport is more sustainable. In the UK this has seen the introduction


of the government’s draft clean air policy, along with the announcement that sales of petrol-only and diesel-only vehicles will be banned from 2040, bringing the role of hybrid and electric vehicles to the fore. In evolutionary terms, these technologies are still in their infancy, and this is where AVID Technologies come in. Based in the North-East of England,


which is now a world-recognised centre for automotive development, AVID Technology is a renowned leader in the design and manufacture of electrified powertrain and advanced thermal management systems for heavy-duty and high-performance electric and hybrid vehicles. Its technology also improves conventional internal combustion engine efficiency through parasitic loss reduction, efficient thermal management, lubrication, electrified ancillary systems and waste heat recovery. The company develops powertrain


improvement solutions for a wide range of electric and hybrid vehicle applications, including high performance passenger cars, heavy duty buses and trucks, as well as motorsport vehicles and off highway machinery. Its high


20 MAY 2018 | AUTOMATION


In order to test and characterise the high performance electric motors used in electric and hybrid powertrains, AVID Technology designed and built a special purpose test rig


high performance electric motors used in electric and hybrid powertrains, AVID Technology designed and built a special purpose test rig. Central to the design of the test rig is a wireless rotary torque measurement device from Sensor Technology. These non-contact surface wave acoustic (SAW) transducers are said to offer significant advantages compared with strain gauges, magnetic torque sensors and optical devices that might be fitted to a conventional dynamometer for motor characterisation. Sensor Technology SAW-based devices are non-contact, robust and highly accurate. TorqSense torque sensors use two tiny SAW devices made of ceramic piezoelectric material containing frequency resonating combs. These are glued onto the drive shaft at 90-degrees to one another. As the torque increases the combs expand or contract proportionally to the torque being applied. In effect the combs act similarly to strain gauges but measure changes in resonant frequency. The adjacent RF pickup emits radio waves towards the SAWs, which are then


reflected back. The change in frequency of the reflected waves identifies the current torque. This arrangement means there is no need to supply power to the SAWs, so the sensor is non-contact and wireless. These characteristics make the


TorqSense transducers suitable for use in the stepper drive test rig. AVID Technology sales director, Jordan Taylor, explains: “The TorqSense transducer was chosen as it allowed us to use a fixed pedestal load motor and eliminate frictional losses and parallax errors from the load installation in the measurements. This allows AVID to produce very accurate performance characterisation results compared to a conventional motor dynamometer.”


ACCURATE RESULTS Not only has the sensor delivered superior and more accurate characterisation results, it also enabled AVID to design a simpler test rig. Reporting that the device has performed flawlessly in the application to date, AVID Technology is confident that its test rig will be key in enabling it to enable even smarter powertrain electrification, delivering on its vision of a cleaner, greener world.


Sensor Technology T: 01869 238400 www.sensors.co.uk


When Terex Pegson MPS needed a reliable and flexible system to measure stress on its LJ5139 stone crushing machine, it turned to HBM to provide a comprehensive and effective solution. Following a thorough study of the issues faced by


Terex Pegson MPS, HBM specified its rugged DAQ, SomatXR series, which is particularly suitable for use in harsh environments. To compliment this package, HBM also suggested the Somat MX1615B- R module and related accessories, which included RF-9 strain gauge rosettes. Given the demanding environment, it was


important that Terex Pegson MPS specified the correct equipment. The powerful SomatXR data acquisition system is specifically developed for use in harsh environments. The modules provide a wide temperature range and are protected from humidity, dust, shock and vibration.


Flexible solution for machine stress measurement The data acquisition system provides a web


interface for simple operation without any software installation. This allows for convenient channel parameterisation, monitoring of measurement jobs and visualisation of measured data far away from the measuring point. This was a particularly significant feature for Terex MPS, given the nature of the measurement task. HBM data acquisition systems are suitable for a


wide range of mobile testing applications. Despite the immense load requirements and extreme environmental conditions, HBM was able to provide Terex MPS with a reliable and flexible solution. In addition to specifying and supplying Terex


MPS with a system to meet its needs, HBM also provided engineers with training and support.


HBM T: 01525 304980 www.hbm.com /AUTOMATION


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