Transducer Design Considerations
Force & Torque Products
SensorData’s design philosophy is to provide the optimum and as compact as possible product for the application. Obvious benefits to this approach are; higher stiffness, higher natural frequencies, lower mass moment of inertia and lower weight. All cater to the ever demanding measurement community of today.
A quick comparison between any of our sensors and a typical competing product will put the above statement in perspective. In Figures-1 & 2 below, two SensorData models T260 and T258 drawn in yellow are compared to two typical industry offerings, drawn in red. A comparison between the dynamic characteristics of the two clearly shows the SensorData edge.
An added advantage to the lower weight of our sensors in general, lies in the ability to float them between the driver and the UUT (unit under test) without the need for foot mounts. Foot mounts, needed when the weight of the sensor is prohibitive, generally complicate setups and add to the stringency of driveline alignments.
Our catalogue of standard force and torque measurement devices covers most all measurement requirements and it continues to grow as our customers keep adding to their wish list of new applications.
If you do not see what exactly you are looking for in our catalogue, we will be happy to adapt, modify or even redesign something that fits your needs.
Multi Component and Special Design Products
Another area our design team excels at is the design of multi-component force and torque measurement devices. A good number of SensorData’s multi-axis (from simple two to complex six axis) sensors are deployed worldwide on tire conformity, tire testing, or other large scale testing machines. Two primary challenges usually encountered in the design of such sensors; the integrity of the structure to bear the combined stresses induced by multiple components without adversely affecting the load/output sensitivity ratio, and the ability to minimize the parasitic cross-talk effects of one component over the others. Techniques used in cross-talk optimization are either via look-up tables, or by using intricate electronic cross-talk circuitry. However, at SensorData we have found that the best way to combat cross-talk is not to create it in the first place. A carefully designed structure where the Wheatstone bridges are deployed on members that are only sensitive to the components they are measuring proves to be a more effective approach. Through this approach SensorData is usually able to limit cross-talk to less than 3% naturally. Further proprietary techniques are used to bring it further to less than 1.0% if needed.
Two other special product lines that are unique to SensorData, are the dual range and the super high overload families.
The dual range family of sensors was developed to address an old aspiration of the measurement community, namely; to be able to run high and low value measurements on the same test item without having to tear down the test setup, change the sensor, or compromise the accuracy of measurement. This family of sensors was developed to address this very need. Dual range, real-time sensors, with capacity ratios up to 10 times, are becoming one of the most popular in our list of special sensors.
Another significant product development was in response to a request for a super-high overload capacity. This situation usually arises in very low range measurements interrupted by unexpected orders of magnitude spikes. Normally, using a sensor that can withstand the high spikes will deteriorate the quality of measurement. Using a low range sensor will not withstand the unexpected spikes. The solution was to develop a sensor accurate enough at low ranges, but mechanically rugged enough to withstand high range spikes without deterioration of the low end performance.
Both the dual range and the high overload families started as typical special applications by certain customers, but ended up as adding two more winners to our product portfolio.
Since its inception in 1992, SensorData has always welcomed the difficult measurement application. Realizing that such applications require heavy investment in human and financial resources, we always maintained that this would be the only way to stay abreast of the state of the art. Our development team philosophy is that we only participate in areas where we can improve on the state of the art.
Examples of some of these special designs range from miniaturization in size, as in the M211-117, to a 64,000 RPM torque sensor.
As dynamic measurements become more automated, we continue to add to our sensors on-board special features. One such feature is the “TEDS” (Transducer Electronic Data Sheet), which is offered as an option on all of our products, and is the option of choice in military applications.
Dual range sensors also are available in several switching options; real-time, relay switchable or software switchable, to address any special testing requirements.
Even when it comes to our least sophisticated auxiliary components, the slip ring, we have developed a proprietary slip ring/brush assembly line that is designed by SensorData and manufactured by the best in the industry under stringiest military specs.