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1. WZ E E Figure 2 5 Removal of Cover 2 Bolt lower housing part with stator ring to flange plate by using the two lower bolts 77 Flange Plate SS Y Mounting Holes Figure 2 6 Flange Plate Magtrol TMF Torque Flange Transducer Chapter 2 Installation Configuration 3 Carefully insert measuring shaft center to connecting shaft and tighten bolts Tighten all bolts with identical torque CAUTION WHEN PLACING THE SHAFT ON A HARD SURFACE IT MUST ABSOLUTELY BE OBSERVED THAT THE PROJECTING SPEED RING IS NOT DAMAGED SSS q Do not damage speed ring when placing shaft on support plate Figure 2 7 Insertion of Measuring Shaft 4 Rotate measuring shaft by hand and determine if unobstructed rotation is possible and if there is no contact with the stator housing 5 Connect main cable between measuring flange and signal box Further observe perfect ground connection of stator housing with common Otherwise use separate cable 6 Complete other electric connections according to the Operating Manual pertaining to the signal box 2 3 1 INSTALLTION DIMENSIONS Please refer to the Data Sheet in Section 1 4 for dimensions and rotor shaft housing alignment 15 Chapter 2 Installation Configuration Magltrol TMF Torque Flange Transducer 2 4 ELECTRIC CONNECTIONS
2. Infrarot bertragungsstrecke 2 Infrarotubertragungstrecke 1 loptionall Stator mit integrierter Elektronik Figure 1 2 Composition of Measuring Flange z TI e D z O z Q m Z m wv gt m Chapter 1 Introduction Magltrol TMF Torque Flange Transducer 1 3 1 TEMPERATURE COMPENSATION Since the torque transducer itself and the first subsequent steps of electronic processing are functioning on an analog basis a temperature dependent shifting of the operating points cannot be excluded The shaft material elongation due to temperature effects will become noticeable at the output side of the measuring system as an undesired measuring value in the form of a temperature dependent zero point drifting although the strain gauges have been arranged in a so called Wheatstone bridge connection An active switching compensation circuit has been established in order to assure stable operating characteristics of the torque transducer over a wide temperature range With the support of a u Controller integrated at the rotating side temperature data which was determined in an expensive way during the manufacture of the system is picked up and stored in a so called Lock Up Table If during operation of the integrated temperature sensor a change in temperature is determined then the value which had been stored from the Table in advance will be added to the momentarily available measuring value This system has the major adv
3. M AGTROL Model TMF 401 403 Torque Flange Transducer User s Manual While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents Magtrol Inc assumes no responsibility for errors or omissions Additionally no liability is assumed for any damages that may result from the use of the information contained within this publication COPYRIGHT Copyright 2003 Magtrol Inc All rights reserved Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited First Edition August 2003 PA MAGTROL Safety Precautions OPERATOR S DUE CARE OBLIGATIONS The TMF 400 Series The Torque Measuring Flange was designed and built under consideration of a hazard analysis and upon careful selection of the harmonized standards as well as of other technical specifications to be adhered to Thus the system meets the state of the art requirements and guarantees the highest safety standards But such safety can in practice be reached only if all the necessary measures will have been taken It is the machine operator s obligation of due care to plan such measures and to control their execution Above all the operator must assure that e The system is used in accordance with the provisions as intended only see Section 1 1 e The system is operated under perfect and well functio
4. 3B 4A Q 4B AM26LS32 Figure 3 2 RS422 Output Signal Connection 3 3 6 CONNECTING THE TCU1 WITH A PC The TCUI Signal Box can be connected ti the serial I O RS232 of a PC via a 1 1 serial cable The parameters of the serial I O must be set to 9600 Baud 8 data bits 1 stop bit no protocol and no parity 21 Chapter 3 Signal Box Magtrol TMF Torque Flange Transducer 3 4 SETTINGS After all components are connected the unit can be started up If the entire measuring system TMF and TCU1 is ordered together all settings are done by Magtrol If only a TCUI was ordered or a TMF transducer the system must be adapted 3 4 1 OPERATING PRINCIPLE IEEE IEEE A RS422 RS232 Displa Input Md1 iid A RS422 eS CTA High AY Dynamic Frequency Microcontroller RS422 YY Measuring Input N1 16 Bit D A Converter 16 Bit D A Converter _ 4 AMY Cr RS422 Input N2 8 Steps 8 Steps Power Supply Low Pass Filter Low Pass Filter Generator Analog Output1 Analog Output2 Figure 3 3 Operation Flowchart The TCU1 SB1 Signal Box generates a voltage in order to supply power to the connected torque flange transducer The voltage amplitude can be up to 60 V peak to peak with a frequency from 10 40 kHz Four RS422 interfaces serve to receive the signals from the sensing element The microcontroller converts the received signals into analog outputs by using CPLDs and 16 Bit
5. REVISIONS TO THIS MANUAL etiaai Sent aenea dia ii REVISION DATE 0 diodo loan ii TABLE OF REVISIONS ernier ece aeee EEE EEEE E RE REA RE EAEE E EAE ii TABLE OF CONTENTS cn iii PREFAGE C E V PURPOSE OF THIS MANUAL e v WHO SHOULD USE THIS MANUAL iet cento orte tot torte EEEE Irae ee AEE S EEE EEEE EEEE EE A a v MANUAL ORGANIZATION iia v CONVENTIONS USED IN THIS MANUAL eeeeessessserssesersserseeseessesstesecssesstesecssessteseesseestessesseeseessesstestesseesssssesssesseeseseos vi 1 INTRODUCTION r 1 1 1 INTENDED USE ocurrio celia 1 12 COMPOSITION iia 2 LS BUNCTIONAL DESCRIPTION poesin ai e EE A ds 3 1 3 1 Temperature Com pPensati On ia ceevsecengoenveeurseueueednanese 4 1 3 2 Optional Measuring Range iii ii 5 TATDATASHEET MEL 6 2 INSTALLATION CONFIGURATION co sitiada 10 2 1 INSTALLATION SAFETY cia iras ide ia the as eee eei e ni dad 10 2 1 MECHANICAL INSTALLATION OF MEASURING FLANGE AND STATOR eene 11 2 1 4 Suspended Installation ocio RR RUE SO URDU DEO eo east 11 2 1 2 Front Mounting of Stator and Flange Close to a Bearing sese 12 2 1 3 Base Mounted Stator Directly at the Machine Power Take Off eese 12 2 2 TME WITH SIGNAL BOX ia ir 14 2 3 MECHANICAL INSTALLATION STEP BY STEP cil e REL eR eR EU
6. 800 readings s MD1 Torque analog Output 10V max 800 readings s X704 A INPUT 24V 6 pole MIL B MD1 Output C NDOC D Ground N1OC E NC Speed1 F N10C x Imp Umar open Collector NDOC speed direction open Collector MD1 Torque analog Output 10V max 800 readings s For connection to 6400 Display Unit 3 pole power supply 1 VCC 9 30 VDC 2 GND 3 ON OFF 0 9 30 VDC switches the torque flange transducer power supply on off X736 1 N1TTL 15 pole Sub D male 2 NDTTL Service 3 EITTL 4 NOC 5 NC 6 NC 7 CANL 8 Ground 9 N2TTL 10 MDTTL 11 Ground 12 N C 13 N C 14 N C 15 CANH X737 1 N1TTL 15 pole Sub D male 2 NDTTL Service 3 EITTL 4 Md RS422 5 N1 RS422 6 N2 RS422 7 El RS422 8 Ground 9 N2TTL 10 MDTTL 11 Ground 12 Md RS422 13 N1 RS422 14 N2 RS422 15 El RS422 X722 9 pole Sub D female 1 NC 2 TxD b s PD 6 7 8 9 4 NC 5 SIGNAL GROUND 6 NC RS232 7 NC Serial Com Port 8 N C 9 NC X708 Torque BNC analog output 10V max 800 readings s 8 cut off frequencies X722 Speed1 BNC analog output 10V max readings s 8 cut off frequencies X731 Display con 9 pole Sub D 20 Magtrol TMF Torque Flange Transducer Chapter 3 Signal Box 3 3 5 CONNECTING THE RS422 I O OPTIONAL The following wiring diagram is an example how to connect the RS422 output signals G G 1A 1Y 3 TTL 1B 5 2A 2B 3Y 3A 4Y H
7. The electric connections of the individual components with each other are conducted by using the main cable This cable can be used for connecting a signal box The maximum length of the main cable of 50 m should not be exceeded The voltage supply of the entire system depends on the order specifications and may basically be 230 VAC 115 VAC or 12 35 VDC also For the main voltage supply the value indicated on the signal box applies exclusively CAUTION PROBLEM FREE OPERATION CAN BE ASSURED ONLY IF THE STATOR HOUSING INCLUDING THE INTEGRATED RECEIVING ELECTRONIC UNIT HAS A PERFECT GROUND CONNECTION NORMALLY THIS IS AUTOMATICALLY DONE BY BOLTING THE HOUSING TO THE METAL PARTS OF THE ENTIRE STRUCTURE IF THE ABOVE CANNOT BE GUARANTEED THEN A SEPARATE LOW RESISTANCE CONNECTION SHOULD THEREAFTER BE INSTALLED TO A COMMON Figure 2 8 Connecting TMF Measuring Flange with Signal Box 16 3 Signal Box Figure 3 1 TCU1 SB1 Signal Box INTRODUCTION The following paragraphs of this manual describe all steps required of the taking into service and the installation of a Magtrol TCU1 SBI Signal Box Each torque flange transducer from Magtrol can be operated with the TCU1 SB1 The TCUI has a power supply output for the TMF transducer and makes a condition of the received signals for the analog outputs and the display FEATURES e Power supply output 0 48 Vss 10 50 kHz e Input 2 x Torque RS422 and 2 x Sp
8. 232 IEEE 488 interfaces The 6400 can be used as a basic display as an interface with Magtrol TM Software or on the production line using its pass fail feature TM Software Magtrol s TM Software is an easy to use Windows executable program used to automatically collect torque speed and mechanical power data The data can be printed displayed graphically or quickly saved as a Microsoft Excel spreadsheet Standard features of Magtrol s TM Software include peak torque capture direction of rotation multi axes graphing measured parameter vs time adjustable sampling rates and polynomial curve fitting DESCRIPTION MODEL Torque Transducer Display 120 volts 6400 Torque Transducer Display 240 volts 6400A TM Torque Transducer Software SW TM WE TM Torque Transducer Software with Source Codes SW TM WS Torque Transducer Connector Cable 5 m ER 113 011 Torque Transducer Connector Cable 10 m ER 113 021 Torque Transducer Connector Cable 20 m ER 113 031 Due to the continual development of our products we reserve the right to modify specifications without forewarning Zo Om Iz 5 5 33 or Z 2 Installation Configuration 2 1 INSTALLATION SAFETY OBSERVED IN ORDER TO AVOID SYSTEM DAMGE OR PERSONAL INJURIES DURING THE INSTALLATION OF THE MEASURING SYSTEM STOP WARNING THE FOLLOWING ITEMS MUST STRICTLY BE e Any installation work must be conducted by qualified p
9. 4654 in 4 76 2 91 0 91 1 06 3 54 6 30 5 51 3 70 0 35 5 5108 3 62 3 4646 Y 3 03 mm 178 103 41 26 5 120 224 208 97 1119 208h6 0 143 OQ 139H6 127 TMF 402 Y 8 1890 Q 5 4734 in 7 01 4 06 1 61 1 04 4 72 8 82 8 19 3 82 0 43 8 1878 Q 5 63 5 4724 5 00 mm 226 122 65 35 135 260 250 11519 11 9 250h6 4 180 90 170H6 W 154 TMF 403 A Y 9 8425 6 6939 in 8 90 4 80 2 56 1 38 5 31 10 24 9 84 4 53 0 43 9 8414 7 09 6 6929 Q 6 18 MODEL Units P Q R S T U V Ww X Y Z AA BB 8 mmlo 77 2 9 915 17 225 10 74 9 126 O 66 19 145 8 085 9 5 and TMF 401 8 Y M8 in 3 03 0 08 3 602 0 67 0 89 0 39 2 91 4 96 0 26 0 75 0 571 8 0 33 8 0 33 TMF 402 mm 127 3 142 9 16 5 22 5 12 103 90 187 G 9 19 14 5 12 9 12 g9 in 5 00 0 12 5 626 0 65 0 89 0 47 4 06 Y 7 36 0 35 0 75 0 571 12 0 35 12 0 35 TMF 403 mm 154 3 173 5 19 26 14 122190 226 90 11 22 14 5 16 O11 16 11 in 6 18 0 12 6 83 0 75 1 02 0 55 4 80 Y 8 90 0 43 0 87 0 571 16 0 43 16 0 43 Number in parenthesis denotes number of mounting holes Magtrol TMF Torque Flange Transducer Chapter 1 Introduction Mounting amp Accessories MOUNTING EXAMPLES Stator mounted directly on the machine s flange Clamping Element TMF Housing g Testbed i estbe Base P
10. D A converters The microcontroller calculates the physical quantity such as torque and speed out of the received frequencies These values can be shown in the terminal program or on the display Each signal box works together with each TMF torque flange transducer For that several characteristic data must be input via a terminal program or the touch screen display 22 Magtrol Limited Warranty Magtrol Inc warrants its products to be free from defects in material and workmanship under normal use and service for a period of one 1 year from the date of shipment Software is warranted to operate in accordance with its programmed instructions on appropriate Magtrol instruments This warranty extends only to the original purchaser and shall not apply to fuses computer media or any other product which in Magtrol s sole opinion has been subject to misuse alteration abuse or abnormal conditions of operation or shipping Magtrol s obligation under this warranty is limited to repair or replacement of a product which is returned to the factory within the warranty period and is determined upon examination by Magtrol to be defective If Magtrol determines that the defect or malfunction has been caused by misuse alteration abuse or abnormal conditions of operation or shipping Magtrol will repair the product and bill the purchaser for the reasonable cost of repair If the product is not covered by this warranty Magtrol will if requeste
11. utilizing the full accuracy of measurement of the smaller measuring range that the shaft STA assembly should be stopped and released from the load after having conducted a measuring cycle with a high torque load Then the zero push button must be pressed unless otherwise the hysteresis values stored before in the spring body would by principle superimpose itself on the second more sensitive measuring channel Amplifier 2 Voltage IR Transmission to Frequency Converter IR Transmission Amplifier 1 Voltage to Frequency Converter I l i Temperature to Digital Converter H Controller EEPROM Serial Interface 16 Bit temperature values Figure 1 4 Basic Structure of the Second Torque Measuring Range Chapter 1 Introduction Magtrol TMF Torque Flange Transducer 1 4 DATA SHEET TMF 401 TMF 403 Torque Flange Transducers FEATURES e Flat Bearingless Torque Transducer with Infrared Signal Transmission Torque Range 50 N m to 4200 N m 36 lb ft to 3097 Ib ft e Accuracy 0 1 0 05 on request e Overload Capacity 150 e Stator Mounting on Test Bench or Housing e Active Microprocessor controlled Temperature Zero Point Compensation e EMC Susceptibility Conforms to European Standards e Integrated Detection of Speed and Sense of Rotation as an option e Optional Second Measuring Scale DESCRIPTION With it
12. 1 MECHANICAL INSTALLATION OF MEASURING FLANGE AND STATOR The following possibilities are available for connecting the torque transducer with the shaft system SUSPENDED INSTALLATION The measuring flange is mounted to the shaft system without any additional bearing element The stator is bolted to the test bench plate either directly or through a suitable interim element Possible alignment or angular deviations must be compensated within the drive system by suitable clutch elements CAUTION THIS TYPE OF STATOR ATTACHMENT GENERALLY INCLUDES THE RISK THAT DURING HIGH VIBRATION LOADS RELATIVE MOVEMENTS OF AN IMPERMISSIBLY HIGH LEVEL MAY OCCUR TMF Housing ieee Lower Stator Part Fixation Figure 2 1 Suspended Installation Chapter 2 Installation Configuration Magltrol TMF Torque Flange Transducer 2 1 2 FRONT MOUNTING OF STATOR AND FLANGE CLOSE TO A BEARING The measuring flange is directly coupled with an input or output flange of a power drive or a power take off machine The housing must be centered at the face of the bearing plate of the machine and bolted to it Stator mounted directly on the machine s flange Clamping Element TMF Housing E HI ui a SOS dj X NA I gt 1 Is N NI ZZ AA E Testbed Base Plate Figure 2 2 Front Mounted Installation 2 1 3 BAsE MOUNTED STATOR DIRECTLY AT THE MACHINE POWER TAKE OFF Alte
13. N 14 2 3 Anstalltion Dimensions cere eere O 15 24 BEBCTRIC CONNECTIONS cias dp eov ee dee doi dis 16 3 SIGNAL BOX 17 SUI INTRODUCTION zi inerte iro et tia A A e EEE AENT rM 17 5 1 O UC A E O O NS 17 3 2 INSTALLATION Strada iaa 18 3 4 ompon nt Control ii se 18 203 2 Component CODnecblOll o certet over tee e os RE AN AE One Ed DEO Fe Raa da 18 3 3 CONFIGURATION votacion antaras BEER RU ERSTER ida lesan desetepdendsfelavas rhe RENE vusbsezssasesbaens BEP ERRENERF eR ERR SPERM os 19 3 3 1 External Power Supply ueste tero ee tii ida 19 3 3 2 Grounding AM T 19 3 39 95 Accident PREVENTION ssiri niente e eeina eei e ideian ege ee E a eaen Dese bete ive diate sede Us ee id 19 SN E O INN Se Eb Dore oer e Er HEBR dures erbe ueasedesssdeestenastanes oducspantase 20 3 33 Connec ng the RS422 1 0 optional RE AE ai dsc 21 23 3 0 Connectms the TCU T witha PC AMM are eta ERES EERR ERR TR eer Oor ERE eio EE Rer Ero ERREUR ERO ege ERR 21 Table of Contents Magtrol TMF Torque Flange Transducer 34 SELLINGO iion etr er RD ooo podais 22 341 Operatatig Principle mr 22 MAGTROL LIMITED WARRANT Y uccnanct tarn pn tin uta sanis raa ance uua uc Enna nan ceux vc E cu xp nap k HR sce vienna iii 23 TABLE OF FIGURES CHAPTER 1 Figure 1 1 Torque Measuring Syste
14. antage that even non linear temperature characteristics can be compensated Furthermore the values determined by means available at Magtrol can be edited at any time The functional diagram shown below presents an overview of the basic structure of the circuit Amplifier IR Transmission to Frequency Converter Strain Gauge 16 Bit DAC Temperature to Digital Converter u Controller Serial Interface EEPROM 16 Bit temperature values Figure 1 3 Basic Structure of Temperature Compensation Zo O m Az E 33 JUN Z Magtrol TMF Torque Flange Transducer Chapter 1 Introduction 1 3 2 OPTIONAL MEASURING RANGE The entire system was designed in such a way that the optional second measuring amplifier and a second infrared transmission data link can be integrated together with the manufacture of the transducer Q m Z m poj gt m This second amplifier is able to increase the signals originating from the joint measuring bridge circuit in such a way that a second high resolution measuring range can be used for the registration of much smaller torque values Thus the often necessary exchange of the torque transducer for the precise measurement of smaller torque values can be deleted This partial measuring circuit is equipped with the temperature compensation described above and with the SHUNT calibration see Figure 1 3 z TI fe J O Z Note It must be observed when
15. cy adjustable 2 20 50 100 200 400 1000 Hz Rotating Speed Frequency Response RS 422 Option Open Collector TTL 0 to 20 kHz Analog Rotating Speed Output Signal 10 VDC Dynamics of the Rotating Speed Output Signal 800 readings second Sense of Rotation Signal optional Open Collector TTL high low Serial Interface RS 232 9600 Baud Different calibration of RTI available on request max 1 4 x RT nominal Upon request with a longer delivery time Without taking into account the torque which can be transmitted by the assembly Not available with optional 2nd measuring range RT z T fe J e z Q m Z m poj gt m Chapter 1 Introduction Magtrol TMF Torque Flange Transducer Specifications TMF 401 403 Il On DIMENSIONS 2 gt BOTTOM VIEW Rotor Shaft Housing Alignment E TMF Radial Axial z 401 0 2 mm 0 5 mm 402 0 2 mm 0 5 mm 403 0 2 mm t 0 7 mm YA FRONT VIEW SIDE VIEW REAR VIEW NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 or 3 decimal places MODEL Units A B C D E F G H J K L M N mm 121 74 23 27 90 160 140 94 9 140h6 92 88H6 77 TMF 401 5 5118 3
16. d by purchaser submit an estimate of the repair costs before work is started To obtain repair service under this warranty purchaser must forward the product transportation prepaid and a description of the malfunction to the factory The instrument shall be repaired at the factory and returned to purchaser transportation prepaid MAGTROL ASSUMES NO RISK FOR IN TRANSIT DAMAGE THE FOREGOING WARRANTY IS PURCHASER S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE MAGTROL SHALL NOT BELIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSS WHETHER IN CONTRACT TORT OR OTHERWISE CLAIMS Immediately upon arrival purchaser shall check the packing container against the enclosed packing list and shall within thirty 30 days of arrival give Magtrol notice of shortages or any nonconformity with the terms of the order If purchaser fails to give notice the delivery shall be deemed to conform with the terms of the order The purchaser assumes all risk of loss or damage to products upon delivery by Magtrol to the carrier If a product is damaged in transit PURCHASER MUST FILE ALL CLAIMS FOR DAMAGE WITH THE CARRIER to obtain compensation Upon request by purchaser Magtrol will submit an estimate of the cost to repair shipment damage 23 Testing Measurement and Con
17. dividuals concerned with the planning assembly and the taking into service of torque measurement equipment and systems with torque measuring shafts General knowledge of mechanical and electrical engineering is required as a prerequisite for the installation and the operation of the system The torque measurement system should be operated by those individuals only who have been trained instructed and authorized on the system Such personnel must be familiar with the User s Manual and must be acting accordingly The individual authorizations of the operating personnel must be clearly defined MANUAL ORGANIZATION This section gives an overview of the structure of the manual and the information contained within it Some information has been deliberately repeated in different sections of the document to minimize cross referencing and to facilitate understanding through reiteration The structure of the manual is as follows Chapter 1 INTRODUCTION Describes the composition and functions of the TMF 400 Series Torque Flange Transducers and contains the technical data sheet which provides the mechanical and electrical characteristics Chapter 2 INSTALLATION CONFIGURATION Provides information needed for setup of the TMF Transducers including mounting options electrical connections and step by step instructions for mechanical installation Preface Magtrol TMF Torque Flange Transducer CONVENTIONS USED IN THIS MANUAL The followin
18. eed RS422 e 2x analog Output for Torque Speed selectable 10 V 5 V 0 10 V e Serial I O RS232 with terminal function e I O for Touch Screen Display e Zero switch e Diagnostic plug with all signals TTL Outputs Chapter 3 Signal Box Magltrol TMF Torque Flange Transducer 3 2 INSTALLATION 3 2 1 COMPONENT CONTROL The following components are required for the fully operational setup of a measuring system e TMF Torque Flange Transducer e TCUI SBI e Adapter cable for the serial I O or the display e External power supply 10 30 VDC electric connector e This manual 3 2 2 COMPONENT CONNECTION The housing must be grounded with the test bench base by a low resistance connection At the back wall of the housing is a M3 thread A pole shoe can be installed here Connect the TCU1 with the TMF transducer via a central cable 12 pin Connect the power supply of the TCU1 with an external power supply unit 3 For configuration connect the Output X722 with the serial I O of your PC using the cable that was shipped with the signal box 4 If all parts are connected you can switch on the unit Magtrol TMF Torque Flange Transducer Chapter 3 Signal Box 3 3 CONFIGURATION Before delivery each Magtrol instrument is carefully checked for its technical functions The technical specifications must be adhered to in order to successfully comply with the requirements of this check The instrument should be in perfect cond
19. ersonnel only and under consideration of all safety instructions e Before beginning with installation work measuring equipment must be checked for transport damage e The attachment bolts for the flange connections and the stator attachment must be selected for their strength and length in accordance with requirements e The stator attachment must be executed in such a way that no major relative movements can occur between rotor and stator during operation e The distances indicated on the Data Sheet Section 1 4 must be observed specifically during operation with installed speed recording device e Please secure components against loosening if subjected to vibration loads e Please observe the specified torque values e The design of the entire shaft system must be conducted in such a way that no detrimental torsional or bending vibrations can occur at any of the operating points e Please read the section entitled Safety Precautions found at the beginning of theis manual eae Note It must be observed that the torque measuring flange should above all be considered a precision measuring instrument and not so much as acomponent for torque transfer The clutch selection and the quality of the mechanical alignment have a major effect on the accuracy of measurement and the service life of the transducer and the clutches used 10 Magtrol TMF Torque Flange Transducer Chapter 2 Installation Configuration 2
20. etric transmission procedure has been designed in such a way that there is no mutual interference when systems are placed in a close arrangement next to each other Since the system has been set up without bearings the specified distances between rotor and stator must be maintained under all operating conditions For the utilization of the full measuring accuracy it must be observed that the acting radial forces and torsional vibrations will not exceed the permissible load limit values Zo O m Iz E 33 or pa Chapter 1 Introduction Magtrol TMF Torque Flange Transducer 1 2 COMPOSITION The TMF 400 Series Torque Measuring Flange represents a torque measuring system which can be used in multiple applications and in many different ways based on its connecting flanges on both sides Since this measuring system is equipped with a contactless functioning telemetric system and without roller bearings it is completely maintenance free and therefore specifically suited for permanent operation applications The extremely high overload capacity despite its high measurement accuracy of typically 0 1 of the scale end value will enable this system to be used as a clutch element even under critical operating conditions The new series which includes four different sizes is covering a measuring range from 50 to 6 000 Nm One functional unit is composed of the measuring flange itself rotor one housing with upper and lower stator pa
21. g symbols and type styles may be used in this manual to highlight certain parts of the Sy A 2 text Note This is intended to draw the operator s attention to complementary information or advice relating to the subject being treated It introduces information enabling the correct and optimal functioning of the product to be obtained CAUTION THIS IS USED TO DRAW THE OPERATOR S ATTENTION TO INFORMATION DIRECTIVES PROCEDURES ETC WHICH IF IGNORED MAY RESULT IN DAMAGE BEING CAUSED TO THE MATERIAL BEING USED THE ASSOCIATED TEXT DESCRIBES THE NECESSARY PRECAUTIONS TO TAKE AND THE CONSEQUENCES THAT MAY ARISE IF THE PRECAUTIONS ARE IGNORED SSS SS AAA A WARNING THIS INTRODUCES DIRECTIVES PROCEDURES PRECAUTIONARY MEASURES ETC WHICH MUST BE EXECUTED OR FOLLOWED WITH THE UTMOST CARE AND ATTENTION OTHERWISE THE PERSONAL SAFETY OF THE OPERATOR OR THIRD PARTY MAY BE PUT AT RISK THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT AND ACT UPON IT BEFORE PROCEEDING FURTHER vi 1 Introduction 1 1 INTENDED USE The TMF 400 Series Torque Measuring Flange has been intended exclusively for the measurement of the mechanical performance parameters torque and speed Any use in an explosive hazard environment is not permitted Due to the high accuracy of measurement of the system a multiple installation on one drive shaft system is possible e g for efficiency measurements The telem
22. ition when received and this condition should then be checked again In the event the instrument is not in proper condition please compile a damage status report together with the forwarding agent Also please compare the information on the delivery note with the actually delivered units 3 3 1 EXTERNAL POWER SUPPLY The Magtrol TCU1 SB1 Signal Box has been designed for the connection to a DC voltage power supply with an output voltage in the range of 10 30 VDC The current input is 0 54 A depending on the torque flange transducer model which is connected 3 3 2 GROUNDING Uo ee eee SE WARNING THE HOUSING AND THE INTERNAL SIGNAL COMMON STOP OF THE TCU1 ARE CONNECTED TOGETHER THE SHIELDING OF THE INPUT AND OUTPUT LINES MUST BE CONNECTED TO THE HOUSING OF THE CONNECTORS AT THE TCUI SIDE BY FASTENING THE TCU1 TO THE TEST BENCH THE SHIELDING IS CONNECTED WITH THE TEST BENCH GROUND 3 3 3 ACCIDENT PREVENTION The use of this instrument requires that the generally applicable accident prevention regulations are adhered to Chapter 3 Signal Box Magtrol TMF Torque Flange Transducer 3 3 4 PIN ASSIGNMENT X730 A Input El 12 pole MIL B Input El C Input N1 N1 D Input N1 Speed1 E Input N2 RS422 F Input N2 N2 G Input Md Speed2 H Input Md RS422 J Output SpSp Md K Output 15V Torque L Ground RS422 M Ground X705 A MD1 4 pole MIL B N1 Output C NC D Ground N1 Speed1 analog Output 10V max
23. late Val mm Front Mounted Installation Rs SS ARA SAA Speed Pickup TMF Housing TMF Rotor Foot Mount of Stator Lower Stator Part Fixation pended Installation Couplings When Magtrol TMF Series Torque Flange Transducers are to be mounted in a drive train the rotor is directly mounted on the output flange on one side and a double element coupling must be used on the other side The TMF Torque Flange is designed to directly fit Rexnord s Model 920 BSD MODUFLEX coupling series TMF 401 403 SYSTEM OPTIONS TMF SERIES TORQUE FLANGE TRANSDUCER MODEL 6400 DISPLAY TROL INC BUFFALO NY Power Supply AC 10 VDC Model Input Power Auxiliary Input 6400 120V 60Hz Device 6400A 240V 50 Hz PC Based System Configuration Torque Flange Transducer with 6400 Display and TM Software Model 6400 Display Magtrol s Model 6400 Torque Transducer Display is designed specifically for use with all TMF TM TMHS and TMB Torque Transducers This easy to use device powers the transducer and utilizes high speed Digital Signal Processing DSP to display torque speed mechanical power watts or horsepower and direction of rotation The 6400 comes with numerous standard features including English Metric and SI settings tare function analog input and RS
24. m Conftgurdtion iei toten triennio ses irnos 2 Figure 1 2 Composition of Measuring Flange ed Figure 1 3 Basic Structure of Temperature Compensation 4 Figure 1 4 Basic Structure of the Second Torque Measuring Range eese nnns 5 CHAPTER 2 Figure 2 1 Suspended Installation Figure 2 2 Front Mounted Installation Figure 2 3 Base or Foot Mounted Installation iii ree eee a aeta aei ideas 12 Figure 2 4 Torsion resistant Shaft Clutch Element Type 920 eese tenente nennen nenne 13 Figure 2 5 Rem v l of COVE EE Figure 2 6 Flanse Plate rinnen E O E E E E AAEE E talado Figure 2 7 Insertion of Measuring Shaft s Figure 2 8 Connecting TMF Measuring Flange with Signal Box eese 16 CHAPTER 3 Figure 3 1 TCUI SBI Signal BOX ERE I7 Figure 3 2 R5422 OQuiput signal Conh CHols a ia tri to e aote rt Deep Ha rene rer t Rep e 2l Figure 3 3 Operation doo RR 22 Preface PURPOSE OF THIS MANUAL This manual contains all the information required for the setup TMF 400 Series Torque Flange Transducers To achieve maximum capability and ensure proper use of the transducers please read this manual in its entirety before operating Keep the manual in a safe place for quick reference whenever a question should arise WHO SHOULD USE THIS MANUAL This User s Manual was compiled for those in
25. ning conditions and that specifically the safety equipment is checked regularly for its functional integrity e The required personal protective equipment for the operation maintenance and repair personnel is available and is in fact being used e The Operating Manual is always in a readable condition and completely available at the service location of the measuring equipment In addition to the Operating Manual further operating instructions must be made available regarding occupational legislation and legal provisions on the use of technical work aids e Sufficiently qualified and authorized personnel only is executing the operation service and repair of the machine e Such personnel is trained regularly regarding all applicable questions of occupational safety and environ mental protection and that such personnel is aware of the provisions of the Operating Manual specifically the safety instructions included e All safety and warning instructions attached on the machine must not be removed and shall remain in a readable condition SYSTEM MODIFICATIONS For reasons of safety no unauthorized modifications must be conducted on the measuring equipment Any intended modifications mechanical or electrical must be authorized in writing by the corresponding department of Magtrol The given warranty expires before its regular term if the ordering party or any third party conducts unauthorized modifications or repairs on the delivered systems
26. rnatively the stator can be centered through the test bench plate with the measuring flange CAUTION AGAIN THIS INCLUDES THE RISK OF POSSIBLE RELATIVE MOVEMENTS DURING OPERATION BETWEEN ROTOR AND STATOR Speed Pickup TMF Housing VEIS T 77777 d N RS TMF Rotor ES d TT Ree Aa WO S Na HAZARD Foot Mount ZW PR of Stator enm Figure 2 3 Base or Foot Mounted Installation 12 Magtrol TMF Torque Flange Transducer Chapter 2 Installation Configuration In all cases the power drive or the power take off too can be implemented through an existing standard clutch element featuring torsional vibration resistance according to the figure below Figure 2 4 Torsion resistant Shaft Clutch Element Type 920 eS Note me This torsion resistant clutch element equipped with a medium lamellar package is suited for the compensation of axial and angular deviations when connecting two shaft ends with each other If a radial shaft deviation must in addition be compensated too then the installation of a second lamellar clutch will be required The following shaft clutch elements are available as standard equipment Torsion Resistant Shaft Clutch Type 920 Size 4 5 11 28 64 Nominal Torque Nm 450 1100 2800 6400 Maximum Torque Nm 800 2000 5000 12500 Since the accuracy of measurement is not affected by a
27. roller bearing between rotor and stator it does not matter onto which side of the measuring flange the test specimen will be coupled Note The positive direction of the torque has been defined by the factory in such a way that a moment which rotates clockwise when looking at the measuring flange will lead to a positive output signal either in the form of a frequency increase or of a positive voltage signal Chapter 2 Installation Configuration Magltrol TMF Torque Flange Transducer 2 2 TMF WITH SIGNAL BOX The torque transducer can be operated only together with a signal processing electronic system in the form of a signal box along with the corresponding connecting cables Since the torque as well as the speed signals are available as frequency signals and at the same time as analog voltages that are freely programmable over a wide range no further requirements are specified for the user electronic system This can be freely selected depending on the existing tasks In view of uninterrupted signal processing it has been recommended to select the type of continued signal transfer so that the transfer path must not be affected by interruptions The actual measuring values can be read through an additional display module that was designed for switchboard installation and a system parametrization can be conducted 2 3 MECHANICAL INSTALLATION STEP BY STEP 1 Remove top cover of housing md Removal of Cover
28. rt one main cable and one signal box Upper stator part removable Measuring flange ower stator part Signal box Figure 1 1 Torque Measuring System Configuration z T e D E zl e Z Q m Z m poj gt Magtrol TMF Torque Flange Transducer Chapter 1 Introduction 1 3 FUNCTIONAL DESCRIPTION Each TM 400 Series torque transducer registers the elongation of the shaft body generated by the acting torque by means of strain gauges and transmits these signals to the stator side in the form of frequency modulated infrared light An optional second infrared data link can be utilized for the transmission of a second considerably smaller torque measuring range A shifting of the zero signal that can be possibly caused by temperature effects will be suppressed on site as much as possible by a u controlled compensation circuit A standard type integrated speed registration system will at the same time provide a high resolution speed signal featuring two 90 displacement speed tracks Upon utilization of the magneto resistive effect stable square wave speed proportional signals are available beginning with zero speed The relevant measuring units can be tapped off the signal box in an analog form or as frequency signals Primar und Sekundar spule f r Speisespannungs ubertragung Rotor mit Elektronik magnetischer Drehzahlgeber DMS
29. s three available sizes the flat TMF Torque Transducer covers a wide torque range between 50 and 4200 N m The mechanical installation of the system can be carried out either by attaching the transducer onto the baseplate of the test bench stand mounting or by fixing it directly on to the housing of the driving or driven machine BSD MODUFLEX Model 920 torsion proof couplings can also be fitted on each side of the transducer for torque transmission Two magnetic strips providing a signal with a 90 offset and an incremental magnetic transducer are used to determine the rotating speed by generating up to 150 pulses per revolution It is possible to double and to even quadruple the number SYSTEM CONFIGURATION TCU1 Converter TMF 401 403 Torque Flange Transducer Model TM 402 Torque Flange Transducer of pulses The TCUI a separate measuring signal converter included is placed in immediate proximity to the torque transducer and provides all important signals either as pulses or as analog voltages APPLICATIONS TMF Torque Flange Transducers provide dynamic torque and speed measurement of e Automotive engines and transmissions Propellers aerospace marine and helicopter e Reduction gears and gearboxes Supply 10 to 30 VDC 0 5 4 A Torque Analog Output 10 VDC Torque Frequency Output TTL Speed Analog Output 10 VDC Speed Frequency Output open collector TTL Sense of Rotation Frequency Ou
30. tput open collector TTL RS 232 optional RS 422 z TI e D E e z TWYHANAD Magtrol TMF Torque Flange Transducer Chapter 1 Introduction Specifications OPERATING PRINCIPLE The signal processing unit is integrated in an aluminum housing generating frequency and analog voltage output signals The sense of rotation option is indicated by a logical signal While being manufactured the flat torque transducer is brought to its specified maximum working temperature A microprocessor which is integrated in the transducer flange measures the offset caused by temperature variations and TMF 401 403 automatically stores the corresponding correction values in a configuration table The optional second measuring scale is achieved by means of a second independent electronic amplifying circuit transmitting the measuring signal Both amplifiers use the same strain gauge measuring bridge but utilize different amplification factors The active temperature compensation guarantees an excellent zero point stability of the second measuring scale RATINGS TORQUE MEASUREMENT Nominal Rated Torque RT1 TMF 401 TMF 402 TMF 403 450 N m 1100 N m 2800 N m Maximum Dynamic Torque Peak Value Overload Capacity 150 of RT Optional 2nd Measuring Scale RT2 1096 min to 14096 max of RT Maximum Dynamic Torque Without Damage Overload Limit 250076 of RT Combined Error of Linearit
31. trol of Torque Speed Power Load Force Weight Tension Displacement MAGTROL INC 70 Gardenville Parkway Buffalo New York 14224 USA Phone 1 716 668 5555 Fax 1 716 668 8705 E mail magtrol magtrol com MAGTROL SA Subsidiaries in Route de Moncor 4B Germany 1701 Fribourg Switzerland France Great Britain Worldwide Network of Sales Agents Phone 41 0 26 407 3000 Fax 41 0 26 407 3001 E mail magtrol magtrol ch WWw magtrol com
32. without the prior written approval from Magtrol Please use original spare parts only because they were specifically designed for this system SPECIAL TYPES OF HAZARDS If the system is operated without shaft protection device and with the top cover in the open position there will be the hazard of particles being thrown out after having fallen inside or of such particles being jammed between stator and rotor The consequences resulting thereof may in extreme cases lead to a destruction of the shaft system or to considerable personal injuries Revisions To This Manual The contents of this manual are subject to change without prior notice Should revisions be necessary updates to all Magtrol User s Manuals can be found at Magtrol s web site at www magtrol com support manuals htm Please compare the date of this manual with the revision date on the web site then refer to the manual s Table of Revisions for any changes updates that have been made since this edition REVISION DATE First Edition August 2003 TABLE OF REVISIONS First Edition no revisions made to date Table of Contents SAFETY PRECAUTIONS c i OPERATOR S DUE CARB OBLIGATIONS tic oer rien natalie idiota i SYSTEM MODIFICATIONS 5 itieeuks ica FER inodoro torpe ve ERR AIr eco in erede eate gae ra i SPECIAL TYPES OF HAZARDS repitieron reneo ertt eere ere A ice i
33. y and Hysteresis 0 1 of FSD 0 05 on request Temperature Influence on the Zero Point lt 0 196 of FSD 10 K Nominal Temperature Range SPEED MEASUREMENT 10 to 70 C ENVIRONMENT Storage Temperature Range Nominal Rotating Speed Nmax Higher speeds available upon request 12 000 rpm 10 000 rpm 8 000 rpm Pulses Per Revolution standard 90 120 150 Output Signal RS 422 Option Open Collector TTL 2 signals with a 90 offset Minimum Rotating Speed Guaranteeing a Sufficient Pulse Quality gt 0 rpm 23 C to 80 C Operating Temperature Range 10 C to 70 C Mechanical Shock according to IEC 68 2 27 Class D3 Vibration according to IEC 68 2 6 Class D3 Protection Class MECHANICAL CHARACTERISTICS Torsional Stiffness IP 44 400 kN m rad 880 kN m rad 2300 kN m rad 295 000 Ib ft rad 649 000 Ib ft rad 1 696 000 Ib ft rad 1 3 gum 9 7 g m 33 6 g m ponent si Leon 0 957 b fts 7 1501b fts 24 760 lb ft s2 Weight of Rotor 1 5 kg 3 3 Ib 5 kg 11 Ib 11 kg 24 lb Balancing Quality INPUT AND OUTPUT SIGNALS Power Supply max voltage current G2 5 according to ISO 1940 10 to 30 VDC 0 5to4A Torque Frequency Response RS 422 Option TTL 60 20 kHz Analog Torque Output Signal 10V 0to5V 0to10V DC Dynamics of the Frequency Response gt 1 5 kHz Dynamics of the Analog Output 800 readings second Filter Cutoff Frequen
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