DATAFLEX 42/... Torque Measuring Shaft Assembly
Contents
1. PT Ls j picture 5 assembly of the clamping ring hubs picture 6 adjusting to the Ls dimension Table 2 DATAFLEX coupling size 42 200 42 500 42 1000 N coupling size clamping bolt size number of bolts z tightening torque Ta Nm transmittable torque Nm 1 H7 k6 shaft hub fit Assembly of the Driven and Driving Side Hubs e Assemble the hubs on the shafts of the driven and driving side picture 7 The ends of the shafts must not protrude through the hubs e Move the units in the axial direction until the dimension L is achieved e If the unit is fixed move the hubs on the shaft to achieve the E dimension ATTENTION Se On request the hubs can be machined for a grub screw to secure the hubs in the axial direction Please make this request during ordering CAUTION During assembly please make sure the correct L is observed table 2 If this is not done the measuring shaft coupling can be damaged Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK VIVAL TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 5 we D 48407 Rheine Assembly Operating Instructions edition 2 Assembly of the Driven and Driving Side Hubs L2 m picture 7 assembly of t2. A usv 10 9 3 74 4 5 3 24 t M Nm 0 T T T T T T T T gt DATAFLEX 42 200 200 160 120 80 40 0 40 80 120 160 200 DATAFLEX 42 500 500 400 300 200 100 0 100 200 300 4 00 500 DATAFLEX 42 1000 1000 800 600 400 200 0 200 400 600 800 1000 picture 12 1 voltage to torque relationship A W m 20 0 18 4 4 16 8 4 Bi 13 64 12 0 10 4 4 884 HP 5 6 M Nm 40 T T T T T T T T ir DATAFLEX 42 200 200 160 120 80 40 D 40 80 120 160 200 DATAFLEX 42 500 500 400 300 200 100 0 100 200 300 400 500 DATAFLEX 42 1000 1000 800 600 L00 200 0 200 400 600 800 1000 picture 12 2 current to torque relationship e Filter voltage output If the connection housing DF1 is used the signal of the voltage output can be filtered Table 7 Low Pass Button Button adjustment TP left fe ee Low Pass on Low Pass off The limit frequency of the filter can be changed by variating the DIP switches see picture 13 inside the connection housing 12T picture 13 DIP switch top view Table 8 Adjustment of the requested filter frequency Limit frequency Hz button 1 button 2 button 3 button 4 A filter frequency of 1 000 Hz is preset Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01
3. KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 1 D 48407 Rheine Assembly Operating Instructions edition 2 DATAFLEX is a maintenance free torque measurement shaft with integrated speed measurement In connection with the RADEX N steel disc coupling it is a torsionally stiff double cardanic coupling with integrated measuring shaft General Hints Read these instructions thoroughly before operating the measurement shaft Please pay special attention to the safety instructions The assembly instructions are a part of this product Please store them carefully close to the measuring shaft The copyright for these assembly instructions belongs to KTR Kupplungstechnik GmbH Safety and Advise Hints DANGER Danger of injury to persons AN CAUTION Damages on the machine possible S ATTENTION Pointing to important items General Hints to Danger DANGER With the assembly operation and maintenance of the measuring shaft it is important that the entire drive train has been secured against unintentional engagement Please read through and observe the following safety instructions All work with and to the measuring shaft must be carried out with the idea of Safety First Secure the measuring shaft and the disengaged drive before work is carried out e Secure the drive system against unintentional engagement for example place warning signs at the switch or remove t
4. torque measuring shaft Quantity Designation Quantity DATAFLEX 2 2 flange hub 1 1 torque measuring shaft 3 2 laminae package 4 2 clamping ring hub 5 2 Components of RADEX N coupling with clamping ring grub screw DIN 916 picture 1 DATAFLEX torque measuring shaft with RADEX N DANGER bB The maximum permissible bore diameter dima and domax See RADEX N catalogue should not be exceeded If these values are not followed the a coupling can break Flying broken parts can put lives in danger H e When the customer manufactures the bore it is important that the customer holds the following runout 5 and concentricity tolerances see picture 2 e The values dimax and dmax Must be observed e Align the hubs carefully before making the finish bore L picture 2 runout and concentricity Displacements The misalignment values given in table 1 provide security in order to compensate for outside influences for example thermal expansion or foundation shifting CAUTION In order to ensure a long life of the measuring shaft the shaft ends must be precisely aligned The misalignment values given must be observed see table 1 If these values are exceeded the coupling will be damaged Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurc
5. Lt L2 L3 L2 jt po a oma Le Ls j i __ __ D i od p od y picture 18 Table 10 dimension and technical data coupling size DATAFLEX 42 200 42 500 42 1000 Dimensions mm dimension d dimension D dimension Li dimension Le dimension L3 dimension L4 dimension Ls Electrical Data nominal torque Tkn Nm 200 200 Nm 500 Nm 1000 1000 Nm limit frequency torque signal kHz 16 measuring inaccuracy 1 temperature influence K 0 05 nominal temperature range C 0 55 supply voltage V DC 24 4 max current consumption mA 100 Torque Output output voltage torque V output current torque mA Speed Output number of impulses revolution output signal V Mechanical Data static load limit Tkmax 150 breaking load Tk break l 300 max bending torque Nm 50 135 max radial force N 280 750 max axial force KN 12 20 weight kg 4 71 4 84 torsion spring stiffness CT Nm rad 40929 102321 torsion angle at Tkn degrees 0 28 mass moment of inertia kgm 0 0007343 0 0007603 0 0008048 permanent speed 1 min 7000 peak speed 1 min 7 8500 1 referred to Tkn 2 after shrinkage of the bearings Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ers
6. gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH _ Torque Measuring Shaft sheet 9 D 48407 Rheine Assembly Operating Instructions edition 2 Technical Description c Output Speed Un For determining the speed a square wave with a frequency of 60 impulses per revolution is available The height of the square wave voltage is 24 Volts 24 V speed 1 min 1 ta s speed 1 min f 1 s ta picture 14 5 Digital Input and Output The general parameters for calibration of the measuring Pin 10 shaft are stored electronically and can be changed by EL Pin 3 9 12 Program operating the external calibration input T1 and T2 As done in gt V Program Leo the connection box DF1 accessory the connections for the Pin 9 LED output and the calibration input are wired as shown in picture 15 see Table 4 Te T1 Auto Offset Pin 8 in 15 xA Fault LED Pin 15 picture 15 a LED 1 Program For calibration of the measuring shaft the factors for amplification and offset can be set in steps According to the description of the procedure in chapter 4 calibration the PROGRAM LED shows a change in the mode of operation b LED 2 Error Error Signal The perfect function of the measuring system is permanently controlled An electronic defect is shown by a error
7. etztdurch CT WYK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 12 D 48407 Rheine Assembly Operating Instructions edition 2 DATAFLEX Torque Measuring Shaft in Combination with RADEX Ls picture 19 dimensions DATAFLEX with RADEX N Table 11 dimension and technical data 42 200 42 500 42 1000 coupling size RADEX NC Dimensions mm dimension d d max 60 dimension D 130 dimension Dz 138 dimension D3 88 dimension L 364 dimension L gt 254 dimension L3 55 dimension L4 114 dimension Ls 232 dimension E 11 Clamping Screw mm dimension G dimension t 20 tightening torque Ta 10 Torque of the Coupling 690 1380 230 mass moment of inertia kgm torsion spring stiffness Nm rad 1 higher speeds on request Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI
8. h CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 3 D 48407 Rheine Assembly Operating Instructions edition 2 Please note e The misalignment values given in table 1 are maximum values They cannot occur at the same time When radial axial and angular misalignment occur simultaneously these values must be reduced see picture 4 e Please check using dial indicator ruler or feeler gauges whether the permissible misalignment values in table 1 are being observed eee T Ss x lt D one 4 angular displacements radial displacements picture 3 displacements axial displacements Table 1 DATAFLEX RADEX N max axial displacement max angular displacement size size AK mm AKw degree 42 200 42 500 42 1000 80 100 picture 4 combination of A A 90 v displacements 5 g s 80 amp Example for the misalignment ae ee combinations given in picture 4 z 60 amp Example 2 50 a AKr 60 amp 40 20 v 30 AKw 20 F 30 10 20 5 50 AK 20 S ane 5 10 10 480 90 10 20 30 40 50 60 70 80 90 100 Ktotal AKa AKR AKw lt 100 rad
9. he driven and driving side hubs picture 8 adjusting to the Lz dimension Assembly of the Laminae Packages CAUTION During assembly it is important that the laminae packages are assembled stress free in the axial direction If this is not done the coupling can be damaged e Assemble the laminae packages and the DATAFLEX on the measruing shaft picture 9 e Initially only hand tighten the parts and alternate the bolts left and right e Tighten the bolts with a torque wrench until the values given in table 3 are reached picture 9 assembly of the laminae packages Tightening Torque of the Shoulder Bolts The shoulder bolts should be tightened to the torque given in table 3 ES LT Table 3 DATAFLEX coupling size RADEX N coupling size 60 80 bolt size M8 M10 tightening torque Ta Nm 33 65 CAUTION After the coupling has been put into operation the tightening torque of the shoulder bolts should be checked during normal maintenance intervals Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gem DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 6 g D 48407 Rheine Assembly Operating Instructions edition 2 Assembly Hints e Fix the Housing CAUTION The housing must be secured against rotat
10. he fuse e Do not touch the measuring shaft when it is in operation e Protect the measuring shaft from unintentional contact Use an appropriate cover or shield You are only allowed to assemble operate and maintain the measurement shaft if you e have carefully read and understood the assembly instructions e you are authorized and have the proper training The coupling can only be used in accordance with the technical data see sheet 11 Unauthorized alterations to the measuring shaft are not allowed We do not take any responsibility for any resulting damage In the interest of further technical development of the product we reserve the right for modifications The DATAFLEX measuring shaft described corresponds to the technical status at the time of printing these assembly instructions Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 2 D 48407 Rheine Assembly Operating Instructions edition 2 Generally the measuring shaft is delivered in subassemblies Before assembly the measuring shaft should be checked for completeness The position of the DATAFLEX is variable The measurement system can be mounted horizontally as well as vertically Components of DATAFLEX Torque Measuring Shaft Components of DATAFLEX
11. ial displacements AKp gt Assembly of Hubs ATTENTION Se We recommend that the bores shafts keyway and feather key are checked to make sure they are the correct dimensions before assembly Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz fiir KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 4 D 48407 Rheine Assembly Operating Instructions edition 2 Assembly of the RADEX Clamping Ring Hubs on the DATAFLEX Measuring Shaft The force is transmitted through a frictional connection The fit for the shaft and clamping ring hub is H7 h6 During assembly please pay attention to the following procedures e Please clean and degrease the contact surfaces of the hub bores and the shafts before assembly CAUTION Oil and grease with Molybdenum Disulfide or other hydrocarbons as well as grease paste should not be used e The clamping bolts must be lightly loosened the clamping ring hub should be placed on the shaft and adjusted to the Ls dimension e The clamping bolts must be tightened evenly crosswise The tightening torques should be increased in steps This procedure should be repeated until the tightening torque of all of the clamping bolts is the value given in table 2
12. ion For this purpose a threaded pin is on the underside of the housing e insulation All DATAFLEX measuring shafts of type 42 correspond to the Protection IP50 according to DIN EN 60529 e Maintenance The DATAFLEX measuring shaft is maintenance free CAUTION Opening the housing is not required and can lead to damage of the measurement shaft Technical Description 1 General Description All of the electronics are located in the fixed housing so that no additional equipment is needed to send the signal The measuring shaft can be wired by the connection housing DF 1 available as accessory or manually by the 15 pole High Density Sub D coupling for connection diagram see table 4 The measurement system contains three measurement outputs from these the analog output values for torque and speed are readable Over two digital outputs the actual operating condition is shown and two digital inputs can be used during calibration ATTENTION Se The measuring shaft should initially be turned on when all of the connections have been properly connected After it has been turned on for the first time the measuring shaft will take around 5 minutes until this warm up phase is finished and the measurement device will have its standard accuracy 2 Pin assignment of the measuring shaft Table 4 Pin assignment of the D Sub connection Connection Sub D Pin Characteristic Input Voltage Supply Voltage 24V in 14 24VDC 4V 100 mA S
13. nput Zero Offset Alignment Ground Digital Connections Output Error Signal In case of error 24V 50 mA Operational Control Indicators Program LED State Indicator Error LED Error Indicator 00o aw w Oe Button Auto Offset Autom Zero Alignment Button for Programming New Calibration DOCM Low Pass Button Filter on off Connection Measuring Shaft 1 1 Connecting Cable picture 11 connection housing DF1 DATAFLEX Anschlussgeh use DF1 4 Analoguous outputs a Supply Voltage 24V The supply voltage is 24V DC with a maximum current consumption of 100 mA b Torque Output U I To control the torque there are a voltage and a current output available Both outputs can be used at the same time Table 6 Relationship between Torque Output Values 42 200 2 5 V 100 Nm 4mA7100 Nm 42 500 1 V7 100 Nm 1 6 mA 7100 Nm 42 1000 0 5 V7 100 Nm 0 8 mA 100 Nm The characteristic curves of the output are shown in pictures 12 1 and 12 2 Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI A KTR Kupplungstechnik DATAFLEX 42 49010 E GmbH Torque Measuring Shaft 8 g D 48407 Rheine Assembly Operating Instructions a Technical Description The characteristic curves of the output values see pictures 12 1 and 12 2
14. plification determines the correct relationship between l adjustment of EET the torque and the output voltage as well as the output current FH ine amplification the offset It influences the steepness of the curves shown in picture 12 1 and 12 2 The displacement of the curves in vertical direction depends on the offset alignment Both parameters can be set and saved one after the other see picture 16 picture 16 flow of the manual setting saving Instructions for a new calibration 1 Press the T2 Program key for 2 seconds The PROGRAM LED will blink two times An adjustment of the amplification factor is now possible 2 The measurement shaft should now be alternately loaded and unloaded by a defined weight The difference between the output values should be compared to the actual difference between the load and unload 3 Through a quick press of the T1 AUTO OFFSET key the amplification factor can be roughly varied While a fine variation of the amplification factor can be made using a quick press of the T2 PROGRAM key One after the other all of the types of amplification factors can be adjusted see picture 17 1 4 Ifthe difference of the displayed measurement values of the loading and unloading corresponds with the outside determined torque difference then the adjustment of the amplification is finished 5 Press the T2 PROGRAM key for 2 seconds The PROGRAM LED will blink 4 time
15. s The manual setting of the offset can now begin 6 As described under point 3 the keys can be pressed quickly to set all of the values see picture 17 2 When no torque is present the measurement shaft should be adjusted to an output voltage of 5 0 V or rather an output current of 12 0 mA 7 When the offset adjustment is finished pressing the T2 PROGRAM key for two seconds will save all of the new parameters The PROGRAM LED will blink one time The measuring shaft will once again be in its normal operating mode M i i picture 17 1 picture 17 2 CAUTION With saving all of the old data will be overwritten ATTENTION S e The calibration can be interrupted if the measurement device is turned off for a short time and then turned back on The previously saved parameters will then be reproduced e The safe measurement operation can be carried out after saving the new parameters point 7 or after interrupting the power supply e After saving the new parameters point 7 the parameters will stay the same even if the power supply is interrupted Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__ Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 11 D 48407 Rheine Assembly Operating Instructions edition 2 DATAFLEX Torque Measuring Shaft ma
16. signal If an error is shown permanently the measuring system is defect and must be returned to KTR For an easy connection in control systems the error signal is accessible in the connection housing DF1 connection pin ERROR Table 9 LED 2 FaultSignal _ Normal Operation OFF oV Error ON 24V c Automatic Offset Correction If in torqueless state an incorrect value is indicated 5 0 V an automatic offset alignment can be effected by pressing the button T1 Auto Offset for 2 seconds For this the torque is reduced to 0 and the button T1 AUTO OFFSET must be pressed for 2 seconds After successful alignment the saving of the new values is confirmed by 6 fold blinking of the programme LED and the normal measuring operation is continued automatically For an easy connection in control systems the Auto Offset Connection is acessible in the connection housing DF1 connection clip NULL Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH _ Torque Measuring Shaft sheet 10 D 48407 Rheine Assembly Operating Instructions edition 2 Technical Description 6 Calibration Manual adjustment of amplification and offset ATTENTION S The measurement shaft is delivered calibrated We recommended checking the calibration every half year The am
17. upply Voltage GND Torque Output Output Voltage 0 10 V Ra 1 kQ Output Voltage Output Current 4 20 mA Ra lt 500 Q Output Current Speed Output Output Speed 12 24 V 60 impulse revolution Output Speed Program LED 5 V 5 mA prepared for LED picture 10 plug connection DATAFLEX Fault Signal 24 V 5mA prepared for LED Calibration Input Auto Offset 8 activ on connection with Program GND Pin 15 Urheberschutz Gezeichnet 19 07 02 Sha Koe Ersatz f r KTR N v 08 02 01 gemaB DIN 34 Gepr ft 23 07 02 Sha__Ersetztdurch CT WICK V VAT TT MY KCI T KTR Kupplungstechnik DATAFLEX 42 KTR N 49010 E GmbH Torque Measuring Shaft sheet 7 g D 48407 Rheine Assembly Operating Instructions edition 2 Technical Description 3 Connection housing DF1 The connection housing DF 1 has 12 screw clips where the connections of the measuring shaft can be connected see table 5 Table 5 Pin assignment of the connection housing DF1 No Designation Function Characteristic Ss O OO0O Input Voltage 10 24V Supply Voltage 24VDC 4V 100 mA Wal D e GND Supply Voltage e00 Torque Output a e Output Voltage 0 10 V Ra 1 kQ ian Ground Torque Output Ww Output Current Speed Output DRZ Speed Output 24 V 60 impulse revolution GND Ground Speed Output Digital Connections Auto Offset I
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