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Torque measurement: How to prevent machine shutdowns

Detect and repair damage on gearboxes on time

Problems with your powertrain?

Are you struggling with unplanned shutdowns of your machines? Why a torque measurement could help and what to consider

Do you know the current torque in the components of your system and if it is still appropriate for your needs? Measuring the actual torque in your powertrain is only detectable with complex and costly measuring technology, but there are good reasons to take a closer look at this issue. The reason for this: torque peaks occur regularly during a production process, impacting the quality of the product and causing damage to your machine components. Why and when should you consider to conduct torque measurements on your powertrain?

Powertrain: Why component design is important

Are you regularly experiencing unplanned shutdowns that are caused by your powertrain? If this is the case, a professional torque measurement may be the solution to your problem. In many cases, components of a powertrain are not designed according to the existing load. This increases the risk of breaks in the drive shaft.

Torque specifications that are calculated in advance are often imprecise and drive shafts are often not the correct size due to lack of data or the necessity to save costs. Measuring the actual torque using special sensors helps determine the correct size and expose any weak points. As a maintenance expert, we can also help you by designing and commissioning a drive shaft according to the actual specifications.

Do you need help in designing your powertrain?

We are maintenance specialists and offer users of work machines a comprehensive 360° service and support for your powertrain – from commissioning, to monitoring, analysis, maintenance, inspection, repair and optimisation.

How a torque measurement raises the potential of your machines

Conducting a torque measurement not only helps you to identify risks or problems, it will also provide valuable insight into the untapped potential of your system. If you are considering to improve your productivity or to manufacture different products on your machines, you should consider in advance if your system is up to the challenge. In addition to calculating the theoretical torque, you should also validate your calculations by measuring the actual torque. A carefully conducted torque measurement can uncover your system’s further potential and reduce risk of overburdening.

How does a powertrain work?

All components which generate and transfer power for the motor are subsumed unter the term “power train” – that includes motor, gears, shafts, etc. Equipment which takes torque from the output side of the powertrain is called machines.

There are many reasons to take a closer look at the strain put on the powertrain – it reduces the risk of unplanned shutdowns and subsequent damage in the system. Torque measurement offers a clear identification of all interacting process parameters, causing short torque peaks which lead to long-term damage. Preventative solutions which avert future damage can only be implemented when the customer is aware of the problem. The benefits are increased reliability of powertrain components and enhanced life-span.

How does torque measurement work?

Taking precise torque measurements using torque sensors on the engine, especially on rotating parts, is a challenge for designers and users of test rigs. There are two methods to conduct torque measurements in industry applications: the direct and indirect method. The direct method uses sensors to measure the torque signal directly by measuring the torque in the powertrain. Those sensors usually measure without contact by using a digital torque measuring flange. Indirect measurement works by measuring the electrical output of the electric motor at the motor inverter.

OHP Services uses a telemetry unit to assess torque on rotating powertrain components. Different signals from the torque sensor can be transmitted through the telemetry unit to machine control or directly to a data collection system. Those sensor signals are regularly analysed and interpreted by the powertrain experts at OHP Services. More information about the technology and the procedure HERE.

Due to the complex measurement technology, it is recommended to consult an external powertrain and maintenance expert. Make sure that the provider you chose does not only conduct the measurement on the system itself, but also provides you with a expert analysis of the generated powertrain data. Many service provider leave their customers alone with the results, and this is not desirable.

A service partner like OHP Services will not only conduct measurements, but will also provide you with a detailed analysis of the collected data and support the implementation of custom solutions. Our affiliation with Walterschein Powertrain Group and their drive shaft production ensures that you will receive a full-service solution.

Are you interested and would like to learn more about torque measurements? Find out more HERE.

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