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LORD Torque-Link-LXRS User Manual

Wireless torque sensor
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LORD Sensing USER MANUAL
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Torque-Link-LXRS
Wireless Torque Sensor

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Summary of Contents for LORD Torque-Link-LXRS

  • Page 1 LORD Sensing USER MANUAL ® Torque-Link-LXRS Wireless Torque Sensor...
  • Page 2 LORD Sensing Systems 459 Hurricane Lane Suite 102 Williston, VT 05495 United States of America Phone: 802-862-6629 Fax: 802-863-4093 9:00 AM to 5:00 PM (Eastern Time US & Canada) http://www.microstrain.com sensing_support@LORD.com sensing_sales@LORD.com Document 8500-0059 Revision E Subject to change without notice.

  • Page 3: Table Of Contents

    ® Torque-Link -LXRS User Manual Table of Contents Wireless Sensor Network Overview Node Overview 2.1 Component List 2.2 Interface and Indicators 2.3 Assembly and Disassembly 2.4 Node Operational Modes 2.5 On-board Temperature Sensor System Operation 3.1 Software Installation 3.2 System Connections 3.3 Gateway USB Communication 3.4 Connect to Nodes 3.4.1 Adding a Node by Address...
  • Page 4 ® Torque-Link -LXRS User Manual 4.3.2 Strain Gauge Placement 4.3.3 Strain Gauge Wiring Torque-Link-LXRS Installation 5.1 Mounting the Assembly 5.2 Re-Using the Assembly Strain Gauge Calibration 6.1 Example Lab or Field Calibration 6.2 Calculating a Linear Slope 6.3 Theoretical Torque Formula 7.1 Maintenance...
  • Page 5 ® Torque-Link -LXRS User Manual 10.3 Torque-Link RPM Limits 10.4 Power Profile 10.5 Radio Specifications 10.6 Frequency Setting Safety Information 11.1 Battery Hazards 11.2 Disposal and Recycling References 12.1 Related Documents...

  • Page 6: Wireless Sensor Network Overview

    User Manual Wireless Sensor Network Overview The LORD Sensing Wireless Sensor Network is a high- speed, scalable, sensor data acquisition and sensor networking system.  Each system consists of wireless sensor interface nodes, a data collection gateway, and full- featured user software platforms based on the LORD Sensing Lossless Extended Range Synchronized (LXRS) data communications protocol. ...

  • Page 7: Node Overview

    User Manual Node Overview The Torque-Link-LXRS strain gauge node is an application-specific node assembly used for monitoring the torsional strain on a rotating shaft.  Torque-Link-LXRS assemblies are designed to fit most shafts sizes and integrate with field-installed strain gauges.  ®...

  • Page 8: Interface And Indicators

    The other half simply has the cutouts for the strain gauge and wiring. In the optional two channel version of the Torque-Link-LXRS, both haves have an electronics and battery compartment. For more information...
  • Page 9 ® Torque-Link -LXRS User Manual Figure 2 - Interface and Indicators Indicator Behavior Node Status Device Node is OFF status Rapid flashing on start-up Node is booting up indicator 1 (slow) pulse per second Node is idle and waiting for a command Table 1 - Indicator Behaviors...

  • Page 10: Assembly And Disassembly

    The Torque- Link - LXRS contains an internal, non- rechargeable lithium battery. The Torque-Link-LXRS is disassembled for installation and service using a standard 9/64" hex key. The battery compartment cover is removed with a T8 Torx (star) driver. Figure 3 - Disassembly 2.4 Node Operational Modes...
  • Page 11 User Manual Figure 4 - Node Operational Modes NOTE The Torque-Link-LXRS is powered-on whenever the battery is connected. With no activity, it goes into sleep mode and must be reactivated with an idle, wake, or stop command to resume use.

  • Page 12: On-Board Temperature Sensor

    -LXRS User Manual 2.5 On-board Temperature Sensor The Torque-Link-LXRS has an on-board, solid state temperature sensor mounted on the surface of the circuit board. The temperature sensor output is connected to channel 3 of the Torque-Link-LXRS Refer to the node specification table for the temperature sensor operating parameters see Operating Specifications on page 66 The temperature sensor has a measurement range of - 40˚C to +85˚C range with an...

  • Page 13: System Operation

    The Torque- Link - LXRS contains an internal, non- rechargeable lithium battery. The gateway is the interface between LORD Sensing sensor nodes and the data acquisition computer.  The gateway co- ordinates the configuration and sampling of the nodes and can handle many nodes simultaneously.

  • Page 14: Gateway Usb Communication

    ® Torque-Link -LXRS User Manual The sensor, node, gateway, and software selection are application-dependent, but the basic interfaces are the same.  The WSDA-101 gateway utilizes local serial connections to the host computer, such as RS232 and USB, and interfaces with the Node Commander software. Gateways with analog outputs can be connected directly to stand-alone data acquisition devices for data collection, however system configuration will still occur through a USB interface to Node Commander.

  • Page 15: Adding A Node By Address

    ® Torque-Link -LXRS User Manual 3.4.1 Adding a Node by Address Adding a node by address requires the node to be on the same communication frequency as the gateway. The node address and frequency are indicated in the documentation included with the node when it is purchased.
  • Page 16 ® Torque-Link -LXRS User Manual Figure 8 - Node Channels Menu Figure 9 - Channel Setup...

  • Page 17: Sensor Calibration

    ( Figure 10 - Sample Settings Menu ).The Torque-Link-LXRS has four primary sampling modes: Synchronized Sampling, Low Duty Cycle Sampling, Streaming, and Datalogging. Some modes have user- configurable settings for sample rate, sample duration, and datalogging .

  • Page 18: Data Acquisition

    ® Torque-Link -LXRS User Manual 3.8 Data Acquisition When data acquisition is started, each of the sampling modes has different menu options and views. Some open a settings menu before data acquisition begins and may include a data list view and/or a graph view.
  • Page 19 ® Torque-Link -LXRS User Manual c. Lossless: enables the lossless data protocol. The protocol enables buffering and retransmission of data in order to provide 100% data collection success. Using this feature may increase data display latency. Figure 12 - Synchronized Sampling Menu d.
  • Page 20 ® Torque-Link -LXRS User Manual Once sampling has started it will continue as configured without the need to leave Node Commander open. However, if the node is powered off and is not configured to sample on boot-up, data acquisition will end and must be restarted. Synchronized sampling features two data views: Grid view and Graph view.
  • Page 21 ® Torque-Link -LXRS User Manual Use the view menu to select the Graph view of the data ( see Synchronized Sampling Graph View on page 21 ). Click on the node name to view the graph for that node. Click again to hide it. Figure 14 - Synchronized Sampling Graph View a.

  • Page 22: Connect To Sensorcloud

    MathEngine interface. Leveraging the open source API, SensorCloud can also be used to collect data from other LORD Sensing sensor products or third-party systems. Basic SensorCloud services are available to all users free of charge at: http://www.sensorcloud.com/.
  • Page 23 CSV Uploader - The data upload feature enables data from any source (such as non-Ethernet LORD Sensing gateways, or third-party sensor) to be uploaded to the SensorCloud platform. The data must be in the LORD Sensing CSV format.
  • Page 24 ® Torque-Link -LXRS User Manual Figure 18 - SensorCloud Data View ® Figure 19 - MathEngine View...

  • Page 25: Sensor Data Files

    Figure 20 - FFT Graph in SensorCloud For more information about SensorCloud features and navigation, refer to the SensorCloud website:http://www.sensorcloud.com/, or contact LORD Sensing Technical Support.  3.8.3 Sensor Data Files Data acquired in Node Commander is stored in .CSV format and can be opened with Microsoft Excel, Quattro Pro, Open Office, or another CSV editor/spreadsheet program. ...
  • Page 26 ® Torque-Link -LXRS User Manual Figure 21 - Exploring Data NOTE The Microsoft Excel the Time data column in the data file may have to be changed to "m/d/yyyy h:mm:ss:000" format to make it more readable.

  • Page 27: Installing Strain Gauges

    -LXRS User Manual Installing Strain Gauges The Torque-Link-LXRS wireless node is designed for use with differential input sensors in a Wheatstone Bridge configuration. The node provides a 3 V excitation voltage, signal processing, and programmable gain settings ( see Node Differential Inputs on page 27...
  • Page 28 ® Torque-Link -LXRS User Manual applied across the two parallel sets of series resistors, and the resulting voltage measured across the Figure 23 - Wheatstone Bridge adjacent series resistors (Vo) ( Figure 23 - Wheatstone Bridge The Wheatstone bridge is the basis for all strain gauge configurations. To measure strain, one, two, or four of these resistors are replaced by strain gauges, which are functionally just variable resistors.

  • Page 29: Strain Gauge Installation

    ASTM E1237-93, Standard Guide for Installing Bonded Resistance Strain Gauges.  Failure to properly attach and connect the gauges will result in erroneous data. 4.3.1 Tools and Equipment The following are required for installation of the Torque-Link-LXRS sensor node:...

  • Page 30: Strain Gauge Placement

    4.3.2 Strain Gauge Placement When installing the strain gauges on the shaft, the primary considerations are the orientation of the gauges, and the position of the gauges relative to the Torque-Link-LXRS assembly and the cutouts for the gauges and wiring.
  • Page 31 ).  Gauges, terminals, and wiring are installed so that they are completely contained within the cutouts when the Torque-Link-LXRS is installed.  Check-fit the assembly over the gauges during the gauge installation process to ensure proper clearance ( see Torque-Link-LXRS Installation on page 34 ).

  • Page 32: Strain Gauge Wiring

    For the connector wiring, refer to Table 2 - Strain Gauge Wiring It is best practice to keep the wires as short as possible and the same length as each other to avoid influencing sensitive measurement. Once connected to the Torque-Link-LXRS, the connectors will...
  • Page 33 ® Torque-Link -LXRS User Manual be tucked inside the gauge pocket. Wiring is shown for dual-element full-bridge configuration ( Wheatstone Bridge Tutorial on page 27 Connector pin Signal Wire color Strain element R1 & R4 yellow element 2 center green element 1 center black R2 &...

  • Page 34: Torque-Link-Lxrs Installation

    Torque-Link-LXRS Installation 5.1 Mounting the Assembly The Torque-Link-LXRS is mounted on the shaft with the cutouts aligning over the gauges and wiring. Figure 28 - Assembly Installation 1. Disassemble the collar into the two halves, if not already done. Remove the collar screws completely.

  • Page 35: Re-Using The Assembly

    Assembly Installation 5.2 Re-Using the Assembly The Torque-Link-LXRS assembly can be re-used on other shaft assemblies as long as the shaft is the same size. Use new collar placement tape for the new installation ( see Parts and Configurations on page 61 ).

  • Page 36: Strain Gauge Calibration

    ® Torque-Link -LXRS User Manual Strain Gauge Calibration The field calibration requires calculation of the calibration slope and offset values, and manual entry into Node Commander. When completing the calculation, the applied loads can either be entered as strain values or torque values depending on how they were measured during the calibration. Either way, Node Commander assumes a linear relationship using the formula y = mx + b .
  • Page 37 ® Torque-Link -LXRS User Manual 5. Select the Auto Balance button to tare the no-load value of the strain gauge. Observe the value returned for the Auto Balance value. Figure 30 - Channel Settings...
  • Page 38 6. Select the Strain Wizard. 7. Select Internal or External calibration. An internal calibration uses a shunt resistor inside the Torque-Link-LXRS to apply a fixed load on the strain input. An external calibration uses a user-installed shunt resistor attached to the input.
  • Page 39 ® Torque-Link -LXRS User Manual Figure 32 - Strain Gauge Calibration 13. Select Finish to end the Strain Wizard.  Note that the slope and offset values have been calculated automatically.  Figure 33 - Completed Strain Wizard...

  • Page 40: Example Lab Or Field Calibration

    ® Torque-Link -LXRS User Manual 14. Select OK to exit the Channel Configuration window. 15. In the Node Configuration window, select Apply to write the configuration and calibration values to the node. 16. Select OK to exit. Figure 34 - Apply Node Settings 6.1 Example Lab or Field Calibration 1.
  • Page 41 ® Torque-Link -LXRS User Manual c. PGA Settings, Hardware Gain: 104 d. PGA Setting: Midscale (for positive and negative going signals) 4. Select the Auto Balance button to tare the no-load value of the strain gauge. Click OK to apply the node settings and exit configuration. Figure 36 - Channel Settings 5.
  • Page 42 ® Torque-Link -LXRS User Manual Figure 38 - Node Sampling...

  • Page 43: Calculating A Linear Slope

    ® Torque-Link -LXRS User Manual 8. After making all measurements, calculate a slope from the data using the formula y=mx+b in a data analysis program, such as Microsoft Excel. See Calculating a Linear Slope on page 9. Return to the Node Configuration screen for the sensor channel, and select the Conversion Coefficients Class and Units, and enter the Slope and Offset values derived in the data analysis program.
  • Page 44 ® Torque-Link -LXRS User Manual 2. Enter the A/D value (bits) measurements and applied load in the desired engineering units in two columns. Enter A/D value in the left column ( x -axis value) and the applied load in the right ( y -axis value).

  • Page 45: Theoretical Torque Formula

    ® Torque-Link -LXRS User Manual Figure 41 - Plot Trendline 6. The formula of the line is y=mx+b , where y is the engineering units at a given point (measurement), m is the slope of the line that represents the linear ratio, x is the A/D value at a given point, and b is the fixed zero load offset of the sensor.
  • Page 46 ® Torque-Link -LXRS User Manual Figure 43 - Theoretical Torque Formula...

  • Page 47: Maintenance

    For instructions on how to change the battery, see Changing the Batteries on page 48 . To order replacement parts, see Parts and Configurations on page 61 For other service or repair needs contact LORD Sensing Technical Support ( see Technical Support on page 59...

  • Page 48: Changing The Batteries

    ® Torque-Link -LXRS User Manual 7.2 Changing the Batteries Torque- Link - LXRS contains internal, non- rechargeable lithium battery. 1. Remove the battery compartment cover using a T8 Torx (star) driver ( Figure 44 - Battery Installation 2. Disconnect the battery connecter inside the compartment, and remove the battery 3.

  • Page 49: Troubleshooting

    ® Torque-Link -LXRS User Manual Troubleshooting 8.1 Troubleshooting Guide...
  • Page 50 1.5 node or gateway is damaged If all power settings and connections have been verified, and the node is still unresponsive, contact LORD Sensing Technical See Technical Support on page 59 Support ( 2.1 node or gateway has no power Verify the node and gateway have power applied and that 2.
  • Page 51 If no conclusion can be determined or to send a device in for repair, contact LORD See Technical Support on page Sensing Technical Support ( 3.1 no communication to node or gateway...
  • Page 52 Torque-Link -LXRS User Manual Possible cause and recommended solution connections contact LORD Sensing Technical Support ( Technical Support on page 59 3.5 sensor channel not configured correctly Verify that the sensor is configured on the correct channel and has been enabled for data acquisition. ...

  • Page 53: Device Status Indicators

    ® Torque-Link -LXRS User Manual 8.2 Device Status Indicators The following is a complete summary of the Torque-Link-LXRS status indicators. Indicator Behavior Node Status Node is OFF or sleeping Node is sleeping with radio check OFF, with occasional flash intervals enabled (default is every 5...

  • Page 54: Optimizing The Radio Link

    ® Torque-Link -LXRS User Manual 8.3 Optimizing the Radio Link NOTE In the event of communication difficulties, it may be necessary to disable WIFI on the host computer, or use a USB extender when collecting data. The best method for ensuring optimal radio communication is to conduct an RF survey of the installation site.

  • Page 55: Battery Connector

    ® Torque-Link -LXRS User Manual Figure 45 - Range Test Menu 2. The total RSSI range for the node and gateway is -90 to 0 dBm. The higher the value (closer to zero), the better, but reliable communication can be achieved between -75 dBm and 0 dBm.
  • Page 56 ® Torque-Link -LXRS User Manual Battery terminal Signal Wire color Connector pin Battery + Battery - black Table 4 - Battery Wiring...

  • Page 57: Updating Node Firmware

    Commander version 2.7.0 or greater can be used to update any mXRS or LXRS node or gateway firmware to the most current version.  Updates are found on the LORD Sensing website.  Technical Support on page 59 for contact and website information.
  • Page 58 ® Torque-Link -LXRS User Manual 5. Release the F1 key. 6. Click Upgrade Firmware, and the Node Firmware Upgrade window will appear. 7. Click Browse, and navigate to the downloaded .zhex file. 8. Click Write, and the upgrade sequence will begin.  When completed, "Upgrade Success" will appear in the Status column.

  • Page 59: Repair And Calibration

    LORD Sensing model number and serial number as well as your name, organization, shipping address, telephone number, and email.  Normal turn- around for RMA items is seven days from receipt of item by LORD Sensing. Warranty Repairs LORD Sensing warrants its products to be free from defective material and workmanship for a period of one (1) year from the original date of purchase.
  • Page 60 ® Torque-Link -LXRS User Manual sensing_support@LORD.com Phone: 802-862-6629 Fax: 802-863-4093 9:00 AM to 5:00 PM (Eastern Time US & Canada) SKYPE: microstrain.wireless.support Live Chat is available from the website during business hours: 9:00 AM to 5:00 PM (Eastern Time US & Canada)

  • Page 61: Parts And Configurations

    Parts and Configurations 9.1 Standard Configurations The Torque-Link-LXRS is available in standard sizes based on the shaft size it will be installed on. It is also available with one or two channels for attaching strain gauges. For example part numbers,...

  • Page 62: Replaceable Parts

    LORD Sensing Description Part Number Torque-Link-LXRS with non-recharagble battery, 2.05" outer diameter, 6330-2051 and one sensor channel Torque-Link-LXRS with recharagble battery, 6.55" outer diameter, and 6331-6552 two sensor channels Table 5 - Example Torque-Link-LXRS Part Numbers 9.2 Replaceable Parts LORD Sensing...
  • Page 63 ® Torque-Link -LXRS User Manual LORD Sensing Model Description Part Number various models G-Link2-LXRS Wireless Accelerometer Node Wireless 2-Channel Analog Input Sensor various models SG-Link-LXRS Node Wireless 2-Channel Analog Input Sensor various models SG-Link-OEM Node Ruggedized Wireless Analog Sensor Input...
  • Page 64 -LXRS User Manual Product Ordering Products can be ordered directly from the LORD Sensing website by navigating to the product page and using the Buy feature.  http://www.microstrain.com/wireless For further assistance, our sales team is available to help with product selection, ordering options, and questions.

  • Page 65: Specifications

    -LXRS User Manual Specifications 10.1 Physical Specifications The Torque-Link-LXRS is available in many sizes to fit a variety of standard shaft diameters ( see Parts and Configurations on page 61 ). All variations are the same height. Figure 50 - Torque-Link-LXRS Dimensions...

  • Page 66: Operating Specifications

    FCC (U.S.), IC (Canada), ROHS 10.3 Torque-Link RPM Limits The maximum g -force that can be applied to the Torque-Link-LXRS is 500 g . Depending on the size of the Torque-Link-LXRS, there is a corresponding limit on the rotational speed (revolutions per minute -...

  • Page 67: Power Profile

    Node power use is highly dependent on the operational parameters such as sample mode and rate.  More active channels and higher sample rates equate to increased power use.  Below is an example approximation of the power profile of a Torque-Link-LXRS over a range of sample rates operating in Synchronized Sampling mode. ...

  • Page 68: Radio Specifications

    Figure 52 - Example Torque-Link-LXRS Power Profile 10.5 Radio Specifications The Torque-Link-LXRS employs a 2.4GHz IEEE 802.15.4-compliant radio transceiver for wireless communication.  The radio is a direct- sequence spread spectrum radio and can be configured to operate on 14 separate frequencies ranging from 2.405 GHz to 2.475 GHz.  Following the 802.15.4 standard, these frequencies are aliased as channels 11 through 26. ...

  • Page 69: Frequency Setting

    Torque-Link -LXRS User Manual including antenna changes not expressly approved by LORD Corporation could void the user’s authority to operate the equipment. Cet appareil est conforme à la Partie 15 des Règles de la FCC des États-Unis et aux RSSS exempts de licence d'Industrie Canada.

  • Page 70: Safety Information

    User Manual Safety Information This section provides a summary of general safety precautions that must be understood and applied during operation and maintenance of components in the LORD Sensing Wireless Sensor Network. 11.1 Battery Hazards The - LXRS contains an internal, non- rechargeable Lithium Magnesium Dioxide (Li/MnO ) battery pack. ...
  • Page 71 ® Torque-Link -LXRS User Manual ® The Torque- Link - LXRS contains internal batteries, printed circuit boards , and electronic components. These items are known to contain toxic chemicals and heavy metals that are harmful to humans health and the environment.  Disposal is subject to federal and local laws. ...

  • Page 72: References

    12.1 Related Documents Many references are available on the LORD Sensing website including product user manuals, technical notes, and quick start guides.  These documents are continuously updated, and new applications are added. They may provide more accurate information than printed or file copies. ...
  • Page 73 ® Torque-Link -LXRS User Manual Calibration: to standardize a measurement by determining the deviation standard and applying a correction (or calibration) factor Configuration: a general term applied to the node indicating how it is set up for data acquisition.  It includes settings such as sampling mode/rate, number of active channels, channel measurement settings, offsets, hardware gain, and calibration values. ...
  • Page 74 ® examples of nodes manufactured by LORD MicroStrain ® Node Tester Board: The node tester board is a device designed by LORD MicroStrain that can be plugged into nodes to test their functionality. Offset: When describing a mathematically-linear relationship, the offset is the value where the line that represents the relationship in a graph crosses the y -axis. ...
  • Page 75 ® Torque-Link -LXRS User Manual RS232: a serial data communications protocol Sensor: a device that physically or chemically reacts to environmental forces and conditions, producing a predictable electrical signal Sleep: a command transmitted to the node to put it into sleep configuration Sampling: the process of taking measurements from a sensor or device Sampling Mode: the type of sampling that is being utilized, such as event-triggered, continuous, or periodic. ...

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