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Binsfeld TorqueTrak 10K User Manual

Torque telemetry system
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TorqueTrak 10K
Torque Telemetry System
User's Guide
869500-9_G

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Summary of Contents for Binsfeld TorqueTrak 10K

  • Page 1 TorqueTrak 10K Torque Telemetry System User’s Guide 869500-9_G...

  • Page 2: Table Of Contents

    Field Testing Bench Testing Calibration Warranty and Service Information FCC Rules Part 15: Computing Devices Appendix A: TorqueTrak 10K Specifications Appendix B: Calibration Calculations B1: Torque on Round Shafts B2: Axial Strain on Round Shafts B3: Single Grid (1/4 Bridge)

  • Page 3: System Overview

    Change Transmitter setup without tools or removal from shaft Infrared signal transmits up to 20 feet (6 meters) Handheld with a simple keypad The TorqueTrak 10K is a robust, precision strain measurement instrument ideal for short-term data collection and diagnostic testing.

  • Page 4: System Components

    System Components A standard TorqueTrak 10K Torque Telemetry System includes the following items: TX10K-S Transmitter Transmitter Antenna RX10K Receiver Receiver Antenna Element Receiver Antenna Magnetic Base with 25ft Cable RM10K Remote Control BH10K Battery Holder 110VAC-12VDC or 220VAC-12VDC Wall Plug Transformer...

  • Page 5: Features And Controls

    When an operational error is detected, the top line of the display alternates between the corresponding error code and the actual signal. See Appendix C for a complete list of error codes. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 4...
  • Page 6 ±10VDC and a maximum range of ±12VDC. The digital data signal is an RS-232 type signal for input to a PC “Com” port. See Appendix A for the pin out and protocol. Binsfeld Engineering Inc. Maple City, MI (+1) 231-334-4383 www.binsfeld.com Tested to Comply...
  • Page 7 Negative half scale input is simulated +FS/4 Positive quarter scale input is simulated -FS/4 Negative quarter scale input is simulated +00328 -_ _ _ _ _ █ _ _ _ _ _+ Input: ransmitter Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 6...
  • Page 8 1) too many “TxRx Data” errors, 2) the signal from the TX10K-S is over or under range, or 3) the Input parameter is not set to “Transmitter”. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 7...
  • Page 9 Transmitter Gain (i.e., ¼ to 4 times the Transmitter Gain) for convenient output scaling. The equation below relates strain input to Voltage Output. RX10K System Measured Gage Voltage Gain Factor Strain (e) Output (V) Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 8...
  • Page 10 Holding down the ADJUST ▲ key while powering up the RX10K resets the RX10K to the default values listed below. Default Description Rx Ch Input Transmitter Filter 500Hz Input AutoZero Polarity Positive Gain Output Offset Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 9...

  • Page 11: Tx10K-S Transmitter

    Infrared Receiver lens, a Transmitter Antenna connector, and a screw terminal block for making power and sensor input connections. Antenna Connector Infrared Receiver Status Indicator Light Screw Terminal Block Figure 3: TX10K-S Transmitter Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 10...
  • Page 12 NOTE: If there is only one flash when changing Gain or Channel, then the high or low limit has been reached and cannot change any further in that direction. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 11...

  • Page 13: Rm10K Remote Control

    NOTE: The RM10K is designed to transmit commands to the transmitter when it is stationary. It will work at slow rotation speeds, typically less than 100 rpm. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 12...
  • Page 14 When the TRANSMITTER ON key is pressed, the green SENDING light on the RM10K will come on for about 3 seconds. The desired function key must be pressed within this 3-second Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 13...
  • Page 15 Appendix A.) REFERENCE 2 Operation is the same as Reference 1 but simulates a 500 microstrain input in the positive direction with a 350Ω gage and 2.0 Gage Factor (see Appendix A). Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 14...
  • Page 16 3 seconds after the TRANSMITTER ON key has been pressed. This indicates the RM10K is in high power mode, and any command sent during the next 3 seconds will be at the high infrared power level. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 15...

  • Page 17: Product Safety

    10 or more wraps is not too much. Installation Procedure The TorqueTrak 10K System is designed for ease of use. The procedure for a typical setup on a shaft for obtaining torque measurements is detailed in the Field Testing section below.

  • Page 18: Field Testing

    NOTE 1: This method of securing the transmitter and battery holder is for temporary use only. For long term use this tape should be examined frequently for the effects of environmental influences (e.g.: excessive oils) or extreme conditions (e.g.: Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 17...
  • Page 19 In this case, steps may have to be taken to balance the transmitter (TX10K) and the battery and housing (BH10K). Please discuss this with your Binsfeld Engineering Sales Representative. 4. Cut an appropriate length of 2-conductor power cable (red &...
  • Page 20 Transmitter Gain setting, 2) apply a shunt resistor to balance the gage, or 3) replace the strain gage. For further assistance, contact Binsfeld Engineering Inc. 11. Scroll RX10K display to Filter parameter screen. Set the Filter to the desired level.

  • Page 21: Bench Testing

    (“0”). NOTE: The BS900 Bridge Simulator is not a calibrated reference. Its purpose is to provide a full bridge circuit to the TX10K-S to verify functionality and assist in troubleshooting. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 20...

  • Page 22: Calibration

    (“0”) for a duration of 5 seconds. Calibration The TorqueTrak 10K System is calibrated prior to shipping using instruments traceable to the United States National Institute of Standards and Technology (NIST). Calibration can be checked at any time with a NIST traceable reference such as a calibrated voltmeter with sufficient (millivolt) resolution.

  • Page 23: Warranty And Service Information

    Binsfeld Engineering Inc. will not be liable for any special, indirect, incidental or consequential damages or loss, whether in contract, tort, or otherwise.

  • Page 24: Fcc Rules Part 15: Computing Devices

    I, the undersigned, hereby declare that the equipment specified above conforms to the above requirements. Place: Maple City, MI Date: April 14, 2016 Signature: Stephen Tarsa, CEO Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 23...

  • Page 25: Appendix A: Torquetrak 10K Specifications

    Appendix A: TorqueTrak 10K Specifications TT10K-S Transmitter Power supply voltage 7 to 18 Vdc Power supply current Transmit mode 40 mA (nom), 50 mA (max) Standby mode 4 mA (nom), 5 mA (max) 9V Ultralife lithium battery life Transmit mode...
  • Page 26 ±16000 ±20 2000 1000 ±8000 ±10 1000 4000 2000 ±4000 ±5 2000 8000 4000 ±2000 ±2.5 1000 4000 16000 8000 ±1000 ±1.25 2000 8000 32000 16000 ±500 ±0.625 4000 16000 64000 Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 25...
  • Page 27 10 to 18 VDC @ 300mA (max) (110 or 220VAC adapter included) Antenna input connection Power input connector 2.1 mm jack (5.5 mm x 2.1 mm plug) -20 to 70˚C (-4 to 158˚F) Operating temperature range Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 26...
  • Page 28 Dout = Vin x Asys x 1000 Dout = streaming digital output sample data Vin = TX10K transmitter voltage input (gage or sensor voltage) Asys = TT10K system gain factor TorqueTrak 10K Telemetry System Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 27...
  • Page 29 TX10K-S Transmitter gain level = 4000 RX10K filter set at 500 Hz Pelican case details: Outer dimensions: 20” x 14” x 5” (508mm x 356mm x 127mm) Shipping weight:13 lbs (5.9 kg) Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 28...

  • Page 30: Appendix B: Calibration Calculations

    The equations in this Appendix define the relationship between the input signal to the TX10K-S Transmitter (typically from a strain gage) and the Full Scale output voltage of the TorqueTrak 10K System. The calculations are based on parameters of the device being measured (e.g.

  • Page 31: B1: Torque On Round Shafts

    Full Scale Torque (ft-lb) Bridge Excitation Voltage = 2.5 volts Full Scale Output of System = 10 volts  Poisson’s Ratio (0.30 for steel) For example, given a solid steel shaft with: Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 30...
  • Page 32 ¼ to 4 times the Transmitter Gain. The equation below defines the Scale Factor (Z): Legend of Terms Scale Factor (0.25 to 4.0) Full Scale Torque (ft-lb) Reference Full Scale Torque (ft-lb) Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 31...
  • Page 33 500 ft-lb of torque. The System Gain would be adjusted until the output was equal to 1 volt. NOTE: It is recommended that in order to be meaningful, the deadweight should create a torque Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 32...
  • Page 34 Factor of 2.0. Alternatively, precision resistors can be placed in parallel with one arm of the bridge to simulate a torque load. The Tech Info section on our website (www.binsfeld.com) has a helpful Torque Strain Calculator to assist in determining the strain a given resistor value simulates.
  • Page 35 Simulated Strain values are not 100 and 500 µe, respectively. Use our online calculator or the equation on page 33 to calculate the simulated strain in this instance (use GF = 2.0). Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 34...

  • Page 36: B2: Axial Strain On Round Shafts

    4000 for ±770 microstrain range) Full Scale Force (tension or compression) (lb) Bridge Excitation Voltage = 2.5 volts Full Scale Output of System = 10 volts  Poisson’s Ratio (0.30 for steel) Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 35...
  • Page 37 )(2.25 in) = 89,739 lb (2.045) (4000) so 10 V output from the RX10K indicates 89,739 lb of force or 8974 lb/volt. For information on output scaling and calibration, see section B1. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 36...

  • Page 38: B3: Single Grid (1/4 Bridge)

    (16)  = 1956 x 10 inches/inch (2.045)(4000) so 10 V output from the RX10K indicates 1956 microstrain or 196 microstrain/volt. For information on output scaling and calibration, see section B1. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 37...

  • Page 39: Appendix C: Error Codes

    TX10K-S is too high Rx Power Low Error The power supply voltage level of the RX10K is too low Rx Power High Error The power supply voltage level of the RX10K is too high Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 38...

  • Page 40: Appendix D: Strain Gage Application

    Cut a strip of graph paper greater than the circumference of the shaft. Tape it to the shaft while lining up the edges. Mark desired gage position with a scribe or permanent marker. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 39...
  • Page 41 Repositioning can be done as the PCT-2M tape will retain its mastic when removed and therefore not contaminate the gaging area. Positioning the Gage on the Shaft Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 40...
  • Page 42 This forces the glue line to move up and across the gage area. A very thin, uniform layer of adhesive is desired for optimum bond performance. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 41...
  • Page 43 This protects the gage from moisture and dirt. To further protect the gage, cover with a 1.5 inch square patch of rubber sheet and a piece of M-Coat FA-2 aluminum foil tape (optional) then wrap with electrical tape. Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 42...
  • Page 44 Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 869500-9_G Pg. 43...

This manual is also suitable for:

Rx10kTx10k-sRm10k

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