Mounting instructions Torque transducer – Flexplate TCA MPZ1901037 HBM: Business Document
Directory 1 Safety Instructions ........................................................................................................................................ 3 2 Markings used ............................................................................................................................................... 1 2.1 Symbols on the transducer.................................................................................................................. 1 2.
1 Safety Instructions FCC Compliance & Advisory Statement Important Any changes or modification not expressly approved in writing by the party responsible for compliance could void the user’s authority to operate the device. Where specified additional components or accessories elsewhere defined to be used with the installation of the product, they must be used in order to ensure compliance with FCC regulations. This device complies with Part 15 of the FCC Rules.
Fig. 1.2 Example of the label Appropriate use Flexplates are used exclusively for torque measurement tasks as well as control and adjustment tasks directly connected thereto. Use for any additional purpose shall be deemed to be not in accordance with the regulations. Stator operation is only permitted when the rotor is installed. The flexplate may only be installed by qualified personnel in compliance with the specifications and with the safety requirements and regulations of these mounting instructions.
Use as a machine element The flexplate can be used as a machine element. When used in this manner, it must be noted that, to favor greater sensitivity, the transducer is not designed with the safety factors usual in mechanical engineering. Please refer here to the section “Loading capacity limits", and to the specifications.
when using the flexplate. Flexplates can break, particularly in the case of overloading. The breakage of a flexplate can also cause damage to property or injury to persons in the vicinity of the flexplate.
1 2 Markings used 2.1 Symbols on the transducer Label example Label example with FCC ID number, Location of label on the stator unit. Symbol: Meaning: Read and note the data in this manual Symbol: Meaning: Statutory waste disposal mark The electrical and electronic devices that bear this symbol are subject to the European waste electrical and electronic equipment directive 2002/96/EC.
2 2.2 The markings used in this document Important instructions for your safety are specifically identified. It is essential to follow these instructions in order to prevent accidents and damage the property. Symbol Meaning This marking warns of a potentially dangerous situation in which failure to comply with safety requirements can result in death or serious physical injury.
3 3 Application The flexplate has especially been developed in order to measure the torque between motor and transducer in automatic transmissions. Measurements and physical attributes almost correspond with the original component, compact rotor electronic and rotor-/stator antenna, technical data, as supply voltage 9 … 36 V DC; analogue output 0 … 10 V DC and temperature range up to 120°C are adapted to the conditions in the vehicle.
4 4 Structure and mode of operation The torque transducer consists of two separate parts: the rotor and the stator. The rotor comprises the measuring body and the signal transmission elements. Strain gauges (SGs) are installed on the measuring body. The rotor electronics generates the bridge excitation voltage and transmits the measuring signal to the stator unit and are located at the outer circumference of flex plate. Diametric on the opposite side a balancing weight is mounted.
5 Fig. 4.1: Transducer with stator antenna and evaluation unit Fig. 4.2: EMI suppressor Important The use of the shielding plates is important to ensure compliance with FCC regulations. If the shielding plates has to be removed for any purpose (e.g. installation or maintenance), they must be replaced in the original position before the product is used.
6 5 Mechanical installation 5.1 Important precautions during installation NOTE A flexplate is a precision measurement element and therefore needs careful handling. Dropping or knocking the flexplate may cause permanent damage. Make sure that the flexplate cannot be overloaded, even while it is being mounted. • Handle the flexplate with care.
7 Important Even if the unit is installed correctly, the zero-point adjustment made at the factory can shift by up to approx. 0.5% of the characteristic value. If this value is exceeded, we advise you to check the mounting conditions. If the residual zero offset when the unit is removed is greater than 1% of the sensitivity, please send the transducer back to the Darmstadt factory for testing. 5.
8 5.6 Mounting the rotor 1. Clean the plane surfaces of the flexplate and the counter flange. For safe torque transfer, the faces must be clean and free from grease. Use a piece of cloth or paper soaked in solvent. Make sure that no solvent drips into the inside of the transducer and that the transmitter coils are not damaged during cleaning. Important If alternating loads are expected, use threadlocker (medium strength, e.g. LOCTITE No.
9 4.6 Installing the telemetry system The telemetry system consists of the following component parts: • Rotor antenna • Stator antenna (2 pieces) • Stator unit • Evaluation unit • Connection cable • EMI suppressor The stator antenna (pcb board) is to be mounted on the engine on the designated place with small screws in adequate length or an adequate epoxy glue (for example HBM’s X-280). The shape of this pcb board must be fitted to the surface of engine for example with a file before fixation.
10 Important • • • • • Do not bend the connection cable Do not shorten or stretch the connection cable Do not guide the cable close to energy- or power circuit lines The stator antenna has to be mounted directly above the rotor antenna The stator antenna has to be mounted in the middle of the adjustment range of the rotor antenna • The stator antenna must not touch the rotor antenna CAUTION • At all mounting- dismounting or repair operations, switch of the power supply of the system.
11 4.6.1 Stator antenna and stator unit The stator antenna is connected to the stator unit with a twisted cable pair (screw tightening torque 5N·m). The stator unit can be positioned and mounted flexibly according to the cable length. The stator unit is connected to the evaluation unit with a special cable of 5m length. NOTE • When you connect the stator antenna, please take regard to a stress relief • Use thread locker (medium strength, e.g. LOCTITE No.
12 6 General information • With extension cables, make sure that there is a proper connection with minimum contact resistance and good insulation. • All cable connectors or swivel nuts must be fully tightened. 6.2 EMC protection The product offered is a special assembly for stationary systems that is not available on the general market or a transducer for installation by system integrators and plant manufacturers.
13 Electrical and magnetic fields often induce interference voltages in the measuring circuit. Therefore: • Use shielded, low-capacitance measurement cables only • Only use plugs that meet EMC guidelines. • Do not route the measurement cables parallel to power lines and control circuits. If this is not possible, protect the measurement cable with e.g. steel conduit. • Avoid stray fields from transformers, motors and contact switches. • Do not ground the transducer, amplifier and indicator more than once.
14 6.3 Evaluation unit Fig. 6.
15 Functional overview of the evaluation unit (See fig. 6.1) Item Function description 1 Display Shows analog output voltage. For monitoring only - accurate measurement values to be read out on the output BNC connector 2 LED power The LED indicates the on/off status of the device 3 LED RF-level The LED indicates an acceptable RF signal strength from the transmitter 4 BNC output Voltage ±10V / frequency 10kHz±5kHz (select with switch no.
16 Technical details Supply voltage 9…36 VDC Max. power consumption 30 VA Signal bandwidth Switchable 1000 Hz / 100Hz Voltage output ±10 V Frequency output 5 … 15 kHz TTL Signal-to-noise ratio 63dB (1000Hz) / 83dB (100Hz) Signal transit time 450µs Wireless shunt calibration Key button at control unit Protection class IP40 Weight 700 grams Temperature range -10 … +70 °C Table 6.2: Technical details of the evaluation unit Dimensions of the evaluation unit 191,0 mm 113 mm 60,5 mm Fig.
17 6.4 Supply voltage The transducer must be operated with a separated extra low voltage (supply voltage 9 … 36 VDC). The supply voltage is electrically isolated from signal out puts and shunt signal inputs. Connect a separated extra low voltage of 9 V … 36 V DC to bracket 7 (+) and bracket 8 (-) of the evaluation unit. The cable can be up to 50m long for voltages ≥24V, otherwise it can be up to 20m long. The current during operation is about 0,7…0,9A.
18 6.5 Use of EMI suppressor To suppress high frequencies two EMI suppressors on the cable between rotor and stator has to be used. Use at least 3 loops of the cable for the ring EMI suppressor. The snap ferrite has to be mounted on the cable directly behind the connector at the Axon control unit. Fastening must be done in an area not subject to mechanical loads (i.e. no unwanted vibrations, etc.) using cable ties fit for the specific application. Fig 6.
19 Ring ferrite: Type: Vitroperm 500F Model No.: T60006-L2063-W517 Size: external diameter x internal diameter x height = 63 x 50 x 25 Snap Ferrite: Type: Würth 742 711 31 Fig 6.2: Picture of installation example of both EMI suppressors Important The use of the EMI suppressor on the power cable is mandatory to ensure compliance with FCC regulations.
20 7 Shunt signal The special torque flange delivers an electrical shunt signal that can be activated from the evaluation unit for measuring chains with HBM components. The transducer generates a shunt signal of about 50% of the nominal (rated) torque; the precise value is specified on the type plate. After activation of push button no. 15 (see Fig. 6.1), the shunt signal is activated for a time span of 5s.
21 8 Functionality testing You can check the functionality of the rotor and the stator from the LEDs on the evaluation unit. LED no. 2 (green), power status LED (orange), cal-function status LED no. 3 (green), RF level status Fig. 8.1: LEDs on the evaluation unit LED Color Significance LED no. 2 (power status) Green (permanently lit) normal operation The main switch (no. 6 in Fig. 6.
22 9 Maintenance The torque transducer is maintenance‐free. 10 Waste disposal and environmental protection All electrical and electronic products must be disposed of as hazardous waste. The correct disposal of old equipment prevents ecological damage and health hazards. Symbol: Meaning: Statutory waste disposal mark The electrical and electronic devices that bear this symbol are subject to the European waste electrical and electronic equipment directive 2002/96/EC.
23 11 Dimensions HBM: Business Document
24 12 Specifications Customized flexplate – MPZ1901037 Type Nominal torque Mnom Measurement bandwidth Sensitivity tolerance (deviation of the actual output quantity at M nom from the nominal (rated) sensitivity) Thermal effects per 10 K in the nominal (rated) temperature range on the output signal, relative to the actual value of the signal spread Linearity deviation including hysteresis, relative to the nominal (rated) sensitivity Rel.
25 13 Supplementary technical information To ensure that the flexplate retains its characteristics once it is installed, we recommend that the customer also chooses the specified form and position tolerances, surface quality and hardness (42+4 HRC) for the connections provided.
26 14 Declaration of conformity HBM: Business Document
27 Hottinger Baldwin Messtechnik GmbH. Subject to modifications. All product descriptions are for general information only. They are not to be understood as a guarantee of quality or durability. Hottinger Baldwin Messtechnik GmbH. Änderungen vorbehalten. Alle Angaben beschreiben unsere Produkte in allgemeiner Form. Sie stellen keine Beschaffenheits- oder Haltbarkeitsgarantie im Sinne des §443 BGB dar. Hottinger Baldwin Messtechnik GmbH Im Tiefen See 45 • 64293 Darmstadt • Germany Tel.
