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Study of noncontact torque measurement method with magnetic sensor band

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DOI: 10.1007/s12206-015-0835-1

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 Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903
www.springerlink.com/content/1738-494x(Print)/1976-3824(Online)
DOI 10.1007/s12206-015-0835-1

Study of noncontact torque measurement method with magnetic sensor band†

Kyungshik Lee and Chongdu Cho*
Department of Mechanical Engineering, Inha University, Incheon, 402-751, Korea

(Manuscript Received November 4, 2014; Revised May 7, 2015; Accepted May 20, 2015)

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Abstract

This paper presents a method for measuring torque applied to the rotating shaft of a gear box without physical modifications. As a re-
sult, the new measurement unit can detect the applied torque with an error of less than 1 % for the whole targeted speed range of 100 -
500 rpm. A Magnetic sensor band (MSB) is used to eliminate any need for calibration during the use of the unit. The major disadvantage
of this system is the fact that it is not suitable for measurement of torque under the stopped condition. This shortcoming is found to be
unable to overcome, and therefore the new unit has only limited application. However, the sensor module has sufficient engineering mer-
its, since it is implemented with a simple hardware method and is associated with a lower cost than current, commercially available
torque sensors.
Keywords: Noncontact torque sensor; Magnetic intensity monitor; Dynamic torque; Hall sensor; Magnet sensor band
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

the torque measuring method, without special treatments of

1. Introduction
the shaft, uses the magneto-elastic effect of ferromagnetic
Previously, the paradigm of transportation development was materials [5]. Another project targeted for a new type of sensi-
dependent on high speed and acceleration, but the tendency tive and fast-response micromagnetic sensors utilized the
has moved nowadays to a focus on riding with comfort and magneto-impedance effect in amorphous wires [6]. A more
with high energy efficiency. Therefore, significant research recent research project was devoted to pressure and torque
targeted on the direct measurement of torque applied to the measurement of automotive sensors based on both the Surface
rear end of the driving shaft of the gear box is in progress. acoustic wave (SAW) reflective delay lines and resonators [7].
Because of the manufacturer’s documented limitation with In this paper, we propose a method of non-contact sensor
open loop control methods, abrupt torque changes of the ro- with special magnetic bonding technology applied to the clas-
tary shaft need to be avoided. However, thus far there has sic concept of an existing gearbox, in order to achieve the
been no remarkable development in this area, primarily be- desired improvements. We previously confirmed the possibil-
cause of the difficulty to introduce a new design that will be ity of successful experimental results for this problem; how-
verified to be able to maintain safety and performance, as a ever, additional studies need to be pursued to allow compensa-
result of the stringent fixed space available and other envi- tion for the various constraints that must be improved for prac-
ronmental constraints. tical applicability.
Currently, the most widely used method for measuring the The twist angle detecting type torque sensor with reflector
torque of a highly reliable rotary shaft is a strain gauge type optical unit cannot use in unclean condition like oil exist, and
in-line sensor that is inserted between the driving shafts. How- with encoder type has problem that need slip ring like strain
ever, insertion of such a measurement sensor is impossible gauge type. That is reason our approach can be unique solu-
due to its size and the necessary slip ring part that needs fre- tion.
quent maintenance to prevent a durability problem. The classic concept used in this study is the phenomenon in
In order to compensate for industrial advancements in the which the twisting angle of the shaft with original symmetric
field, prior accomplishments have been actively studied [1]. cross-section at any point along its axis is proportional to the
The functionality of a magneto-strictive torque sensor is based applied torque within the allowable stress range. If torque is
on the iteration of periodic time differences [2-4]. Furthermore, applied along the axis of the circular cross-section of the shaft,
then Eq. (1) shows the relation of the twisting angle and the
*
Corresponding author. Tel.: +82 860 7321, Fax.: +82 868 1716 applied torque. In this expression, if temperature effects are
E-mail address: cdcho@inha.ac.kr
†
Recommended by Associate Editor Gil Hoo Yoon ignored, all the expression elements (except the twist angle)
© KSME & Springer 2015 become fixed quantities. Therefore, it is possible to calculate
3898 K. Lee and C. Cho / Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903

the torque applied to the shaft by measuring the angle of twist. Table 1. Specification of hardware components used.

Component list Model Spec

JGF p R 4G
T= = F. (1) Servo motor MR-J2S-12KA 200 N·m
L 2L
Powder break HSC-20Y 200 N·m
Strain gauge type sensor HKT-TRC 200 N·m
In our early studies [8-10] bench tests verified this tech-
nique with a pair of rubber pad magnets and hall sensors Coupling ROTEX-GS-14 200 N·m
placed on a small diameter shaft, under the condition of a low Hall sensor AMI302 2 Gauss
acting torque and a low rotating speed. Such early designs, at DAQ board NI-4472 102.4 kS/s
non-optimal operating ranges, were proposed to assess the Software LabViewTM Ver. 2013
technical feasibility of this torque measurement sensor. How-
ever, for industrial use, the proposed system need to achieve
the required performance characteristics, higher speed range
up to 5000 rpm, with a large diameter shaft, an increased ap-
plication torque. But we decide test speed range 100 - 500 rpm
and 25 mm diameter of shaft due to limitation of test bench.
Here we propose a modified design with the replacement of
employed magnets by rare-earth industrial magnets and mag-
netic pads, and the increase of the number of magnet pairs Fig. 1. Photograph of the test bench setup for the new sensor.
placed in symmetrical arrangements to meet the dynamic bal-
ance of the signal. However, in order to improve the reliability
in the performance improvement and coverage of increased
rotation speed, we applied a new Magnetic sensor band
(MSB) that can increase linearity in response.
Additionally, one of the key points of improvement was that
pairs of angular ball bearings were installed on both sides of
the shaft, and axial preload was added to minimize the vibra-
tion during rotation, keeping the distance between axis and the
sensors. The bench with normal ball bearing has the signal Fig. 2. Detail view of main sensor module (2).
deviation from vibration, cannot be reduced by software, of
the measured value due to gaps from both the connected with their most important properties being shown in Table 2.
points between the shaft and the ball bearing. They were considered suitable for testing for the reason that
Total test system configuration is shown in next section and the magnetic force generated is stronger in such small sized
detailed selection criteria of magnet, MSB, and data acquisi- magnets and their magnetic properties are maintained up to
tion part are presented in chapters 3~5. An analysis of experi- approximately 200°C. The Curie temperature, lost its magnet-
mental result and discussions are in the final section. ism, is 310-370°C.
A strong magnetic field intensity helps get a better quality
2. System configuration signal through an increased signal to noise ratio. Magnetic
strength must be stronger than hall sensor max specification
2.1 Hardware configuration
because strength can adjustable with distance between magnet
As shown in Fig. 1, the testing system consists of a servo and sensors.
motor responsible for shaft rotation (1), the main sensor mod- A neodymium magnet (also known as NdFeB, NIB, or Neo
ule (2), a commercial inline type of a torque sensor for evalu- magnet), is a type of a rare-earth, permanent magnet, made
ating the reliability and repeatability and role of calibrator for from an alloy of neodymium, iron, and boron to form the
new sensors (3), a powder brake for applying a variable torque Nd2Fe14B tetragonal crystalline structure. This is one of the
(4), a plug-in coupling component for compensation mis- strongest types of materials currently used for permanent
alignment of the axes and power transmission, a Data acquisi- magnets. In practice, the magnetic properties of neodymium
tion (DAQ) board, and software for displaying the collected magnets depend on their alloy composition, their microstruc-
data and for subsequent calculations and processing. Major ture, and the manufacturing technique employed for their con-
specifications and models of these parts are given in Table 1. struction [11].
The detail view of main sensor module is in Fig. 2. The optimum distance between the sensor and magnets was
set to 10 mm that is the optimized distance by the repeated
testing with adjustable micro stages. It is the distance where
2.2 Selection of magnets
magnetic field strength sensing value of hall sensor becomes
Neodymium magnets of 2 mm3 in size were used in this test, maximum measurable value of its specification to use full
 K. Lee and C. Cho / Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903
Table 2. Material properties of neodymium magnets.
Curie temperature (℃) 310-370
Maximum operating temperature (℃) 80-200
Density (g/cm3) 7.4-7.6
range of DAQ board.
The two pieces of MSB utilized do not lead to any misbal-
ances during rotation of the shaft because the weight-to-
weight ratio is very small (the weight of the MSB is only 30
mg), and the position of attachment is symmetrical about its
origin.
3. Signal processing and algorithm
In practice, a high-capacity servo motor, instead of an inter-
nal combustion engine, in the module introduces significant
noise that feeds through during both the reception and proc-
essing phases of the analog data. In order to remove this pri-
mary noise, we applied noise filtering methods to hardware
components utilized, including the use of a noise filter on the
power line, on a ferrite core driving line and on shielded ca-
bles.
From the software methodology standpoint, we applied the
LabVIEWTM to set a 60 Hz cutoff frequency, low pass filter,
and an averaging filter [12, 13] for noise removal. High-order
spline fitting was also employed to accurately extract the sig-
nal peak points before final calculations.
Torque calculation originally proposed under Eq. (1), can
be modified as in Eq. (2), where Δtmean is the mean time inter-
val of periods between eight detected peaks of magnetic field
wave signal.
np 2 R 4G 1 8 np 2 R 4G
T= å (Dti - Dti' ) = Dtmean = C Dtmean . (2)
60 L 8 i =1 60 L
In the theoretically derived Eq. (2), C is easily calculated to
be 1.9 × 106 at 400 rpm and 14.0 × 106 at 3000 rpm where L =
0.065 m, R = 0.0125 m, and G = 78 GPa. Therefore, a data
acquisition rate (fsample) must be selected (through the system’s
DAQ board) corresponding to C to maintain the error that
occurs due to acquisition frequencies to less than 1 % (without
the application of interpolation) as below Eq. (3).
1 1
DTsample = C Dtsample = C = TFullRange ´ = 1N × m .
f sample 100
We also applied a curve fitting method to extract the accu-
rate time of the data gathering instances and estimated the
average time period of the last several acquired cycles to re-
duce the error to within the desired values.
4. Selection MSB material and mounting
The newly presented approach can be applied without re-
3899
Fig. 3. Photograph of magnetic sensor bands.
Fig. 4. Installation of MSB on the rotary shaft.
gard to the shape of cross-section or the materials, even
though we used magnetic field on the steel shaft.
The problems encountered in prior research efforts associ-
ated with a magnetic field strength that changed with time
have been minimized in this effort through the use of the thick
MSBs to prevent the magnetization of ferromagnetic axle
from permanent magnets.
If the number of the system’s magnet pairs is increased, the
frequency of the modified sine curve is increased at the same
rotation speed. It helps to increase the measurement repeat-
ability by estimating the mean data from waveform data of
shorter periods. However, it is important to increase the num-
ber of magnets and to attach them at uniform intervals. The
algorithm that computes the positions of the peaks of the de-
tected magnetic field signals becomes complex, if the peak
intensities exhibit significant differences.
As a ring shaped band sensor cannot be directly mounted on
a pre-assembled shaft, we tackled this problem by dividing the
bands into two semi-circular halves as shown in the Fig. 3. Fig.
4 shows bands installed on the shaft. Due to the nature of ap-
plication, the required material properties for the band are:
1. Stability at high temperatures (up to 200oC)
2. Easy bonding to the shaft
3. Least temperature dependence of the modulus of elasticity.
(3)
For the above given properties we considered Polytetra-
fluoroethylene (PTFE), Polycarbonate (PC) and Polypropyl-
ene (PP). Some of the typical physical properties of these plas-
tics materials are shown in Table 3. We selected PC as it fa-
cilitates a high-temperature epoxy adhesive and can be stable
up to 120°C.
The effect of temperature on the measurement of the torque
was further investigated to make sure stable measurements
could be taken within automobile industry specific tempera-
ture range of -40-120°C. Temperature dependence of the
3900 K. Lee and C. Cho / Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903
Table 3. Material properties of targeted engineering plastics.
Properties PTFE PC
Density (g/cm3) 2.18 1.2
Melt temp. (℃) 327 155
Bond-ability (Epoxy) No Yes
Fig. 5. Temperature dependency effect on elastic modulus E.
elastic modulus value was also considered, as shown in Fig. 5.
During the experiments the temperature was measured by a
thermocouple sensor, however it was measured at the connect-
ing part near to the shaft instead of the actual rotating shaft
because of difficulty associated with the insertion of the slip-
ring during shaft rotation. Furthermore, the structure could
become complicated, and reduce life time just in the same
manner as the strain gauge type torque sensors.
The variation of the temperature test is not included herein
because of the limitations of the experimental apparatus. If the
influence of temperature on the measurement is accounted for,
G in Eq. (1) must not be constant, and it may be represented
by Eq. (4), using the interpolation formula listed in Fig. 5.
E of full scale is estimated, while the data of 200-500 rpm show
G=
2(1 + n )
-284.769 Tp3 + 30508.665 Tp2 - 49 ´ 106Tp + 202 ´ 109
» .
2(1 + v)
In the present study, we decided not to consider effects of
temperature because the maximum variation of temperature of
the test device was only about 5°C.
After increasing the number of magnets to eight, uniformly
mounted on the shaft, each of 25 mm in diameter, we obtained
a modified sine curve with a nearly uniform period, using the
MSB. The linear data were obtained without nonlinearities or
singular points, even at the initial twisting conditions,
achieved by bonding the MSB (which has a large contact area)
between the ring and the shaft, without deformation of contact
point between band and magnet.
We also replaced the ball bearing with an angular ball bear-
ing with preload to make the isolation effective, and improve
the repeatability and reproducibility by reducing the vibration
PP
0.91
168
No
Fig. 6. Twist angle per unit torque variation against rotational speed
within the range of 100-500 rpm.
coming from the gap of the sensor shaft and the body of the
measuring unit. This gap is main root cause of changing the
distance of the sensor and magnets. Because of this effect,
even if the axle induced vibration, the proposed methodology
elicited stable values, even in the cases of shaft and sensing
block vibration.
5. Results and discussion
Fig. 6 shows experimental data of the twisting angle per
unit torque applied to specified range of rotational speeds to
measure the reliability and repeatability of the sensitivity of
the fabricated sensor module. A total of four experiments were
evaluated for reliability in a week, or two- week periods. At a
rotational speed of 100 rpm a slope deviation of about 3.6 %
less than 1 % deviation. As shown in the hardware configura-
tion of Fig. 1, as well according to our expectation, the data
variation within the range of 100-200 rpm comes from the
difference between the position of the new sensor and com-
(4) mercial sensor. A variation at speed of 300 rpm or above is
very small, because the dynamic friction coefficient is smaller
than static friction coefficient. In practical applications, the
calculated mean value of 2.24ｘ10-5 rad/N·m must be applied
in the dynamic friction effect zone; however, Eq. (6) was also
used for correction to compare with the measured data from
inline torque sensor in this experiment. We know that the cali-
bration must do in the linear region that act dynamic friction to
get designed data without uncertainty.
2L rad
F= T = 2.244 ´ 10-5 *T (5)
p R 4G N×m
where L = 0.065 m, R = 0.0125 m, and G = 78 GPa with the
chosen material being SUS316 stainless steel. The constant
values (rad/N·m) from Eq. (5) are 99.9 % similar to the aver-
 K. Lee and C. Cho / Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903 3901

Fig. 7. Initial torque error measured for the range of rotational speeds
from 100-500 rpm.
Fig. 8. Real measurement data of twist angle versus testing torque for a
rotational speed of 400 rpm.
age slope of Fig. 6, as indicated by the experimental results. It
means the theoretical value is highly matched with the ex-
perimental result. Therefore, the new torque measurement
system has adequate reliability and the ratio of F and T can
be determined from the theoretical calculation instead of cali-
bration.

F
T= + Foff ( n )
Fsen ( n )
(6)
106 ´ F
= + Foff ( n ) .
-0.074n + 0.928n3 - 3.953n 2 + 6.226n + 20
4

The initial offset value is represented as one of the impor-

tant parameters of the measurement instrument, as indicated in
Fig. 7. If it does not converge to a certain finite value or zero,
it is left as an initial error that could not be compensated. At a
rotational speed of 100 rpm, data variation was about 2%, the
variation of other speed range is measured stably in about
0.5 % or less in the full-scale range. Therefore, the initial error
was maintained at less than 0.5% (the case in the 100 rpm was
excluded), after the calibration was performed. In order to
compare the value of Foff between the new sensor and the
commercial one, Eq. (6) can be changed to Eq. (7) by using
the multi-dimensional interpolation for compensation of the
initial offset.
Foff ( n ) = 0.0144n 4 - 0.295n3 + 2.165n 2 - 6.633n + 5.529 . (7)
The cause of the initial offset is the difference in the reduc-
tion of torque from a couple of bearings and rings, between
the two positioned sensors, as shown in Eq. (8). Therefore, the
Foff can be applied to zero when using the proposed sensor for
actual torque measurement.
Tnew = Tbearing + Tstrain
where Tnew is the torque acting on the new sensor position,
Tbearing is the applied torque on the bearing and coupling and
Fig. 9. Averages measurement data for twist angle versus testing
torque between the ranges of rotational speeds of 100-500 rpm.
Tstrain is the torque acting on the strain gauge type sensor.
Fig. 8 shows all the measured data and the averaged data
(marked with crosses) up to 100 N·m, at every 5 N·m at 400
rpm. The coefficient of determination R2 of the least squared
fitted line for the averaged data is 0.9997, indicating that the
proposed system exhibits good linearity within the entire
measurement range. The distribution of experimental data
from the eight magnets symmetrically varies about the aver-
aged data. Therefore, increasing the number of magnets
proved to be as one of the most important factors for compen-
sation of the dynamic balance of measurements.
Fig. 9 compares the twist angle with micro-radian and unit
torque for each rpm. The data clearly shows linearity in re-
sponse but the slope is slightly different at some specific speed.
In addition, it can be seen that the graphs almost overlap 300-
500 rpm. The data is overlapped at high torque values, be-
(8) cause the maximum applied torque is less than the desired
torque of 100 N·m, due to the limitations of the experimental
apparatus for rotational speeds of 400 rpm and above. The
correct data is calculated with Eq. (6) to compensate differ-
3902 K. Lee and C. Cho / Journal of Mechanical Science and Technology 29 (9) (2015) 3897~3903
Fig. 10. Measurement data using the acquisition software.
ence of slope from Figs. 6 and 7.
Fig. 10 shows a graph of sensing detects the variable torque
at the actual program, it can be verified that to obtain the de-
sired value. The solid line represents the measured values of
the inline sensor and the dotted line the measured values of the
proposed sensor module. The strain gauge type torque sensor
can operate in real time, but the proposed sensor with the cur-
rent hardware system cannot, because it uses an average value
of the number of cycles to overcome the limitations of the
hardware specification. Symptoms from applying average
method can make signal delay compare with real time data.
This phenomenon can be improved with the application of a
high-speed DAQ board in planned future work.
6. Conclusions
In this study, a torque measuring method that uses permanent
magnets and hall sensors has been demonstrated to prove preci-
sion and reliability. More accurate results could be obtained by
using real-time feedback data of rotational speed as an impor-
tant parameter. It is shown that sensor calibration is one of the
most important factors that must be executed at high rotational
speed operations to allow accurate parameter estimation. The
initial offset values from each magnet pair signal must be set
from calibration but the ratio of torque and twist angle can be
set either by calibration or from theoretical calculation.
The measurement results within the range of 100-500 rpm
depicted an overall error under 1% after processing calibration.
In the low speed region, even though there was a mechanical
improvement due to the torque and vibrations occurring in the
bearing, the results cannot be confirmed that the error is less
than 1% because of calibration data in Fig. 6. If measurement
unit is configured with frictionless bearings instead of the
current experimental apparatus, result will show small initial
angle gap difference in every rotation speed.
The MSB that has been studied in this paper with engineer-
ing plastic has the following four advantages:
- It possesses features that complement the nonlinearity and
non-uniformity of the initial deformation occurring by at-
tachment of a number of separate magnets directly to the
drive shaft with heat-resistant glue, instead of using a me-
chanical method to maintain the original shape of the
shaft.
- It requires a frequent calibration because the strength of
the magnetic field changes within a short time period due
to the magnetization generated by attachment of the mag-
net to the axis of the ferromagnetic material.
- It possesses the advantage of detecting the peak of mag-
netic field wave signal with a constant period to locate
magnets in regular interval.
- Overcomes strain gauge sensor failure to accurately oper-
ate at temperatures above 50°C due to thermal strain ef-
fects, with a thermal sensor operating range theoretically
extending up to 120°C in this study.
In addition, the major disadvantage of the measurement
concept is that it cannot measure torque at the zero or slow
rotation speed, but it might be overcome according to apply-
ing specified purpose. For example, we can make the excep-
tion processing of the control loop at very low driving speeds,
because does not require changing of transmit gears or apply
on the system need to rotate shaft always after system turning
on like helicopter or turbine.
Future considerations will focus on the tester to allow its
application to rotational speeds, over 500 rpm up to 5000 rpm,
in the high regime and to confirm effects of high temperature.
Acknowledgment
This work was supported by Inha University.
Nomenclature------------------------------------------------------------------------
G : Shear modulus
n : Rotational speed of shaft
R : Radius of shaft
L : Distance between two sensors
Φ : Twist angle of shaft
J : Polar moment of inertia
Tp : Temperature of shaft
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3903
Kyungshik Lee was born in Seoul, Korea,
in 1976. He received the B.S. degree in
mechanical engineering from Inha Uni-
versity in 2010. He is currently pursuing
the Ph.D. degree with the College of Me-
chanical Engineering, Inha University,
Incheon, Korea. His research interests
include noncontact torque meters.
Chongdu Cho has been teaching as a
professor of Mechanical Engineering at
Inha University, Incheon, South Korea
since 1992. He has won a fellow profes-
sorship at Inha University since 2008.
Dr. Chongdu Cho received his Ph.D. in
Mechanical Engineering and Applied
Mechanics from the University of
Michigan, Ann Arbor, Michigan, USA. He received his
Bachelor of Science in Mechanical Engineering at Seoul Na-
tional University and a Master in Science at KAIST, South
Korea. His major research area is the thermo-mechanical be-
havior of materials and composites and their fracture mechan-
ics. He also has numerous publications on NEMS/MEMS in
the field of Carbon nanotubes, micro switches and biosensors.
He has published more than 160 SCI(e) peer reviewed interna-
tional papers, 135 international conference proceedings and
numerous domestic articles and papers.