Traction Motor Torque Sensor Adapter Weld Calculations

This calculation is to determine the weld strength the welds on the traction motor torque sensor adapter. The assembly
consists of 3 welds, a fillet on the shaft side and 2 grove welds on each side with a leg length of 6 mm, and the flange is
press fit onto the cylinder with an interference fit. Should the calculations show that the current size of the welds are
insufficient, the frictional strength of the press fit will be considered, otherwise as a conservative approach the fit will be
considered as frictionless. This repersensts the press fit failing and the . The adapter will see a maximum torque of 12kNm.
Resistance to other forces (Axial, shear andmoment forces) will aslo be considred.

The known values are:

3
MMax 12 10 N m hweld 6 mm r 160 mm σut 427 MPa (E60xx AWS Electrode)

2
Aweld 2 2 π hweld r 8530,3352 mm

3
hweld 8 4
Jweld 2 π hweld r 1,6327 10 mm
2

3
hweld 7 4
Iweld π hweld r 8,1633 10 mm
2

τallowed 0,3 σut 128,1 MPa (AISC Code for Weld Metal)
Traction Motor Torque Sensor Adapter Weld Calculations

Torsion

The primary force that will act on the welds is a tortional force from the traction motor of 12kNm. For each of the welds:

MMax r
τtorsion 11,76 MPa τallowed Jweld
Jweld Tallow 130,7143 kN m
r

Bending

The bending force acting perpendicular to the axis of rotation of the adapter is unknown. This bending force may be a result of
missalignment of the shafts or vibration. The maximum allowable moment acting on the welds is:

τallowed Iweld
Mallow 65,3571 kN m
r

Shear

The shear force permissable is:

Sallow τallowed Aweld 1,0927 MN

Stress due to centrifugal forces

The spinning adapter will result in a centrifugal force acting on the welds. The mass of the welds can be calculated as

1 2 kg
Mweld h 2 π r 7860 0,1422 kg
2 weld 3
m
ω 2 π 3000 rpm

2
Fc Mweld r ω 88,6695 kN

Fc
τcent 10,3946 MPa
Aweld