LORD Torque-Link-LXRS User manual

LORD Sensing USER MANUAL
Torque-Link-LXRS®
Wireless Torque Sensor

LORD SensingSystems
459HurricaneLane
Suite102
Williston, VT 05495
UnitedStatesofAmerica
Phone: [phone]
Fax: [phone]
9:00AM to5:00 PM (EasternTime US & Canada)
http://www.microstrain.com
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Document 8500-0059 Revision E
Subjecttochange withoutnotice.

Torque-Link®-LXRS User Manual
Table of Contents
1. Wireless Sensor Network Overview 6
2. Node Overview 7
2.1 Component List 7
2.2 Interface and Indicators 8
2.3 Assembly and Disassembly 10
2.4 Node Operational Modes 10
2.5 On-board Temperature Sensor 12
3. System Operation 13
3.1 Software Installation 13
3.2 System Connections 13
3.3 Gateway USB Communication 14
3.4 Connect to Nodes 14
3.4.1 Adding a Node by Address 15
3.4.2 Using Node Discovery 15
3.5 Channel Configuration 15
3.6 Sensor Calibration 17
3.7 Sampling Settings 17
3.8 Data Acquisition 18
3.8.1 Connect toSensorCloud 22
3.8.2 Navigating Menus 22
3.8.3 Sensor Data Files 25
4. Installing Strain Gauges 27
4.1 Node Differential Inputs 27
4.2 Wheatstone Bridge Tutorial 27
4.3 Strain Gauge Installation 29
4.3.1 Tools and Equipment 29

Torque-Link®-LXRS User Manual
4.3.2 Strain Gauge Placement 30
4.3.3 Strain Gauge Wiring 32
5. Torque-Link-LXRS Installation 34
5.1 Mounting the Assembly 34
5.2 Re-Using the Assembly 35
6. Strain Gauge Calibration 36
6.1 Example Lab or Field Calibration 40
6.2 Calculating a Linear Slope 43
6.3 Theoretical Torque Formula 45
7.1 Maintenance 47
7.2 Changing the Batteries 48
8. Troubleshooting 49
8.1 Troubleshooting Guide 49
8.2 Device Status Indicators 53
8.3 Optimizing the Radio Link 54
8.3.1 Range Test 54
8.4 Battery Connector 55
8.5 Updating Node Firmware 57
8.6 Repair and Calibration 59
9. Parts and Configurations 61
9.1 Standard Configurations 61
9.2 Replaceable Parts 62
9.3 Recommended Strain Gauges 62
9.4 Wireless System Equipment 62
10. Specifications 65
10.1 Physical Specifications 65
10.2 Operating Specifications 66

Torque-Link®-LXRS User Manual
10.3 Torque-Link RPM Limits 66
10.4 Power Profile 67
10.5 Radio Specifications 68
10.6 Frequency Setting 69
11. Safety Information 70
11.1 Battery Hazards 70
11.2 Disposal and Recycling 70
12. References 72
12.1 Related Documents 72

Torque-Link®-LXRS User Manual
1. 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. Bi- directional wireless communication
between the node and gateway enables sensor data collection and configuration. Gateways can be
connected locally to a host computer or remotely via local and mobile networks. Some gateways also
feature analog outputs for porting sensor data directly to stand-alone data acquisition equipment.
The selection of available nodes allows interface with many types of sensors, including accelerometers,
strain gauges, pressure transducers, load cells, torque and vibration sensors, magnetometers, 4 to 20 mA
sensors, thermocouples, RTD sensors, soil moisture and humidity sensors, inclinometers, and orientation
and displacement sensors. Some nodes come with integrated sensing devices such as accelerometers.
System sampling capabilities include lossless synchronized sampling, continuous and periodic burst
sampling, and data logging. A single gateway can coordinate many nodes of any type, and multiple
gateways can be managed from one computer with the SensorConnect™ and SensorCloud™ software
platforms. Integration to customer systems can be accomplished using OEM versions of the sensor nodes
and leveraging the LORD Sensing data communications protocol.
Common wireless applications of LORD Sensing Sensing Systems are strain sensor measurement,
accelerometer platforms, vibration monitoring, energy monitoring, environmental monitoring, and
temperature monitoring.
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Torque-Link®-LXRS User Manual
2. 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.
The Torque-Link-LXRS utilizes the SG-Link®-OEM wireless sensor technology to acquire and distribute
the strain gauge data. The Torque-Link-LXRS has 16-bit resolution, can log data to internal memory,
transmit in real-time, and support event-driven triggers with both pre- and post- event buffers.
To acquire sensor data, the Torque-Link-LXRS is used with any LORD Sensing LXRS®data gateway
such as the WSDA-101 and WSDA-1500, and either the Node Commander or SensorCloud™ software
interfaces. The Node Commander software is included with the gateways and allows configuration of the
node.
Figure 1 - -LXRS
2.1 Component List
The Torque-Link-LXRS comes with the components shown in Table 1 - Component List . The standard
assembly ( 2.1 Component List ) has one sensor channel, which accommodates monitoring a full-
bridge strain element array ( see Installing Strain Gauges on page 27 ). A two-channel assembly is also
available for redundant or additional monitoring.
For a complete list of available parts and options, see Parts and Configurations on page 61 .
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Torque-Link®-LXRS User Manual
Item Description Quantity
ATorque-Link-LXRS
(1 channel standard (shown) , 2 channel optional) 1
BLithium battery pack (installed in assembly) 1
CBattery compartment screws - 4-40 x 5/16" 6
DCollar screws - 8-32 x 5/8" 4 or 6
-- Strain gauge connector 1
-- Strain gauge and wiring terminal kit (optional) 1
Table 1 - Component List
2.2 Interface and Indicators
TheTorque-Link-LXRS consists of two half collars. One half includes compartments for the node
electronics and battery pack, and cutouts for a strain gauge and wiring. The electronics compartment
is potted at the factory to make it suitable for harsh environments. 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 see Parts and
Configurations on page 61 .
From the electronics compartment there are two connectors. One goes directly into the battery
compartment for connecting power, and the other is trained through the wiring channel to connect to
the strain gauges.
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Torque-Link®-LXRS User Manual
Figure 2 - Interface and Indicators
Indicator Behavior Node Status
Device
status
indicator
OFF Node is OFF
Rapid flashing on start-up Node is booting up
1 (slow) pulse per second Node is idle and waiting for a command
Table 1 - Indicator Behaviors
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Torque-Link®-LXRS User Manual
2.3 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
Sensor nodes have three operational modes: active , sleep , and idle . When the node is sampling, it is in
active mode. When sampling stops, the node is switched into idle mode, which is used for configuring
node settings, and allows toggling between sampling and sleeping modes. The node will automatically
go into the ultra low-power sleep mode after a user-determined period of inactivity. The node will not
go into sleep mode while sampling.
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Torque-Link®-LXRS 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.
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Torque-Link®-LXRS User Manual
2.5 On-board Temperature Sensor
lThe Torque-Link-LXRS has an on-board, solid state temperature sensor mounted on the
surface of the circuit board.
lThe temperature sensor output is connected to channel 3 of the Torque-Link-LXRS
lRefer to the node specification table for the temperature sensor operating parameters
( see Operating Specifications on page 66 ).
lThe temperature sensor has a measurement range of - 40˚C to +85˚C range with an
accuracy of ± 2˚C @25˚C.
lThe sensor is made by Texas Instruments (part number LM60). Specifications may be
found on the manufacturer’s website.
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Torque-Link®-LXRS User Manual
3. 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. Communication between the nodes and gateway is wireless and uses the LORD Sensing
LXRS and LXRS+ data communications protocols.
LORD Sensing has two software programs available for data acquisition from the wireless sensor
network: SensorCloud and Node Commander. SensorCloud is an optional web-based data collection,
visualization, analysis, and remote management platform based on cloud computing technology. Node
Commander is PC-based software used for configuring gateways and nodes, selecting sampling modes
and parameters, initializing data acquisition, and viewing and saving data.
3.1 Software Installation
To install Node Commander®Software Suite on the host computer, run the installer executable file
and follow the on-screen prompts. The software is provided with all gateways and is also available on
the LORD Sensing website ( see References on page 72 ).
The suite includes the following programs:
lSensorConnect is used for configuring nodes and acquiring, viewing, and saving data.
lLive Connect is a TCP/IP-to-serial conversion tool that translates the communications
between Node Commander and an Ethernet gateway.
lWSDA Data Downloader is used to download acquired data to a host computer from the
flash memory card embedded in an applicable gateway.
SensorCloud is an optional data collection, visualization, analysis, and remote management tool. It is
based on cloud computing technology and is accessed directly from a web connection. For more
information go to: http://www.sensorcloud.com/.
3.2 System Connections
To acquire sensor data the following components are needed in addition to the node: strain gauges
and application materials, a LORD Sensing wireless sensor node, a LORD Sensing data gateway,
and a host computer with access to the data acquisition software.
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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.
Figure 5 - System Connections
3.3 Gateway USB Communication
1. Power is applied to the gateway through the USB connection. Verify the gateway status
indicator is illuminated, showing the gateway is connected and powered on.
2. Open the Node Commander software.
3. The gateway should appear in the Controller window automatically with a communication
port assignment ( Figure 6 - USB Gateway Communication ) . If the gateway is not
automatically discovered, verify the port is active on the host computer, and then remove and
re-insert the USB connector.
Figure 6 - USB Gateway Communication
3.4 Connect to Nodes
Several methods can be used in Node Commander to establish communication with the nodes. This
quick start section covers the two simplest methods; adding a node by address and by using the node
discovery feature.
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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.
1. The node address and frequency are indicated in the documentation included with the node.
Enter the node address, and select OK. If the node is not found, a message will appear and
provide the option to scan for the node on other frequencies. Alternately, the Node Discovery
feature can be used.
Figure 7 - Adding a Node by Address
3.4.2 Using Node Discovery
NOTE
Automatic node discovery may not work in some boot-up modes. If the node is not in
normal boot up mode, the assigned one can be bypassed to enable node discovery.
For more information see Troubleshooting Guide on page 49.
1. Turn the node power on.Within a few seconds, the node will transmit a message with its
operating frequency.
2. When the device status indicator on the node ends the rapid flash sequence and begins
pulsing at one-second intervals, the node has completed the normal boot-up sequence and is
running in idle mode. At this point the node should be listed in the Controller window;
scanning can be stopped by selecting the Stop button in the Node Discovery window.
3.5 Channel Configuration
Each sensor is assigned a channel number. The sensor settings are stored in the node memory for that
channel. The configuration menus only show the channels and configuration options available for the
type of node being used.
1. To enter the configuration menu, right-click on the node name, and select Configure to
display options for the node> Configure Node. The Channels tab displays channel options
available for the node.
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Torque-Link®-LXRS User Manual
Figure 8 - Node Channels Menu
Figure 9 - Channel Setup
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Torque-Link®-LXRS User Manual
3.6 Sensor Calibration
3.7 Sampling Settings
Sampling settings are accessed through the Configure Node menu. There is a tab for each sampling
mode available for the particular node ( 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 . Other settings are automatic, depending on number of active channels and other
variables. For more information on sampling modes, refer to the Node Commander user manual ( see
References on page 72 ).
Figure 10 - Sample Settings Menu
In general, when determining what sample mode and rate is most suitable for the application, refer to
the following guidelines;
lUse a sample rate at least twice the value of the target measurement frequency. This is the
minimum sample rate required to produce an accurate digital representation of the measured
signal. The higher the sample rate, the more accurate the digital representation.
lUsing the minimum required sample rate will increase battery life and minimize the allocated
network bandwidth.
lUsing periodic burst sampling in place of continuous sampling will increase battery life. The longer
the sample interval, the more power and network bandwidth will be saved.
For synchronized sampling, use the online calculator to evaluate network bandwidth at different
sampling settings :
http://www.microstrain.com/configure-your-system
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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. For more information about synchronized sampling and using the gateway beacon see
Data Acquisition on page 18 . For more information about other sampling modes, refer to the Node
Commander user manual. ( see References on page 72 ).
To start a sampling session, nodes can be selected individually or as a group. When selected as a
group, they will all be set to the same sampling mode. Right-click on the nodes, and select Sample >
Synchronized Sampling.
Figure 11 - Starting a Sampling Session
When a synchronized sampling session is started, the sampling menu appears and includes settings to
enable optional sampling features, configure nodes, and to specify where the data will be saved. The
built-in bandwidth calculator displays the total bandwidth used by the nodes selected for synchronized
sampling ( Figure 12 - Synchronized Sampling Menu ).
a. Save Location: indicates where the data file will be saved on the host computer. Use the
Browse button to select a location.
b. Node configuration: includes the node serial number, sampling settings, bandwidth
calculation, and current status. Highlight any node or group of nodes, and the Remove,
Configure, and Refresh buttons become active. The Configure button opens the node
configuration menus to adjust settings as needed and recalculates the node bandwidth.
Multiple nodes can be configured together by using the Shift or Ctrl key to select them.
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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. High Capacity: optimizes bandwidth and power use for nodes with slower sample rates by
reducing the transmit rates. It may increase data latency.
e. Network Bandwidth: is the total calculated bandwidth used by all the nodes. The bandwidth
changes as nodes are added, removed, and as the settings are changed.
f. Enable Beacon on Start: When synchronized sampling is started the nodes wait for the first
beacon transmission to initiate sampling. When this option is selected (default), the gateway
beacon is enabled and will begin transmitting at a fixed interval when sampling is started.
Disabling the beacon on start (unchecking the box) will set the nodes to wait for the beacon,
but it does not actually start the beacon when sampling is started. This can be used if there
is a need for sampling to be initiated later, or if the beacon is being received from another
source than the gateway. Enabling the beacon in this way is the same as enabling the
beacon in the gateway menu
g. Apply settings and start sampling: Before acquisition can begin, use the Apply Network
Settings to save the session settings to the node. When completed, select Start Sampling to
begin.
h. Close sampling window (with the red "X") to exit sampling or, once the sampling has
started, to view the data window behind it.
NOTE
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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. Once sampling has
started, the grid view is the default view ( Figure 13 - Synchronized Sampling Data View ).
Figure 13 - Synchronized Sampling Data View
a. Device status: Node sampling mode and gateway status are displayed in parentheses next
to the device name.
b. Node information: includes node serial number and sampling statistics. Right-click on the
node name for more menu options such as Stop Nodes.
c. Data: is a display of the sampled data with each channel in its own column.
d. Radiostrength: indicates the strength of the communication between the gateway and
node. See Range Test on page 54 .
e. Data file: is the location and size of the data file, as data is added. View the data in .CSV
format with the Open File button.
f. View menu: Allows user to toggle between Data Grid and Graph views.
g. End sampling: The red "X" is used to exit the sampling window and/or end sampling.
NOTE
When synchronized sampling is set to slower sample rates it may take several seconds after
sampling is initiated for the first sample to appear.
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