LORENZ MESSTECHNIK DR-2112 User manual

LORENZ MESSTECHNIK GmbH Obere Schloßstr.131
73553 Alfdorf
(07172 / 93730-0
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Operation Manual
for Torque Sensor
For below and similar Types
DR-2112
DR-2112-R
DR-2412
DR-2412-R
DR-2212
DR-2212-R
DR-2512
DR-2512-R

LORENZ MESSTECHNIK GmbH Obere Schloßstr.131
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Imprint
Manufacturer, Place
Lorenz Messtechnik GmbH, D-73553 Alfdorf.
Valid for... DR-2112; DR-2412; DR-2112-R; DR-2412-R
DR-2212; DR-2512; DR-2212-R; DR-2512-R
Copyright © 2006 Lorenz Messtechnik GmbH, Alfdorf.
Reprint Interdiction Reprints, even in extracts, only with written authority.
Modification Technical changes reserved.
References in this Text
1.6 Warning Notes; Page 5
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for
commissioning, maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons.
These demands can be modified if other sufficient safety devices are available. During
operation, the safety precautions must be operative. By vibrations, damages can occur at
the device.
4 Mechanical Assembly; Page 7
During the assembly, the sensor must be supported to protect if from falling down.
4.1.3 Alignment of the Measurement Arrangement; Page 7
For further references see coupling manual.
4.2 General; Page 7
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign
particles may adhere to them. The hub must fit corresponding to the connection.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings. At small torques (< 20 N·m) connect the sensor electrically during the assembly
and observe the signal, the measurement signal may not exceed the limit values
4.2.1 Torque Sensors of 0,03 N·m to 15 N·m; Page 8
Sensors with nominal torques below 20 N·m are very sensitive to overload, therefore
these sensors need to be handled with greatest caution.
4.3 Freefloating Assembly; Page 8+9
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
In this installation case, double-jointed couplings can not be used for both sides!
Risk of Breakage!
4.4 Foot Version Assembly; Page 9
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
6.1 Engaging; Page 11
Warming-up period of the torque sensor is approx. 5 min.
6.4.2 Natural Resonances; Page 12
An operation of the device in natural resonance can lead to permanent damages.

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Contents
1 Read First .............................................................................................................................................. 4
1.1 Safety and Caution Symbols .......................................................................................................... 4
1.2 Intended Use .................................................................................................................................. 4
1.3 Dangers .......................................................................................................................................... 4
1.3.1 Neglecting of Safety Notes...................................................................................................... 4
1.3.2 Remaining Dangers ................................................................................................................ 4
1.4 Reconstructions and Modifications................................................................................................. 4
1.5 Personnel ....................................................................................................................................... 4
1.6 Warning Notes................................................................................................................................ 5
2 Term Definitions..................................................................................................................................... 5
2.1 Terms ............................................................................................................................................. 5
2.2 Definition of the Pictograms on the Torque Sensor ....................................................................... 5
3 Product Description ............................................................................................................................... 5
3.1 Mechanical Setup ........................................................................................................................... 5
3.2 Electrical Setup............................................................................................................................... 6
3.2.1 Sensors with Analog Output.................................................................................................... 7
3.2.2 Sensors with RS485 Interface................................................................................................. 7
3.2.3 The Serial Communication...................................................................................................... 7
4 Mechanical Assembly............................................................................................................................ 7
4.1 Couplings........................................................................................................................................ 7
4.1.1 Misalignment Possibilities of Single-Jointed Couplings .......................................................... 7
4.1.2 Double-Jointed Couplings ....................................................................................................... 7
4.1.3 Alignment of the Measurement Arrangement ......................................................................... 7
4.2 General........................................................................................................................................... 7
4.2.1 Torque Sensors of 0,03 N·m to 15 N·m................................................................................. 8
4.2.2 Torque Sensors from 20 N·m.................................................................................................. 8
4.3 Freefloating Assembly.................................................................................................................... 8
4.4 Foot Version Assembly .................................................................................................................. 9
5 Electrical Connection ........................................................................................................................... 10
5.1 Pin Connection ............................................................................................................................. 10
5.2 Calibration Control........................................................................................................................ 10
5.2.1 Calibration Control at Analog Output .................................................................................... 10
5.2.2 Calibration Control at RS485 ................................................................................................ 10
5.3 Cable ............................................................................................................................................ 11
5.4 Shielding Connection ................................................................................................................... 11
5.5 Running of Measuring Cables ...................................................................................................... 11
5.6 Angle (Option) .............................................................................................................................. 11
6 Measuring ............................................................................................................................................ 11
6.1 Engaging ...................................................................................................................................... 11
6.2 Direction of Torque ....................................................................................................................... 11
6.3 Static / Quasi-Static Torques........................................................................................................ 11
6.4 Dynamic Torques ......................................................................................................................... 12
6.4.1 General.................................................................................................................................. 12
6.4.2 Natural Resonances.............................................................................................................. 12
6.5 Speed Limits................................................................................................................................. 12
6.6 Disturbance Variables .................................................................................................................. 12
7 Maintenance ........................................................................................................................................ 12
7.1 Maintenance Schedule................................................................................................................. 12
7.2 Trouble Shooting .......................................................................................................................... 13
8 Decommission ..................................................................................................................................... 13
9 Transportation and Storage................................................................................................................. 13
9.1 Transportation .............................................................................................................................. 13
9.2 Storage ......................................................................................................................................... 14
10 Disposal ........................................................................................................................................... 14
11 Calibration ........................................................................................................................................ 14
11.1 Proprietary Calibration .............................................................................................................. 14
11.2 DKD-Calibration........................................................................................................................ 14
11.3 Re-Calibration........................................................................................................................... 14
12 Data Sheet ....................................................................................................................................... 14
13 Literature .......................................................................................................................................... 14

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1 Read First
1.1 Safety and Caution Symbols
Caution:
Injury Risk for Persons
Damage of the Device is possible.
Note:
Important points to be considered.
1.2 Intended Use
Torque sensors are intended for the measurement of torques. This measurand is further suitable for
control tasks. The valid safety regulations should be absolutely respected. The torque sensors are not
safety components in the sense of the intended use. The sensors need to be transported and stored
appropriately. The assembly, commissioning and disassembling must take place professionally.
1.3 Dangers
The torque sensor is fail-safe and corresponds to the state of technology.
1.3.1 Neglecting of Safety Notes
At inappropriate use, remaining dangers can emerge (e.g. by untrained personnel). The operation manual
must be read and understood by each person entrusted with the assembly, maintenance, repair,
operation and disassembly of the torque sensor.
1.3.2 Remaining Dangers
The plant designer, the supplier, as well as the operator must plan, realize and take responsibility for
safety-related interests for the sensor. Remaining dangers must be minimized. Remaining dangers of the
torque measurement technique must be pointed out.
Human mistakes must be considered. The construction of the plant must be suitable for the avoidance of
dangers. A danger-analysis for the plant must be carried out.
1.4 Reconstructions and Modifications
Each modification of the sensors without our written approval excludes liability on our part.
1.5 Personnel
The installation, assembly, commissioning, operation and the disassembly must be carried out by
qualified personnel only. The personnel must have the knowledge and make use of the legal regulations
and safety instructions.

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1.6 Warning Notes
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for
commissioning, maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons.
These demands can be modified if other sufficient safety devices are available. During
operation, the safety precautions must be operative. By vibrations, damages can occur
at the device.
2 Term Definitions
2.1 Terms
Measuring Side:
Mechanical connection of the torque sensor in which the torque to be measured is applied. Usually this
side has the smallest moment of inertia.
Drive Side:
Mechanical connection of the torque sensor on the opposite side of the measuring side, usually with the
largest moment of inertia. At static torque sensors the housing is fastened on this side.
Low Torque Resistance Side:
The shaft of the arrangement (drive, load) which can be turned considerably smaller with torque than the
nominal torque of the torque sensor M << M
nenn
.
2.2 Definition of the Pictograms on the Torque Sensor
The measuring side of the torque sensor is designated as follows:
Measuring side:
or M
More information can be found on the data sheet, if needed.
3 Product Description
The sensor measures static and dynamic torques. The mounting position of the torque sensor is
horizontally.
Caution: it is to be differentiated between measuring side and drive side, see data sheet of the sensor:
http://www.lorenz-sensors.com
3.1 Mechanical Setup
The sensors consist of a torsion shaft. Depending on design, the mechanical connection possibilities are
executable with round shafts or feather key connections etc. The torsion shaft, applied with two strain
gauge full bridges, is bedded in a housing through ball bearings. For the signal transmission and/or the
supply of the strain gauge full bridges, a rotating transformer, according to the principle of a transformer,
is arranged in the sensor. For supply and measuring signal conditioning, electronics are integrated in the
stator and the rotor.
M

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3.2 Electrical Setup
The supply of the rotor electronics occurs by an alternating voltage, generated in the stator, which
transfers to the rotor through a rotating transformer. There, it is rectified and stabilized. With this supply,
the strain gauge bridge is fed.
For the electrical calibration control of the sensor, a control signal is up-modulated to the supply by the µ-
processor in the stator and transferred to the rotor. There, it is filtered and evaluated by the µPC, which
also activates the internal switch for the detuning of the strain gauge bridge.
The measuring signal of the strain gauge bridge is conditioned in an amplifier and then converted into a
digital signal, which will be transferred to the stator by another rotating transformer. Compared to the
analog signal, the measuring signal in digital form is much more disturbance-free. The remaining distance
of the measuring signal within the sensor occurs in digital form, completely. Thus, the measuring system
achieves a high reliability of operation.
This signal is further conditioned in the stator, comes into a µ-processor, then - depending upon sensor
type - it is converted to a voltage signal, digital signal or to current and will then reach the output of the
sensor and can be directly measured at the connector.
DC / DC
Oscillator
4 MHz
Signal
Conditioning
Signal Adaption
Analog or Digital
Signal
Conditioning
A/D-Converter
± 11 bit
± 15 bit
µ - Processor
µ - Processor
Rotation Angle (Option)
SG
Supply
Voltage
Calibration
Control
Signal
Output
Rotation
Angle Output
( Option )
Amplifier
Stator Rotor
Rotating Transformer
Serial Data Transmission
A
B
AC
DC
Filter for
Control Signal
Cycle and
Control Signal
Supply and
Control Signal
Rotating Transformer
Block diagram for serial signal transmission
SG
Rotating transformer
Shaft
Measuring sideDrive side
Electronics in the stator
Option
Angle Sensor
Electronics in the rotor

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3.2.1 Sensors with Analog Output
At this output, the digital signal is converted into DC voltage of 0 V ±5 V, proportionally to the torque and
is available at the connector output.
3.2.2 Sensors with RS485 Interface
The torque sensor has a digital interface RS485 for the signal output and automatic sensor identification.
The protocol enables high dynamics.
See separate manual for further information.
3.2.3 The Serial Communication
See Lorenz Protocol, Document Number 090110, Lorenz Messtechnik GmbH.
4 Mechanical Assembly
For the assembly of a torque sensor in a shaft line, we always recommend to use couplings which can be
misaligned.
During the assembly, the sensor must be supported to protect if from falling down.
4.1 Couplings
We recommend multi-disc couplings for our torque sensors. Couplings must be able to balance an axial,
radial or angular offset of the shafts and not allow large forces to act on the sensor. The assembly
instructions of the respective coupling manufacturer must be considered.
4.1.1 Misalignment Possibilities of Single-Jointed Couplings
Note: Radial misalignments are only possible in the combination of
single-jointed coupling - torque sensor (as adapter) - single-jointed coupling.
Thus, with both single-jointed couplings the torque sensor forms a double-jointed coupling.
4.1.2 Double-Jointed Couplings
Double-jointed couplings are used for the balance of inevitable angular, axial and radial misalignments.
4.1.3 Alignment of the Measurement Arrangement
Precisely alignment of the couplings reduces the reaction forces and increases the durability of the
couplings. Disturbance variables are minimized as well.
Due to the multitude of applications, an alignment of the coupling with a straight edge in two levels,
vertical to each other, is sufficient.
However, in drives with high speed an alignment of the coupling (shaft ends) with a dial gauge or a laser
is recommended.
For further references see coupling manual.
4.2 General
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign particles
may adhere to them. The hub must fit corresponding to the connection.
Angular misalignments Axial misalignments
Radial misalignments

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Connections with Clamping Piece:
The indications of the clamping piece manufacturer must be considered. The clamping piece must be
able to transfer the arising torques safely.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings. At small torques (< 20 N·m) connect the sensor electrically during the assembly and
observe the signal, the measurement signal may not exceed the limit values
4.2.1 Torque Sensors of 0,03 N·m to 15 N·m
Sensors with nominal torques below 20 N·m are very sensitive to overload, therefore these
sensors need to be handled with greatest caution.
1. Connect the sensor electrically during the assembly and observe the measuring signal; the limit
values may not be exceeded in any case.
2. Align the arrangement before the parts are connected firmly.
3. Assemble the sensor at the low torque resistance side first, then at the stationary side
(this avoids impermissibly large torques from acting on the sensor).
4. Counter-hold by hand, so that impermissibly large torques or disturbance variables can not act on
the torque sensor
4.2.2 Torque Sensors from 20 N·m
The hub must fit corresponding to the connection.
4.3 Freefloating Assembly
The sensor is installed between two single-jointed couplings and contributes to
the balance of an inevitable axis offset between the two mechanical
connections.
If no couplings are used, very large transverse forces can affect the sensor. In
addition, large forces occur on the bearings in drive and output, which limit their
life span very strongly.
Shift couplings on shafts (use entire clamping length of the coupling) and align
shafts.
Assure absolutely that the data of the couplings (axis offset, angular offset, tension, compression) are not
exceeded.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
The housing must be protected from twisting e.g. by a flexible connection. The cable connection may not
be used for this.
The cable connection must be placed loosely (form of goose neck), so that it can follow the light
movements of the stator.
Flexible connection for
housing fixation
Drive Single-jointed coupling Single-jointed coupling Output
Torque sensor
Cable connection

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In this case, with both single-jointed couplings, the torque sensor forms a double-jointed coupling.
A single-jointed coupling can only balance axial and angular misalignments.
In this installation case, double-jointed couplings can not be used for both sides!
Risk of Breakage!
4.4 Foot Version Assembly
The housing of the sensor is designed as a bearing block. A full coupling must
be installed at both shaft ends. By this, inevitable misalignments can be
balanced, which can occur during the period of operation.
If no couplings are used, very large transverse forces can affect the sensor. In
addition, large forces occur on the bearings in drive and output, which limit their
life span very strongly.
Furthermore large bending moments occur in the shaft. At small torques (< 20
N·m) connect the sensor electrically during the assembly and observe the
signal, the measurement signal may not exceed the limit values
Shafts have to be cleaned with solvent (e.g. acetone) before the assembly
No foreign bodies may adhere to them.
Shift couplings on shaft (use entire clamping length of the coupling) and align shafts.
Absolutely note that the data of the couplings (axis offset, angular offset, tension, compression) are not
exceeded.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
Double-jointed coupling Double-jointed coupling
Drive Output
Torque sensor

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12-pin
E Excitation GND
K Calibration control
5 Electrical Connection
5.1 Pin Connection
Also see test certificate.
8-pin Analog
1 Excitation + 12 ... 28 VDC
2 Excitation GND 0 V
3 Signal ±5 V / (±10 V)
4 Signal GND 0 V
5 Calibration control
L<2,0 V;
H>3,5 V
6 Option angle A TTL
7 Option angle B TTL
8 NC
View: socket on soldering side
12-
pin
Analog Digital
A NC NC
B Option angle B TTL Option angle B TTL
C Signal ±5 V / (±10 V) NC
D Signal GND 0 V NC
E Excitation GND 0 V Excitation GND 0 V
F Excitation + 12 ... 28 VDC Excitation + 12 ... 28 VDC
G Option angle A TTL Option angle A TTL
H NC NC
J NC Output B RS485
K Calibration control L<2,0 V;
H>3,5 V
NC
L NC Output A RS485
M Housing Housing
View: socket on soldering side
5.2 Calibration Control
Only use calibration control in unloaded condition of the torque sensor.
5.2.1 Calibration Control at Analog Output
By applying voltage of +5 V to +28 V the calibration control will
switch on.
Voltage below 2,8 V will switch off the calibration control.
5.2.2 Calibration Control at RS485
The calibration control switch on is carried out by a command.
For this, see command SCMD_WriteFullStroke form Lorenz Protocol (document no. 090110).
+
3,5 VDC < U
kal
< 28 VDC
U
kal
Exc. GND
Cal. control