LORENZ MESSTECHNIK DR-2800 User manual

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
Fax [phone]
E-Mail: [e-mail]
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Operation Manual
for Torque Sensor
Type DR-2800

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
Fax [phone]
E-Mail: [e-mail]
Technical changes under reserve
090329a.docx
Internet: www.lorenz-sensors.com
Page 2 of 15
Imprint
Manufacturer, Place
Lorenz Messtechnik GmbH, D-73553 Alfdorf.
Valid for...
Torque sensor type DR-2554
Copyright
© 2012 Lorenz Messtechnik GmbH, Alfdorf.
Interdiction of Reprint
Reprint in whole or in part with written permission, only.
Change Notice
Technical changes are reserved.

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
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References in this Text
1.6 Warning Notes; Page 6
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. Vibrations can cause device
damages. .
4 Mechanical Assembly; Page 8
Caution: Inadmissibly large forces may not act on the sensor or the couplings during the
assembly. Connect the sensor electrically during the assembly and observe the signal, the
measurement signal may not exceed the limit values
To avoid falling down, the sensor must be supported during the assembly.
Admissible assembly offset from rotor to stator: 4.2 Stator Assembly
Caution! At alternating torque, the screws for the flange connections must absolutely be
secured with screw locks.
4.4.1 Alignment of the Measurement Arrangement; Page 11
For details see the manual of the couplings and data sheet of the torque sensor for the
limit thrust load and the limit shear force.
6.1 Engaging; Page 12
The warm-up period of the torque sensor is approx. 5 minutes.
6.4.2 Torsional Natural Resonances; Page 12
Operation of the device in natural resonance can lead to permanent damages.
6.4.3 Bending Natural Resonances; Page 13
Operation of the device in bending natural resonance can lead to permanent damages.

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
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Contents
1Read First.............................................................................................................................................. 5
1.1 Safety and Caution Symbols.......................................................................................................... 5
1.2 Intended Use.................................................................................................................................. 5
1.3 Dangers.......................................................................................................................................... 5
1.3.1 Neglecting of Safety Notes ..................................................................................................... 5
1.3.2 Residual Dangers ................................................................................................................... 5
1.4 Reconstructions and Modifications ................................................................................................ 5
1.5 Personnel ....................................................................................................................................... 5
1.6 Warning Notes ............................................................................................................................... 6
2Term Definitions .................................................................................................................................... 6
2.1 Terms ............................................................................................................................................. 6
2.2 Definition of the Pictograms on the Torque Sensor ....................................................................... 6
3Product Description ............................................................................................................................... 6
3.1 Mechanical Setup........................................................................................................................... 7
3.2 Electrical Setup .............................................................................................................................. 7
4Mechanical Assembly............................................................................................................................ 8
4.1 Rotor Assembly.............................................................................................................................. 8
4.2 Stator Assembly ............................................................................................................................. 9
4.3 Basic Assembly.............................................................................................................................. 9
4.3.1 Assembly Example ................................................................................................................. 9
4.3.2 Using Center Bore ................................................................................................................ 10
4.4 Couplings ..................................................................................................................................... 10
4.4.1 Alignment of the Measurement Arrangement....................................................................... 11
5Electrical Connection........................................................................................................................... 11
5.1 Pin Connection............................................................................................................................. 11
5.2 Cable............................................................................................................................................ 11
5.3 Shielding Connection ................................................................................................................... 11
5.4 Installation of Measuring Cables.................................................................................................. 11
5.5 Speed Sensor (Option) ................................................................................................................ 12
6Measuring............................................................................................................................................ 12
6.1 Engaging ...................................................................................................................................... 12
6.2 Direction of Torque....................................................................................................................... 12
6.3 Static / Quasi-Static Torques ....................................................................................................... 12
6.4 Dynamic Torques ......................................................................................................................... 12
6.4.1 General ................................................................................................................................. 12
6.4.2 Torsional Natural Resonances ............................................................................................. 12
6.4.3 Bending Natural Resonances ............................................................................................... 13
6.5 Speed Limits ................................................................................................................................ 13
6.5.1 Balancing .............................................................................................................................. 13
6.6 Disturbance Variables .................................................................................................................. 13
7Maintenance........................................................................................................................................ 13
7.1 Rotating Sensors.......................................................................................................................... 13
7.2 Trouble Shooting.......................................................................................................................... 14
8Transportation and Storage ................................................................................................................ 14
8.1 Transportation .............................................................................................................................. 14
8.2 Storage......................................................................................................................................... 14
9Disposal............................................................................................................................................... 15
10 Calibration........................................................................................................................................ 15
10.1 Proprietary Calibration.............................................................................................................. 15
10.2 DKD-Calibration........................................................................................................................ 15
10.3 Re-Calibration........................................................................................................................... 15
11 Data Sheet....................................................................................................................................... 15
12 Literature.......................................................................................................................................... 15

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
Fax [phone]
E-Mail: [e-mail]
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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
Lorenz Messtechnik GmbH devices may only be used for measurement tasks and the directly related
control tasks. Any other use is considered improper. 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, residual 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 Residual Dangers
The plant designer, the supplier, as well as the operator must plan, realize and take responsibility for
safety-related interests for the sensor. Residual dangers must be minimized. Residual 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.
.

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
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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. Vibrations can cause device
damages.
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.
Low Torque Resistance Side:
The shaft of the arrangement (drive, load) which can be rotated significantly smaller with torque than the
nominal torque of the torque sensor M << Mnenn.
2.2 Definition of the Pictograms on the Torque Sensor
The measuring side of the torque sensor is identified as follows.
Measuring side:
or M
Further indications can be found on the sensor data sheet.
3 Product Description
The sensor measures static and dynamic torques. The mounting position of the torque sensor is
horizontally.
Caution: it must be differentiated between measuring side and drive side, see data sheet of the sensor:
http://www.lorenz-sensors.com
M

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
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3.1 Mechanical Setup
The sensor consists of a stationary part, the stator and a rotary part, the rotor.
3.2 Electrical Setup
The electronics integrated in the sensor consistsof two parts.
The first part is in the stator and has following tasks:
Stabilization of the supply voltage
Electric supply of the rotor electronics through the rotating transformer
Preparation of the measurement signal from the rotor
Transmission of the torque measurement signal to the cable connection
The second part of the electronics is placed in the rotor of the torque sensor
with following functions:
Supply of the SG full bridge with DC voltage
Preparation of the electrical torque measurement signal
Transmission of the measurement signal to the stator
Stator Electronics
supply and measuring
amplifier
Rotor Electronics
supply of the SG full
bridge and the
measuring amplifier
Stator
Rotating Transformer
signal transmission from stator
to rotor and reversed
Meas. Body
with SG bridge
Cable Connection
electrical connection
Air Gap
for free rotation of
the rotor
Mounting Plate
for fastening of the stator
Slot Hole Drillings 2 x M8
for fastening
Keyway
for stator alignment

LORENZ MESSTECHNIK GmbH
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73553 Alfdorf
07172 / 93730-0
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4 Mechanical Assembly
4.1 Rotor Assembly
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings. Connect the sensor electrically during the assembly and observe the signal, the
measurement signal may not exceed the limit values.
To avoid falling down, the sensor must be supported during the assembly.
Admissible assembly offset from rotor to stator: 4.2 Stator Assembly
The sensor is installed into the shaft string through flanges. Prior to the assembly, flanges must be
cleaned with solvent (e.g. acetone), they must be free of foreign particles. The surface of the flange must
have an evenness of minimum 0,02 mm.
For transportation and easier assembly, the torque sensor is delivered with fixing plates.
The optimal axial position of Stator to Rotor is defined by fixing plates.
(per plate 3 screws M4x10)
Mounted Fixing Plates
Removed Fixing Plates
Without Fixing Plates
Tighten screws evenly on the flanges. Torque transmission by surface pressure, only. The installation and
alignment of the torque sensor occurs with mounted fixing plates.
Use appropriate tightening torques for the screws of strength 10.9 with suitable length. The screws
should be secured with screw locks (e.g. LOCTITE No. 242).
Nominal Torque
Screw
Quantity
Thread depth
Tightening torque
50 / 100 N·m
M 6
8
12 mm
14 N·m
200 N·m
M 8
8
12 mm
35 N·m
500 / 1000 N·m
M12
8
12 mm
120 N·m
2000 N·m
M14
8
17 mm
190 N·m
5000 N·m
M18
8
17 mm
490 N·m
Caution!
At alternating torque, the flange connection screws must absolutely be secured with
screw locks. Otherwise the connection screws may loosen.
The used screws may not be too long:
Shunt of the torque measurement
Flange connection is not twist-protected
Then remove the 3 fixing plates and control the position of shaft to stator:
a) Axial alignment of the shaft
b) Evenness of the air gap (shaft may not grind at the stator)

LORENZ MESSTECHNIK GmbH
Obere Schloßstr.131
73553 Alfdorf
07172 / 93730-0
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4.2 Stator Assembly
Use keyway for the axial alignment
Align stator to shaft
Rotor may not touch the stator
Note the axial position of rotor to stator
Tolerance: ± 0,5 mm
Tighten screws with a torque wrench.
Use suitable washers, if necessary.
Strength:
8.8
Tightening torque:
24 N·m
4.3 Basic Assembly
4.3.1 Assembly Example
To keep shear forces and axial forces to a minimum, shiftable couplings must be used. See chapter
couplings in this manual.
Example combustion engine with joint shaft
Angular displacements result in additional forces on the torque sensor. See data of the manufacturer of
the joint shafts.
DR-2800 Flange Coupling
Specimen
Load machine
Mounting surface
Fixing plate
2x M8
2x M8
Load machine
DR-2800
Combustion engine
Mounting
surface
Fixing plate
Joint shaft
Flange
Keyway
Flange
Flange

LORENZ MESSTECHNIK GmbH
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07172 / 93730-0
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Hose
Sensor
ges
M

S
M

t
M

4.3.2 Using Center Bore
Each part, led through the sensor, means a torque shunt.
By this, a torque portion will bypass the sensor.
This portion is not measured →so the shunt must be small in relation to the measured torque.
The large center bore is suitable for the lead-through of
hydraulic hoses
pneumatic hoses
rods
Note:
The lead-through part may not acquire
torque which will influence the measurement
result
Applied torque Ms for twisting of the led-
through parts must be very small against the
measured torque Mt .
Note at this arrangement:
Stges MMM 
St MM 
e.g.
tS MM 2000
1

Otherwise, a disturbance of the measuring signal will be the result from the torque shunt.
Example for a round shaft:
Twist angle of the torque sensor:  

Twist angle of the lead-through part: 


M = Torque; l = Length of the torsion part; d = Diameter of the torsion part
Both twist angles must be the same.
This means: in order to achieve as small as possible torque resulting from the lead-through part it must
have a small diameter (cross-section)
be long
4.4 Couplings
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.
Axial offset Radial offset Angular offset
ΔKa
Δ
K
w
2
x
Δ
K
w
ΔKr
Torque M
Body
M
l
d