How to measure torque of a motor? | Torque Testing Stand

How to measure torque of a motor? 

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A relatively simple method to estimate electrical motor torque  (AC - Synchronous or Induction; or DC - Brushed or Brushless) is to measure its electrical power input, the voltage and the current in the power line driving the motor. For most motors, torque is directly proportional to the current and can be derived from it by knowing shaft speed and motor efficiency. This is considered an indirect measurement of torque since it is not the true mechanical torque but instead a relation from electrical power quantities to a theoretical and estimated torque value.

Another alternative and indirect method is to create a transversal arm attached to the motor housing using a known arm length. Let the whole motor housing outside case run freely along the attached arm. The arm tip can then be placed on a load cell. The torque can now be measured using a the load cell measurement and the arm length.

However, for a precise and accurate shaft output torque measurement, a rotary torque sensor is the recommended method. Rotary Torque Sensors are frequently used as auditing tools for motor torque testing stand in motors, power tools, turbines, and generators.

In the dynamic world of manufacturing and assembly, torque testing stands as a sentinel, ensuring the efficacy and safety of products. This pivotal process is essential for validating the tightness and stability of threaded fasteners, making it indispensable across industries, from automotive to medical devices. The accurate application of torque is a cornerstone in affirming product integrity and aligning with international standards.

Benefits of Accurate Torque Application

Ensuring Efficiency and Safety

The precision in applying torque is crucial because it ensures unparalleled product reliability and safety across various industries. A deviation from the specified torque, whether by under-tightening or over-tightening fasteners, can precipitate a spectrum of issues, including the loosening or breaking of these critical components.

Especially in sectors like automotive and aerospace, where components are perpetually subjected to high-stress and dynamic environments, accurate torque application becomes synonymous with safety and operational integrity. Inaccuracy in applying torque not only jeopardizes the structural integrity of products but also amplifies the risk of catastrophic failures, with potential repercussions extending to substantial financial loss and compromised safety.

Elevating Brand Reputation

By ensuring that products are not only compliant with established specifications but also guaranteeing their safe functionality throughout their lifecycle, it inherently communicates a brand&#;s dedication to delivering excellence and reliability. This meticulous approach to quality assurance not only fortifies customer trust but also positions the brand as a symbol of reliability and quality in the competitive market.

Moreover, in industries where regulatory compliance is stringent, consistent torque testing becomes a beacon of adherence to both national and international standards. Consequently, torque test does not merely serve as a technical checkpoint but evolves into a strategic tool, elevating brand reputation, and ensuring customer safety.

Torque Testing Process

Torque testing is a vital procedure that evaluates the force applied to a product, ensuring its tightness and stability align with specified standards. Utilizing various methodologies and instruments, it meticulously measures and validates the torque applied to components in diverse industries. This rigorous testing guarantees components are securely fastened, mitigating risks like premature wear and product recalls, and ensuring adherence to safety standards.

Kinds of Torque Testing

• Static Torque Testing: This method measures the torque on a stationary object, vital in scenarios where secure fastening, like in automotive assemblies or electronics, is paramount.
• Dynamic Torque Testing: This involves measuring torque when parts are in motion, essential for motor-driven products to guarantee peak performance and durability.

Key Instruments in Torque Testing

• Torque Sensors: These are the linchpins in measuring the torque during testing, ensuring it's within the desired parameters.
• Torque Testers: These validate the precision of torque-controlled tools, ensuring they're fine-tuned to deliver the necessary torque.
• Torque Meters: These measure torque on rotating systems, like engines or bicycle cranks, ensuring they function safely and efficiently.
• Torque Wrenches: Used to apply a specific torque to a fastener such as a nut or bolt.
• Torque Screwdrivers: Designed to precisely tighten or loosen screws to a specified torque.
• Calibration Equipment: Devices used to adjust the accuracy of the torque measuring instrument.
• Test Stands: Apparatus that holds the object to be tested in place and may also include force measurement devices.
• Data Acquisition Systems: Systems that collect and analyze data from the torque testing process.
• Adapters and Fittings: Various connectors used to fit different types of bolts and nuts during testing.
• Load Cells: Devices that measure force or load applied during the testing.

Implementing Torque Testing in Manufacturing

For manufacturers, a robust torque testing regimen is non-negotiable. Here's a blueprint:

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• Defining Parameters: Pinpoint the torque specifications crucial for product safety and functionality.
• Selecting Appropriate Tools: Opt for torque test instruments that align with the product's specifications.
• Calibration: Regularly calibrate tools to eliminate measurement discrepancies.
• Documentation: Chronicle testing processes, outcomes, and anomalies, ensuring accountability and quality adherence.

Continuous Monitoring and Validation

Consistent monitoring and validation of torque application throughout the manufacturing process are pivotal to maintaining a steady output of high-quality products. This ongoing scrutiny acts as a protective measure, promptly identifying and rectifying any emerging issues. Ensuring this consistency safeguards both the product's integrity and user safety.

Regulatory Bodies Governing Torque Testing

Torque test is mandated and underscored by various regulatory agencies and standards across different industries globally, ensuring safety, reliability, and quality in manufactured products. These entities, among others, underscore the universal significance of torque testing across varied industries, each tailoring its standards to the specific needs and challenges of its respective domain.

• National Electrical Code (NEC) leads in the electrical domain, establishing rigorous standards and guidelines to ensure safe electrical design, installation, and inspection, with a particular emphasis on accurate torque application to prevent issues like overheating and potential fire hazards.
• International Organization for Standardization (ISO) provides various standards, including ISO , which pertains specifically to hand torque tools in manufacturing, ensuring that they are reliable, accurate, and adhere to international safety and quality benchmarks.
• American Society for Testing and Materials (ASTM) stipulates standards such as ASTM F, which concerns insulated and insulating hand tools for electrical applications, ensuring that they meet stringent safety and performance criteria.
• Society of Automotive Engineers (SAE) in the automotive sector sets forth standards like SAE J, which deals with serial data communication between microprocessor systems in heavy-duty vehicle applications, ensuring robust and reliable data exchange.
• Aerospace Industries Association (AIA), through standards like NASM, ensures that aerospace fasteners and components meet stringent torque requirements, safeguarding against failures and ensuring the reliability and safety of aerospace components and vehicles.
• Food and Drug Administration (FDA) in the medical device manufacturing sector mandates adherence to specific torque testing standards to ensure the safety and efficacy of medical devices, ensuring that they perform reliably and safely in various medical applications.

Torque testing is the golden thread in the fabric of manufacturing. It intertwines with product development, assembly, and quality assurance, ensuring products resist premature failure and meet global standards. In today's competitive landscape, where quality is king, torque testing is the unsung hero, bridging safety, quality, and innovation in manufacturing.

Frequently Asked Questions (FAQs)

What is running torque?

Running torque is the consistent, sustained force required to keep an already moving object in continuous rotational motion around an axis. It is the torque necessary to maintain a component&#;s rotation, not initiating it, and is crucial for ensuring the smooth, ongoing operation of machinery, such as motors or valves, by overcoming the internal friction and any other resistive forces encountered during its operational phase.

How to measure running torque?

Measuring running torque typically involves utilizing a torque sensor or a torque transducer that is capable of accurately gauging the rotational force applied during the object's motion. The object or mechanism under observation is set into its regular operational motion, and the torque sensor, often integrated into the system, records the continuous torque applied during the steady-state operation. The data collected is then analyzed to determine how to measure running torque, ensuring it aligns with the specified parameters for optimal functionality and longevity of the component or system.

What is breakaway torque?

Breakaway torque is defined as the initial force required to set a stationary object into rotational motion, essentially overcoming the static friction and initiating movement. It is typically higher than the running torque due to the necessity to counteract the initial inertia and static friction within the system. Understanding what is breakaway torque is pivotal in various applications, such as bolt tightening or valve operation, to ensure that components are not damaged during the initial movement and to validate the efficacy of connections.

How to measure breakaway torque?

To measure breakaway torque, a torque measurement device, such as a torque wrench, torque meter, or a specialized torque tester, is employed. The device is applied to the stationary object, and the torque is gradually increased until the point where the object begins to move or rotate. The torque value recorded at the precise moment of initial movement represents the breakaway torque. Accurate measurement of breakaway torque is crucial in applications like fastener testing and assembly processes to ensure secure connections and adherence to safety and quality standards.