PowerLink JC Series Torque Transducer User Manual

Transcription

1 PowerLink JC Series Torque Transducer User Manual XiangYi (Hong Kong) Power Testing Instrument Co. Ltd. 0

2 JC Series Torque Transducer User Manual How to install the sensor properly JC-type torque transmission speed sensor itself can only measure torque and will not consume the power (power consumption within the sensor generally negligible), it also can not produce power. Thus, when measured as the prime mover machinery (such as electric motors, internal combustion engine or other transmission machinery parts, assembly). In order to absorb the measured mechanical power, certain load should be applied. Load can be electrical dynamometer, eddy current dynamometers, hydraulic dynamometers, DC or AC generators and magnetic brakes or other similar types of machines for the load. When the tested machinery as the load (such as generators, fans, pumps, hydraulic pumps), it should be connected to some of the prime mover. When measuring the mechanical efficiency of a gearbox, a suitable size of torque sensor shall be chosen, otherwise, the measurement accuracy will be affected. General installation The installation method of JC-type torque speed sensor is shown in Figure 3. The driving end of the torque sensor shall be connected to the prime mover. The intermediate support is to ensure that the sensor will not affected by axial changes caused by frequent replacement of the testing equipment, which may lead to data variation and at the same time to avoid the bending of the sensor bending caused by installing different axes which may result in instability of testing data. If alignment of the shaft can be maintained or limited space available at site, the intermediate support can be removed. Typical installation method for the JC type torque sensor 1

3 Back to back installation method for measuring the mechanical efficiency Back to back installation for measuring the mechanical efficiency of a gearbox Installation base The prime mover, sensors, load and intermediate support should be installed in a solid foundation to avoid excessive vibration. Otherwise, instability and inaccuracy of the data will be occurred or even damage the sensor. Coupling Generally adopt a flexible diaphragm coupling dowel pin or a light coupling should be used, which is particularly important to small size sensors and high-speed sensors. In order to make the sensor does not bear bending, we recommend the use of immunity coupling (such as nylon string coupling), which will significantly improve the working conditions of sensors to ensure accuracy. Shaft alignment To avoid bending the sensor shaft, the centerline of the prime mover, sensors and the load shall be well aligned. The bending will reduce the measurement accuracy or even damage the elastic axis of the sensor for some cases. When using smaller size sensors, particular attention shall be paid to alignment process. The JC-type torque and speed sensor generally is installed in horizontal position. It also can be installed in vertical or at any angle direction but to ensure that no excess force exert on the sensor. 2

4 Technical Specifications Torque measurement accuracy: Class 0.1 and Static calibration - when using counter weight to perform calibration, the measurement error shall not be more than ± 0.1% and ± 0.2% for Class 0.1 and Class 0.2 respectively. 2. Additional error due to speed change within the specified speed range, the change in reading cannot be greater than the rated torque by ± 0.18% (the GB standard is ± 0.2%). Torque speed measurement accuracy: ± 1r/min ± 1 word Torque measurement overload capability: 1. When the overload is below 120% of the rated torque, the accuracy is still guarantee. 2. For transient overload not greater than 300% (JC1B type is 500%) of the rated torque, after the load was removed, the torque reading shall not greater than ± 0.1% at zero position. 3

5 Maintenance Warranty The warranty period is 12 under the normal usage. If any discrepancies or the error is greater than the factory standard starting from the date of shipment from the factory, we will provide free repair or replacement. Lubrication of the sensor bearing The roller bearing of the JC-type torque-speed sensor (except the JCG-type by forced lubrication) shall be lubricated with grease. Please refer to the Table 2 for the lubricating cycle: Model Small bearing Large bearing Grease spec Qty Lubricating cycle Grease spec Qty Lubricating cycle JC0 D months D JC1A D months D115 2 JCH1 3 JCL1 D206; D JCG1 D Lithium Grease 10 months JC2B (C) D months D120 2 JCH2 3 JCL2 JC3A D months D months JCG4 DE176119Q1T1 2 Pressure oil lubrication JC4B D months D months JC5 D months D months 4

6 Note A. Bearing lubricating cycle is based on the maximum speed and running for 8 hours a day. If the working speed is lower or shorter in working hours per day, the cycle time can be further extended. B. For JC0, JC1A, JC1B, JC2B, JC2C and other types sensors, generally the operating speeds is higher than 600 r / min and rarely rotate small motor mounted on the sensor, lubrication to the large bearing can be omitted. C. The volume of grease apply to the bearing cannot more than 1/3-1/2 of the space inside the bearing. Too much grease will increase the bearing temperature at high rotating speed. The higher the speed, the lesser of grease apply to the bearing. D. For JC3A, JC4B, JC5-type torque speed sensor is equipped with grease nipple for adding the grease to the bearing. For other type of sensors, the bearing cap shall be removed when apply grease to bearing and reinstate the cap after adding the grease. When adding the grease to the bearing of JC4B torque speed sensor, please remove the screw from the base hole first. E. For JC3A, JCG4, JC4B, JC5 and other types of torque-speed sensor with the small motor mounted on the top of the sensor, the gear between the sensor and the motor shall be greased periodically. The miniature bearing inside the gear shall also be checked and greased periodically. Calibration The JC-type torque speed sensor is a precision measuring instruments. According to the requirement from government regulations, in order to maintain accuracy of the test data, whether use or not, the sensor shall be regularly returned to the manufacturer or a appropriate laboratory to perform the calibration. The calibration cycle is recommended at every two years. 5

7 Zero torque adjustment - The meaning of zero As the principle of the electromagnetic torque phase sensor is to convert the torque to the phase difference of two sinusoidal AC waves. At zero torque (no load), the initial phase angle is not equal to "0" but in 1800 phase shift. Because of the initial phase angle of each sensor is different, so be zero torque adjustment is required. Therefore, before any load test, torque must be adjusted to zero. To adjust the torque to zero, it must be ensured that no load applied to the sensor. If the load can not be separated, or the shaft does not rotate (under the steady state) or at slow speed that the sensor output signal amplitude is smaller than 0.2V, the starting of the sensor at the top of a small motor is required. The setting of the sampling rate shall be greater than 1 second is appropriate. - The steps for adjusting the Zero Press Entry at the Test Mode to allow the system enter into the parameters setting step. When the cursor remains at "zero torque", then press "ENTER" again to let the system to go Zero adjust screen, as Figure 9 below. Before adjusting the Zero, the rotating direction must be confirmed. When the cursor stays at the "forward / reverse" position, you may press the "+ or -" to select rotation. - Press ENTER at test mode to allow the system to enter into zero adjustment screens Figure 9 and 10 below When the cursor at "zero torque", press ENTER again to enter the screen as Figure 9. Zero interface - The definition of Forward and Reverse Forward: the cover of the small motor mounted on the sensor is near the driving end, looking from the driving end, the shaft rotates at clockwise direction is defined as Forward direction. 6

8 Reverse: the cover of the small motor mounted on the sensor is near the driving end, the shaft rotates at anti-clockwise is defined as Reverse direction. When performing the zero adjustment, the rotation of the shaft and the sensor must be the same. The rotating direction can be controlled by the command from the keyboard. - The definition of Auto / Manual Automatic: the system adjusts zero automatically, no need to manually input values; Manual: to input the zero setting by manually. - The definition of Single point / multi-point Single point: only one zero throughout the entire speed range. Multi-point: more than one zero point can be set throughout the entire speed range (maximum 10). - Single-point-zero auto setting 1) On the screen as Figure 9, select the shaft rotation at Auto, select the zero adjustment at Single point, move the cursor by pressing " " to "Enter", then, press the "ENTER" key to allow the system to adjust the single-point-zero automatically. Automatic single-point-zero adjustment 2) In Figure 10, move the cursor to" " by pressing " " key to observe zero reading. When the reading is stable, press "ENTER" to set the zero. Once the zero is set, press "EXIT" to save and exit. 3) If the sensor is required to rotate at both forward and reverse directions, you may need to set zero at both directions. The setting procedures are same as above. 7

9 Note: When change the sensor s rotating direction, the direction in the system and the rotating direction of the sensor must be aligned. - Single-point-zero adjustment (manual) On screen as Figure 9, press " " and "+ -" key to change the "automatic" to "Manual". Move the cursor to "enter" and then press "ENTER" key to allow the system to enter to the manual mode for Single-point-zero as in Figure 11 as below. Manual single-point-zero adjustment Press "store" and "Priet" to move the cursor and use the "+ -" key to adjust the zero value. When adjustment is completed, press "EXIT" to save and exit. - Multi-point-zero (AUTO) The usage of multi-point-zero As the initial phase difference of the sensor will vary with the speed, the error of the sensor is calibrated at ± 0.18% F. S or less at the factory. If user wanted to obtain a higher precision, the "multi-point-zero feature can be applied. Maximum 10 zero points can be set. Note: When performing the Multi-point-zero adjustment, the shaft must be rotated and no load is applied. Under no load condition, and rotate the shaft to certain speed. On the screen as Figure 9, press the " " and "+ -" key to confirm the direction. Select "Automatic" and change "zero adjustment" to "multi", then move the cursor to "enter " and then press" ENTER "key to enter into the screen as Figure 12 as below: 8

10 Multi-point-zero adjustment (AUTO) - Adjustment procedure for Multi-point-zero (AUTO) 1) On this screen, press " " to move the cursor to ">" position. Once the reading is stable, press "ENTER" to insert the zero point to the currently display. 2) Adjust to a shaft to certain speed, repeat 1 procedure to obtain another zero point. 3) Press "EXIT" to save and exit. Maximum 10 zero points and different speed. Set 0 for those without usage. The instrument will automatically set the zero points according to the speed. Attention! Multi-point-zero is more suitable for wider speed range application. It is recommended to use Single-point-zero for those with fixed speed or narrow speed range application. To use the actual speed of the motor to adjust the zero point is highly recommended. During the test, if the torque changed with the speed, please re-adjust the system by using the single-point-zero method (stop the motor and use the small motor mounted on the sensor). If the torque error is reduced or eliminated, it is illustrated that the procedure for setting the multi-point-zero is wrong. Repeat the test procedure again. - Multi-point zero (MANUAL) In Main Figure, select direction, then change to Manual, select Multi, move the cursor by pressing the " " key, press "Enter" and then the system will enter Multi-point-zero (Manual) mode as shown in Figure below: 9

11 Multi-point-zero (manual) In above figure, the first column shows the figures of zero value, the second column shows the corresponding speed of the zero value and the third column shows the serial number of zero. Press " " and the "+ -" keys to change value of the figures. Move the cursor to "<" to position and press "ENTER" to delete the figures. Move the cursor to "delete all" and press "ENTER" will delete all figures. - Steps for multi-point-zero (MANUAL) AUTO Multi-point-zero setting is recommended prior to the MANUAL Multi-point-zero setting. If the torque zero variance change significantly, you may use manual mode to fine-tune the setting. 1) Under the Multi-point-zero manual adjust screen, press " " key to move the cursor to the one that needs the fine-tuning. 2) Press "+ -" to adjust the value. 3) Press "EXIT" to save and exit after adjustment. - Zero point for reverse direction When the sensor shaft rotates at different direction, the zero setting must be performed again. Otherwise the instrument will not show the correct figures. If the system already gone through the zero settings for both directions, the system allows the engineer to change the setting by using the Fig. 9 screen to align the rotating direction. 10

12 - Use Channel 1 ( ON and OFF state) to control the direction The system allows the user to change the rotating direction by inputting a command from Channel 1 as shown in below Figure. Digital input wiring diagram A resistor is connected in series with the input terminals. The ON and OFF can be a mechanical switch, a relay contacts, or a variety of open-collector output of the gate circuit. If the collector does not open, high margin should be 5V. Keyboard settings and Channel 1 input are connected in series, an "and" gate function. In other words, when keyboard as control, the Channel 1 input should be at 1. Similarly, when Channel 1 as control, the keyboard input should be 1. Channel 1 at 1 means high input (OPEN contact). Keyboard set to 1 means Channel 1 input at 1 and change system rotation at reverse direction. 11

13 Procedure for setting sensor zero when measuring the mechanical efficiency of the system As the principle of the electromagnetic torque phase sensor is to convert the torque to the phase difference of two sinusoidal AC waves. At zero torque (no load), the initial phase angle is not equal to "0" but in phase shift. Because of the initial phase angle of each sensor is different, so be zero torque adjustment is required. Therefore, before any load test, torque must be adjusted to zero. To adjust the torque to zero, it must be ensured that no load applied to the sensor. If the load can not be separated, or the shaft does not rotate (under the steady state) or at slow speed that the sensor output signal amplitude is smaller than 0.2V, the starting of the sensor at the top of a small motor is required. Special attention! If the Zero point is not properly set before the test operation, the measurement accuracy will be affected. The torque at zero, the torque display shall also be zero. Most of sensor errors found during the measurement were due to improper setting of the zero point. The user shall pay attention to this! The zero point for the main shaft The load must be disengaged when setting the zero. Start rotating the motor together with the sensor. i) Drive motor to the actual test speed ii) Refer to step for adjusting the zero point Attention! Sometimes may need to repeat 1-2 times for the above operation until the display of the torque value close to zero. After setting the zero, the torque value displayed on the window may not be entirely The value displayed after the decimal point 2 will fluctuate a little, or show negative. This is the inherent error of the sensor. As long as the fluctuation of the value does not exceed 0.1% FS, the performance of the sensor is considered qualified. 12

14 Use the small motor to adjust the sensor zero If the dis-engagement of the load cannot be done, We can use the small motor mounted on the sensor to adjust the zero point. A. Connect 380V three-phase supply to the small motor B. Check the rotating direction of the small motors C. Refer to section for setting the zero Attention! Please ensure the rotating direction of the sensor s gear must be reverse to the rotating direction of the main shaft. If the direction cannot be confirmed, please follow the below steps to calibrate the setting. - Start the small motor record the speed value (n) - Start of driving motor to rotate the load, then the speed value (n) will change. - If the value (n) increase, the rotating direction of the small motor is opposite to the main shaft which is correct setting. - If the value (n) decrease, the rotating direction is same as the main shaft which is incorrect. - If the rotating direction of the gear is same as the main shaft, you may change the rotating direction of the small motor by changing the three-phase sequences. After confirming the direction is in opposite direction, stop the driving motor. - Refer to section to adjust the zero - Start the main motor and stop the small motor Attention! Please delete all zero settings before carrying out the adjustment process. Otherwise, the accuracy of the readings will be affected. Please refer to section for zero adjustment. Other Considerations - No residual stress on the elastic shaft must be confirmed. - It is recommended to perform the calibration process again after the first full load test applied. This will further enhance the accuracy of the system. - If the rotating direction of torque sensor is opposite to the previous test, zero adjustment must be done again. - When performing the test and the direction is changed, zero point must be re-adjusted before beginning the next test. - If the test speed is under 600 rev/min, small motor must be started. the rotating direction of the small motor must opposite to the main shaft direction. In order to get the actual speed of the test machine, the speed of the small motor must be deducted. - If the sensor is far away from the testing panel, shielded cable must be used and the length of the cable must be equaled. 13

15 - In order to reduce the impact loading to the system, and protect the elastic shaft of the sensor from overloading, it is recommended to reduce the moment of inertia of the coupling, or to use the magnetic clutch to protect the sensor. - The accuracy may vary with the temperature change. If the variance is large, please use the below formula to compensate the variance. Compensation formula:xt=xt0[1+ G(t-t0)] - Xt the reading of sensor at temperature t - Xt0 the calibration factor during calibration. - G the temperature factor for the sensor elastic shaft at G,unit at %/ ; - t temperature when carrying out the test - t0 temperature during calibration - Material for the elastic shaft is 40CrNiMoA,and the G is %/ 14