Torque and Shaft Power

Measurement
K Sai Aditya Raman 08M124
Nikhil Das 08M136
Sachin Kamath 08M137
Supreet Dev 08M150
Vishwas Nandan 08M163
Sarvesh Kolekar 08M164
Introduction
Torque in a way represents the power in a
rotating shaft.
P=2NT
can be found using a tachometer.
HOW TO MEASURE TORQUE
Measuring Torque
Cradle and Bearing
Variations in Cradle and Bearing
Angular twist or strain on the shaft (or a torque sensor
coupled into the shaft)
Dynamometers
Dynamometers

Dynamometers: Different Types
Absorption Dynamometers
Prony Brake
Rope Brake
Hydraulic
Eddy current
Swinging field DC
Transmission Dynamometers
Chassis Dynamometers
Measurement of Torque
It is often associated with the determination of
mechanical power
It is required to obtain load information necessary for
stress and deflection analysis

Torque is given by :
T = F.r Nm

P = Tw Watts




Why measure torque?

Measurement of Torque of
Rotating Shafts
Methods of measurement of torque
may involve:
1. Power source :
The machine which supplies power.
2. Power Sink :
The machine which absorbs power.
3. Power Transmitter :
The device responsible for transmission
of power from source to sink.


Methods of measurement of
Torque



The source, sink and transmitter arrangement permits
two methods of measurement of torque:
Torque reaction measurements
Torque measurement using sensors.

Torque reaction Measurement
The reaction torque from the casing can be measured much easily than the
torque output from the shaft
The casing is mounted on the trunion bearing
The reaction torque can be measured by measuring the reaction force F
and radius r
A revolution counter can be added to measure the output power.
Types of Cradling
Torque measurement using
sensors
Torque is measured based on the twist or angular
displacement in the shaft.
Cradling-Bearing Modification
Avoiding friction losses. Flexure pivot system with
strain gages

Stresses on a Shaft
Strain Gauge Mounts
Torque
, where
By using the strain gauge value of principal stress, we
can calculate the torque experienced by the shaft.
Stroboscopic Method
Scale on Flange A and Pointer on Flange B
Relative motion over the length of shaft between the flanges causes
deflection
This deflection is measured using stroboscope (it flashes light at same
frequency as that of the shaft)
Inductance Torque Transducer
To get high sensitivity, angular displacement between two flanges is
measured by using linear displacement transducers which are specially
designed for measurement of small displacements.

Flange A has coil and Flange B carries an Iron core. Core moves in and
out according to relative displacement of the flanges causing a change
in Inductance.
For better sensitivity and linearity four inductive transducers with coils connected as four
arms of an AC bridge are used.
Inductance of two bridges increases and that of the remaining two decreases (just like in
case of strain gages two in compression two in tension)
Sensitivity increased by four times
Measurement by Dynamometers
Absorption
Transmission
Driving Dynamometers

Torque Measurement



Absorption Dynamometers
(complete absorption of power)



Dry Friction
Rope Brake
Prony Brake

Fluid Friction
Air Brake
Water Brake

Eddy current Brake
Inductive Brake
Transmission Dynamometers
(No absorption of power: Torque meters)
Torsion Dynamometer
Belt Dynamometer
Strain Gauge Dynamometer

Driving Dynamometers
(Power supplied by Dynamometer)
DC motor
Rope Brake Dynamometer
Simplest Absorption
Dynamometer
Rope wound around a
Drum coupled with shaft
Rope attached to a
Spring Balance (one
end) Dead weight at
other end
Torque = (W-S).R
W = Dead weight
S = Spring Balance
Reading
R = Radius of the Brake
Drum
Rope Brake Dynamometer
Advantages
Simple in operation
Measure wide range of Torque
Steady as compared to Prony Brake Dyno
Disadvantages
Output is dissipated as Heat
Cooling is an issue
Material for the Rope or Belt

PRONY BRAKES
Definition:
The Prony brake is a simple type of
dynamometer used to measure the amount of
torque produced by a motor or engine in order to
determine its brake horsepower rating.
The device was invented in 1821 by a French
engineer named Gaspard de Prony, and
continues to be widely used by tractor and heavy
equipment manufacturers.
CONSTRUCTION
A Prony brake usually consists of some type of
brake drum along with a pulley that is connected
to an engines output shaft on one side, and a
brake lever on the opposite side. A device used to
measure the amount of force being applied to the
brake arm is also attached to the Prony brake as
well. An additional device is utilized to measure
the number of revolutions per minute (RPM) that
the engines output shaft is turning during the
test. A tension band is also attached to the pulley
in order to apply braking force to the output shaft
of the engine being tested.
WORKING
Weights are applied on the belt which creates
friction between brake drum until the engine stalls
under the friction created by the load. The amount
of weight needed to stall the engine determines
the amount of torque or pulling power that the
engine is capable of producing.
PROCEDURE
The engine is first started and gradual pressure is
then applied to the tension band.
Measurements of the braking force being applied at
the end of the brake arm are then taken, along with
measurements of the engines RPMs.
As the braking load being applied to the output shaft
increases, the engines governor increases fuel
delivery to the engine in order to keep the RPMs
constant.
When the governor can no longer keep the RPMs at a
constant speed, the engine reaches what is known as
its stall point.
The final RPM and brake force measurements are
then taken and recorded and the testing procedure is
concluded.

FLUID BRAKE DYNAMOMETER
The basic operation of a fluid brake dyno uses
the principle of viscous coupling.
Here the horsepower of the prime mover is
converted into heat of the dynamometer fluid
mostly water.
The stators and rotors successfully achieve this
transfer of energy. Both the stators and rotors
have pockets built within them.
CONSTRUCTION
It has an outer casing
and a rotor
In order to generate
necessary torque both
the rotor and the casing
must incorporate some
form of blades and or
cavities to create
turbulance
Heat is removed by
continuous supply of
water through inlet and
outlet pipes
The restraining torque
is applied and this is
measured by a torque
transducer

WORKING
water is brought into the engine
dyno or chassis dyno by
passages in the stator, it is
discharged into the dyno near
the center of rotation of the rotor
assembly.
This water entering the dyno will
flow into the pockets of the rotor.
The water is then accelerated
by the rotation of the rotor
assembly, which is connected to
the output shaft of the engine.
As it speeds up (or accelerates),
the water tends to fly out due to
centrifugal force. And as the
water flies out, it ends up in
pockets in the stator plates.
The amount of water in the
dyno at any given instant
determines the amount of
horsepower that it can absorb.
Rotation of the rotor
relative to the casing of
the machine is resisted by
torque T.
Since the casing must
necessarly experience an
equal and opposite
torque, T maybe
measured by measuring
the torque on the casing
rather than on the rotor.
This is accomplished by
using a torque transducer
mounted at a distance of
radius r, and measuring
the restraining force on
the casing.


EDDY CURRENT BRAKES


ABSORPTION TYPE DYNAMOMETER
Power loss due to eddy currents is used
CONSTRUCTION

Rotor:
Metallic
Non magnetic
D.C. supply:
Energizes the stator
Stator:
Produces a magnetic field
in which the rotor is immersed



RANGE: 300 to 6000 hp
WORKING
The magnetic field is produced by the stator due to DC
energization

When the solid rotor moves in this magnetic field, there
is a considerable amount of power loss.

This power loss is seen as a potential difference

The power is dissipated as heat.Therefore, we have to
circulate cooling water to take away the heat
continuously.

The resistive torque produced indicated the power
generated.













Advantages and Limitations
ADVANTAGES

smaller in size
easily controllable by DC input
capable of measuring high torque and power

DISADVANTAGE

cannot produce any torque at zero speed and
produces low torque at low speeds
DC DYNAMOMETERS

ACCURATE
VERSATILE
ABSORPION
TRANSMISSION
DRIVING


CONSTRUCTION
Dyno acts as generator
Mounted on the trunnion bearings
Driven by a test machine (eg. IC
engine)
A resistor (R) is added in the
generator circuit
Higher the resistance, higher will be
the opposition to the shaft motion
The resistive torque measurement
is shown by the torque arm. The
power dissipated is given by:
P = V^2/R
V-output of the generator




RANGE: 5000 hp
WORKING
The dynamometer is coupled to the machine under test.

WORKING AS AN ABSORPTION DYNAMOMETER
The dyno acts as a generator
The current produced is dissipated across the
resistors, which gives the measure of the power being
produced.

WORKING AS A TRANSMISSION DYNAMOMETER
The dyno acts as a generator here also.
The power produced is recovered as useful power,
measuring which, gives the idea of the power
produced by the machine under test.

WORKING AS A DRIVING DYNAMOMETER

When the dyno acts as a motor.
This motor drives the test machine, a power absorbing
device like a pump.
Since the dyno is driving the device, the power output of
the device would depend on the inputs given to dyno.

Q. A Mild steel shaft is used to connect a motor drive to a constant load
torque. To measure this torque, a resistance strain gage with resistance
of 120 and gage factor 2 is mounted at 45 to the shaft axis. Shear
Modulus of steel is 80GPa, shaft diameter is 50mm and change in strain
gage resistance due to load is 0.1 . Find the load torque.
Given
Gage Factor S
g
=2
Gage Resistance R
g
=120
Shear Modulus of Elasticity G=80GPa
Diameter of Shaft D = 0.05 m
Change in Resistance R
g
=0.1

Solution
Q. Engine running at 450 rpm. Rope brake dynamometer is used
to find out the torque. Brake drum diameter is 1.5 m, spring scale
reads 50 N and the weight in the pan is 500 N. What is power
delivered? What would be the spring scale reading if the power
delivered at the same rpm is 20 kW and weight in the pan is 625N
Solution
i) Net load = W-S = 450 N
Torque = F x r = 450 x 0.75 =337.5 Nm
P=2NT = 2 x (450/60) x 337.5 = 15.904 kW
ii) P=20000 W
T= P/ (2N) = (P x 60)/ (2 x 450) =424.4
W-S = T/r = 424.4/0.75 565 N
S= 625 - 565 = 60 N