Torquetrak Tpm2: Torque and Power Monitoring System
Torquetrak Tpm2: Torque and Power Monitoring System
User’s Guide
866600-9_E
Contents
1 System Overview....................................................3
1.1 System Components .......................................4
1.1.1 Rotating Collar Assembly ......................................... 4
1.1.2 Stationary Interface .................................................. 5
2 Installation ..............................................................5
2.1 Rotating Collar Installation...............................7
2.2 Stationary Ring and Stationary Interface
Installation.................................................................9
2.2.1 Stationary Interface Connections.............................10
2.2.2 Stationary Ring Installation......................................12
3 System Operation and LED Descriptions .............13
3.1 Stationary Interface .......................................13
3.1.1 Startup Operation....................................................13
3.1.2 Normal Operation....................................................14
3.1.3 Stator LED ..............................................................14
3.1.4 Rotor LED ...............................................................15
3.1.5 Torque LED ............................................................16
3.1.6 Speed LED .............................................................16
3.2 Transmitter LED Operation............................16
4 Communications Protocol .....................................17
4.1 Data Byte Format ..........................................17
5 TPM2 Stationary Interface Transmitted Data .......17
5.1 Message Format ...........................................17
5.1.1 Strain Gage Value...................................................18
5.1.2 Shaft Speed Value ..................................................19
5.1.3 Status Information ...................................................19
5.1.4 Checksum...............................................................23
6 TPM2 Stationary Interface Commands (Received
Data)...........................................................................23
6.1 Command Format .........................................23
6.1.1 Command bytes......................................................24
6.1.2 Checksum...............................................................24
Appendix A: TPM2 Specifications .............................29
Appendix B: Troubleshooting ....................................34
Appendix C: Strain Gage Installation .........................36
Appendix D: Dimensions ...........................................41
Appendix E: Maximum Shaft Speeds ........................50
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Warranty and Service Information.............................. 51
New features:
➢ Single turn transmitter and stationary ring with a minimum
number of connections and high reliability.
➢ Fully encapsulated electronics for high reliability.
➢ Eight user selectable input ranges from 0.25 to 32 mV/V
(125 to 16000 microstrain with gage factor of 2.0).
➢ RS-422 serial communications from stationary interface
for long distance error free data transmission to system
monitoring and display equipment.
➢ 15 bit signed strain value, 16 bit signed speed value, and
24 bits of status information contained in every data
sample.
➢ Four dual color LEDs on stationary interface for system
status and error indication in addition to status information
contained in the RS-422 serial communications data.
Rotating Collar
& Transmitter Module
Clamps to shaft with bolts Lead wires to
provided. Houses transmitter
Transmitter Module which
converts strain gage
signal to digital code. Stationary
Interface
Mounting Flange
Communications
Power Connector
Connector
Fuse (2A)
2 Installation
WARNING!
PERSONAL INJURY
DO NOT USE this product as a safety or
emergency stop device or in any
application where failure of the product
could result in personal injury.
Failure to comply with these
instructions could result in
death or serious injury.
*
The end user is responsible for the proper installation and
operation of this device. Improper installation or operation could
result in damage, injury or death.
Certain environments could cause damage or degradation to the
components of the system resulting in mechanical failure.
The TPM2 system must be sealed by the installer for operation in
wet/harsh environments.
Mechanical failure could cause parts to detach from the shaft and
fly off at high speeds. These flying parts could cause equipment
damage, bodily injury and possibly death. Keep equipment and
personnel away from areas where parts flung from the shaft could
enter.
A shield or guard is recommended in applications where
something or someone could come in contact with the rotating
parts of the system.
Mounting
Bracket
1.20
(30)
1.00
(25)
Counter-
weight /
magnet
Transmitter
Transmitter
mounted ring
1
Contact Binsfeld Engineering for other cable lengths.
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2.2.1.2 Communications Connection
The Stator LED has two modes during normal operation. Typically
it operates as an indicator for the status of Stator main regulated
voltage, main regulator over current, power amplifier over
temperature, and connected device communications. It also
indicates the output power level while it varies to produce the
required transmitter voltage level. When the Rotor LED is
flashing, the stator is adjusting and indicating the output power
level.
The Stator LED is solid green when stator power supply voltage is
in range, the power supply current is under the over current
threshold, the power amplifier is below the over temperature
threshold, and no communications errors exist with the connected
device. The acceptable stator power supply range is 10 to 30
volts DC.
Auto baud rate detection of the RS-422 connection is a feature of
the TPM2. Requirements are defined in the TPM2
Communications Specification that allow the TPM2 to properly and
accurately determine the baud rate being used. While operating in
Auto Baud Rate Detection mode, the Stator LED flashes green
with a 50% duty cycle at 5Hz.
The Stator LED will change to red while power supply voltage,
power supply over current, power amplifier over temperature, or
communications errors exist. Communications errors are UART
errors like framing, parity, checksum, and buffer overrun. As soon
as the error condition clears, the LED returns to solid green.
The Speed LED flashes green for 200msec for every magnet
pulse detected when the pulse frequency is low. The Speed LED
flashes green for 20msec for every magnet pulse detected when
the pulse frequency is high. The low pulse frequency threshold is
approximately 1.75Hz when frequency is increasing from below
0.88Hz. The low frequency threshold is approximately 0.88Hz
when frequency is decreasing from above 1.75Hz.
If the duration of speed pulses becomes too short or pulse
frequency is erratic, the Speed LED flashes red (not green).
The combined low byte and high byte of the Strain Gage Value
form a 16 bit signed integer that is used to calculate the torque
strain using the equation:
є = (Valout * 15729) / (Gxmtr * GF * 7864.32)
є = strain (in units of µstrain)
Valout = TPM2 output Strain Gage Value
Gxmtr = user selectable transmitter gain (see Table 3)
GF = gauge factor
(15729 / 7864.32) is a system derived constant
The Torque Strain value, along with the shaft parameters, allow
the monitoring device to calculate the actual shaft torque in force
times distance units (Newton-meters, ft-lbs, etc.) using the
equation:
T = (є * π * E * (OD4 - ID4)) / (KT * OD * (1 + v))
T = torque (N-m or ft-lbs)
є = strain, (in units of µstrain)
E = modulus of elasticity of the shaft material (N/mm2 or Mpsi)
OD = outside diameter (mm or inches)
ID = inside diameter (mm or inches)
v = Poisson’s ratio of the shaft material
KT = torque units dependent constant (for N-m, KT = 1.6 x 1010:
for ft-lbs, KT = 192)
The sign of the Strain Gage Value indicates the relative torque
force direction.
From the torque, the power can be calculated using the equation:
P = (T * 2π * ω) / Kp
P = power
T= torque
2π is radians/revolution
ω = rotational speed (RPM)
Kp = torque units dependent power constant
The combined low byte and high byte of the Shaft Speed Value
forms a 16 bit signed integer. This binary integer value is in either
revolutions per minute (RPM) or hundredths of revolutions per
minute (RPM x 100). The resolution of the Shaft Speed Value is
indicated by the RPM_RES bit in status byte 0.
The sign of the Shaft Speed value indicates the relative direction
of rotation. When looking at the front of the TPM2 Stator, a
positive value indicates clockwise rotation and negative indicates
counter-clockwise rotation. A zero Shaft Speed Value indicates
that the shaft is turning slower than the minimum shaft speed
value or has stopped.
The Shaft Speed Value is measured once per shaft revolution.
This new value is transmitted with the next sample and the
RPM_NEW status flag is set to indicate a new shaft speed
measurement. This same value is transmitted on subsequent
samples, until the shaft completes another rotation and a new
speed is measured.
The status information bytes are grouped bit flags that indicate the
operating status of the TPM2. The flags are active high; bits set to
‘1’ indicate the condition exists and bits cleared to ‘0’ indicate the
condition does not exist. Below is a description of each bit (flag).
Bit Name/Description
0 RPM_NEW
1 = Shaft Speed value in this sample was just measured
0 = Shaft Speed value in this sample is old, a hold from the last
sample measured
1 RPM_ERR
1 = An error was detected in the RPM measurement. Check
rotor-stator alignment and spacing
0 = No RPM measurement errors detected.
2 RPM_RES
1 = The Shaft Speed value’s resolution is 1/100 RPM, set when
the shaft speed falls below approximately 53 RPM.
0 = The Shaft Speed value’s resolution is 1 RPM, cleared when
the shaft speed rises above approximately 105 RPM.
3 ECOM_ACK
1 = A command has been received OK. This is an
acknowledgment that the TPM2 received one or more
commands since the last sample was sent. It is set in the
sample following reception of the command(s), after which it is
cleared.
0 = No command received since last sample sent.
4 ECOM_ERR
1 = An error was detected in external communication link from
the Connected Device. Possible errors: Transmit buffer overrun,
received data parity error, received data framing error, incorrect
received message checksum detected.
0 = No external communication errors detected
5 STAT_PWR_ERR
1 = The Stator main regulated power supply voltage is too high
or low, or an over current error exists.
0 = No Stator main regulated power supply problems are
detected.
6 II_AMP_TEMP_WRN
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1 = The II power amplifier temperature is at or nearing thermal
shutdown.
0 = The II power amplifier temperature is OK.
7 STAT_TEST_MODE
1 = Stator in test mode.
0 = Stator in normal mode.
0 TRQ_HLD_ERR
1 = The Torque value in this sample is a hold from the last good
sample received from the Transmitter
0 = The Torque value is new
1 TRQ_RNG_ERR
1 = The Torque value in this sample is out of range
0 = The Torque value is not out of range
2 GAGE_DIFF_ERR
1 = Gage differential mode input of the transmitter is out of
range. This error will also give a TRQ_RNG_ERR
0 = Gage differential mode input of the transmitter is in range
3 GAGE_COM_ERR
1 = Gage common mode input of the transmitter is out of range.
This error will also give a TRQ_RNG_ERR
0 = Gage common mode input of the transmitter is in range
4 ROT_PWR_LO_ERR
1 = The Rotor power supply voltage is too low.
0 = The Rotor power supply voltage is not low.
5 ROT_DATA_ERR
1 = An error has been detected receiving data from the Rotor
(Transmitter)
0 = Rotor data is being received OK
6 ROT_DATA_GONE
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1 = There is no Rotor (Transmitter) Data being received without
error
0 = Rotor data is being received
7 RFU
Not currently used
0 GAIN0
1 GAIN1
2 GAIN2
3 Shunt 1 is ON
1 = Shunt 1 (200uV/V) is ON.
0 = Shunt 1 is OFF
4 Shunt 2 is ON
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1 = Shunt 2 (1000uV/V) is ON.
0 = Shunt 2 is OFF
5 RFU
Not currently used
6 RFU
Not currently used
7 RFU
Not currently used
5.1.4 Checksum
The checksum byte is simply the low byte of the sum of the 7 other
bytes in the sample.
Commands are sent to the TPM2 for set up and control of TPM2
operation.
6.1.2 Checksum
The checksum (chksum) byte is simply the low byte of the sum of
the three command bytes.
Notes:
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The ECOM_ACK bit in sample data status byte 0 serves as an
acknowledgement to messages sent to the TPM2.
The baud rate, parity, stop bits, sample rate and transmitter gain
parameters are saved in non-volatile memory and retained
through power loss.
The effects of Transmitter Control Commands are delayed due to
internal communications between the Transmitter and the TPM2.
Transmitter control commands that modify either the gain or
shunts require approximately 2.5 seconds to take effect. A
command that modifies both gain and shunts at the same time
requires 4 seconds.
There are multiple features built into the TPM2 system to aid in
troubleshooting. There are four bi-color status LED’s on the
Stationary Interface. There are also 24 status bits in the serial
data transmitted from the Stationary Interface.
Generally the first step in troubleshooting is to observe (if possible)
all LED's on the Stationary Interface.
There should always be at least one LED ON or flashing in
some way. If all Stationary Interface LED's are OFF, it may not
be receiving power:
1. Check the power source and wiring to the TPM2.
2. Check the TPM2 power fuse (5 x 20mm 2 amp fast blow).
Have Ready:
M-Bond (Cyanoacrylate) Adhesive
2” – 5” piece of Teflon tape
Tissues
Limited Warranty
Binsfeld Engineering Inc. warrants that its products will be free
from defective material and workmanship for a period of one year
from the date of delivery to the original purchaser and that its
products will conform to specifications and standards published by
Binsfeld Engineering Inc. Upon evaluation by Binsfeld
Engineering Inc., any product found to be defective will be
replaced or repaired at the sole discretion of Binsfeld Engineering
Inc. Our warranty is limited to the foregoing, and does not apply to
fuses, paint, or any equipment, which in Binsfeld Engineering’s
sole opinion has been subject to misuse, alteration, or abnormal
conditions of operation or handling.