IMEKO 20th TC3, 3rd TC16 and 1st TC22 International Conference

Cultivating metrological knowledge

27th to 30th November, 2007. Merida, Mexico.

Development of the new LNE 50 N·m

deadweight torque standard machine
P. Averlant, A. Gosset
LNE, Paris, France, E-mail : philippe.averlant@lne.fr

Abstract

This paper describes the new LNE 50 N.m deadweight torque standard machine.
Informations on the design, development, and commissioning of this standard are
given. Its design is described focusing on mechanical and metrological characteristics
in particular of the structure, the deadweight, the air bearing and the lever arm.

Keywords : Torque standard machine.

1. Introduction

The development of the Torque standard machine of 50 N.m is part of a

wider scheme which aims at updating French metrological references in Torque
metrology. Indeed, the design of the current calibration machines is outdated
and these do not meet calibration needs. The Laboratoire national de
métrologie et d’essais is conducting this project which involves the development
of several machines: 5; 50; 500 and 5000 N.m. The latter will make the link with
the LNE high capacity 200 kN.m. torque standard machine.
So as to gain sufficient experience in designing the new machines, we first
developed the 50 N.m one (fig. 1). This allowed us to validate the selected
concepts to be used for the development of the other machines.

Figure 1. The new LNE 50 Nm deadweight torque standard machine

The next chapters introduce the different steps taken to develop this 50 N.m
machine: the principles considered and those selected, a description of the
different parts, and the mechanical and metrological features.
2. Principle

Our first target during the development process was to ensure a better
definition of the torque applied by the machine on the instrument to calibrate.
This applies to the magnitude of he torque applied as well as its geometrical
alignment and to the reduction of other applied efforts as far as possible.
The other major aspect was to facilitate the implementation of calibration
procedures for torque transducers in accordance with current practices in this
field [1] while automating the calibration cycle and optimizing the operation
duration. Besides, the system should allow an adjustment to future evolutions in
these processes and the application of specific protocols, for the CIPM key
comparisons for example.
To reach these objectives, the LNE designed the machine, namely the
mechanical elements which play a role in the realization of the Torque quantity.
Several specialized subcontractors were entrusted with its realization. The user
interfacing software for the machine was designed and built by LNE.
The principle opted for is a classic solution that is adopted for most
standard machines recently manufactured in Europe or worldwide, namely a
machine with a horizontal transducer orientation, generating torque using a
lever-deadweight system. The lever beam is mobile in rotation and is supported
in the middle by an air bearing.

The machine (fig.2) is thus mainly made up of :

- the masses generating the forces,
- the platform associated with the weightstack,
- the lever beam and its air bearing,
- the loading device by rotation of the Torque transducer,
- the structure,
- the controlling devices.

The torque measuring device to be calibrate is located between the arm

supported by the air bearing and the reduction gear used to compensate the
torsion angle of the torque transducer and activate loading.

Figure 2. Principal components of the LNE 50 Nm deadweight torque standard

machine
3. Structure

The structure was built in a such a way as to allow the forces applied on the sensor to be
in the best conditions for definition (direction, magnitude, stability) and by reducing parasitical
efforts as far as possible. In order to do so, we focused on the hardness, the isostatism of
structures and the thinness of geometrical features.
Thus, mechanical flaws were reduced as far as possible and deformation of the structure
during load transfer was minimised thanks to the large size of each mechanical component.

The structure (fig.3) is mainly made up of: :

- a supporting base,
- a straight guidance system,
- a movable stage,
- the support of the air bearing.

Figure 3. Structure of the machine

. The Supporting Base

It is one meter long and has a reference groove materializing the machine axis. This
reference is used to position the support of the air bearing on one hand and the movable stage
on the other hand.

. The Straight Guidance System

It is made up of two rails fitted with linear ball bearings of the machine tool type. It allows
the adjustment of the machine workspace length by translation of the stage, while staying
aligned with the lever beam axis.

. The Stage
The mobile stage in translation on the rails integrates the axis materialisation and hosts the
rotation drive system.

. The Support of the Air Bearing

The support of the air bearing has an intermediary plate the height of which is set by
rectification to respect the concentricity tolerance with the drive shaft.
This structure ensures at any time the coaxiality between the rotation axis of the lever
beam and the rotation axis of the drive system as close as 0.01 mm.
The workspace of the structure can host a cylinder 550 mm long and with a 490 mm
diameter. This structure sits on a mechanically welded mount (fig.4).
 Figure 4. Mechanically welded mount

4. The Rotation Drive System

To ensure gradual loading on the sensor to calibrate, we selected a reduction gear with a
reduction of 6000 (fig.5 rep.1). This extremely high ration is necessary because of the stiffness
frequently associated with torque transducers. The reduction device is made up of two worm
gear reducers mounted one after the other. This technology ensures static and dynamic
irreversibility.
A flexible coupling (fig.5 rep.2) between the reducing gear and the drive shaft optimizes the
angular stiffness and thus prevents a significant angular swing while keeping the loading speed
gradual. In order to minimize parasite dynamic torques, two levels of angular speeds are used.
Speed changes are achieved through slow acceleration and deceleration in order to gradually
transfer the torque without shocks and by avoiding causing the lever beam to swing.
The drive shaft (fig.5 rep.3) is positioned in the stage using two hybrid antifriction bearings
with ceramic balls. This technological option is good as it reduces friction, which facilitates very
low rotational speeds and even loading.
A torque sensor (fig.5 rep.4) permanently fitted on the exit of the reduction gear allows the
regulation of loading and monitors the safety thresholds. A friction torque limiter, integrated into
the reduction system, protects the equipment from accidental overloading.
1 4 2 3

Figure 5. Rotation drive system

5. The Weightstacks

We relied on the principle behind the weightstacks of the LNE torque standard machines of
2 kN (1977) and 5 kN (2000). This principle consists in realizing a weight in two main parts: a
“valve” (fig.6 rep.1) and a “bell” (fig.6 rep.3 and 4). The bell of one given weight covers the
valve of the next weight. This principle allows the weights to be attached to one another by a
single vertical movement (fig.7).

Figure 6. Structure of the machine weights.

Figure 7. Diagram of the machine weightstack.

The shapes and the manufacturing limits were chosen so as to ensure the gravity centres
are aligned and to reduce swing movements. The discs are positioned with a centering cone at
45° with supporting surfaces strictly parallel to each other. These features ensure the disks are
stacked very neatly.
The weight steps were chosen in such a way as to allow the calibration of torque
transducers of a measuring range of 10 N.m; 20 N.m or 50 N.m; in ten points distributed
evenly.
Thus, the proportions of the break down selected for the 5 kN machine are adopted. The
length of the torque standard machine lever beam is 0.5 m. This gives the following nominal
values, for each weight and in the sequential order of attachment :

- 10 weights generating 2 N (≈ 204 g)

- 2 weights generating 4 N (≈ 408 g)
- 2 weights generating 2 N (≈ 204 g)
 - 2 weights generating 4 N (≈ 408 g)
- 6 weights generating 10 N (≈ 1020 g) (fig. 8)

Figure 8. Weight « 10 N ».

This weightstack (fig.9) attached to the end of the lever beam allows the realisation of the
following 22 torque steps: 1;2;…;9;10;12;14;15;16;18;20;25;…;45 and 50 N.m

Figure 9 The machine weightstack

The weights are adjusted so as to generate these torque values. The adjustment takes into
account the local gravity and an average value for the air buoyancy. The adjustment was made
in different steps. The final adjustment was carried out on a mechanical element of low weight,
facilitating a high accuracy adjustment up to 2 10-6 in relative value.
All mechanical parts within weights are identified by individual and specific labeling. This
enables us to monitor subgroups and to modify the parts if need be.
So as to ensure a good preservation of the weights with regard to oxidation issues, weights
are made of anti magnetic stainless steel (permeability < 1.01) with improved mechanical
features of the same type as the steal of the 5 kN torque machine: NiCu 30 A1 3 Ti (MONEL
k500) with a density somewhere around 8460 kg.m-3.
6. The Weightstack Plataforms

The weightstacks are integrated to two platforms set at each end of the lever beam. This
makes possible calibrations in the two possible directions: clockwise and anti-clockwize
modes.
Each platform contains a baseplate supporting the weightstack. By moving vertically, this
baseplate allows the suspension of the weights, the first one being attached to the lever beam
connector.
During a load modification, lock stops limit the angular range motion of the lever beam
which is later set to horizontal by rotation of the torque transducer to be calibrated. This
solution with end stops is very beneficial as it ensures that loading is done gradually and
evenly through rotation of the torque transducer, and this reduces swinging movements.
Two solutions were considered as to how to position the lock stops. The first of them is a
classic one which consists in positioning the lock stops between the lever beam and the
mount. However, to load from zero torque to the maximum calibration torque (and inversely), it
is necessary to wait until the weightstack suspension is completed. Loading time becomes too
long to study the drift under load or the torque sensors relaxation. Therefore, we did not keep
this solution.
The other solution has never been put to the test before and was specially implemented for
this machine. It consists in shifting the lock stops towards the weightstack and making them
retractable (fig.10).

Figure 10. Weightstack platform retractable stops

The first weight is hanged either on the lever beam connector or on the end stop
depending on their relative positions. It is possible to prepare a load of several weights by
hanging them on the end stop (fig.11 rep.1).
Then, the transfer of this load on to the lever beam only requires one sequence (fig.11
rep.2).
 Figure 11. Principle of weightstack platform retractable end stops

This solution has the advantage of keeping loading time optimised when loading from zero
torque to the maximum calibration torque when for example realising preloading or when
analysing the drift under load and the sensors relaxation.

7. The Arm and its Bearing

The first option we considered was the old LNE 2 kN.m machine, namely, an arm with
circular ends and winding tape. But we finally opted for an arm to switch back to horizontal
position after each load modification by rotation of the torque transducer. This principle offers
advantages compared to the old bench :
- it makes the initial torque offset, caused by the asymmetry of mechanical elements
(adjustment parts), constant and acknowledged by the torque transducer initial indications,
- it cancels the variable unbalance caused by the tape winding,
- It allows the calibration of torque transducers of strong angular deformation.
The arm must fulfil two essential roles with regard to the vertical forces generated by the
weights: transfer them to the torque transducer and position them at a controlled distance of
the rotation axis. Four solutions were considered.
The first of them is to uncouple these two functions by doubling the arm : one being used
for transferring the effort and the other being used for keeping the distance. This solution is
particularly relevant for substantial efforts. It was not selected for the 50 N.m machine and will
be considered for the design of the 5 kN.m machine.
The second solution which was considered had the particularity of keeping weights on one
side of the arm only, the other side being fitted with a counterweight. This distinctive feature is
interesting in terms of automation, as a single level of weights requires only one actuation. The
downside was a noticeable increase of the lever arm weight, namely caused by the
counterweight, which resulted in deteriorating the arm mobility and sensitivity essential
properties. This solution was rejected.
Another solution was to make an arm with a material of high thermal stability, such as
invar. This solution, frequently adopted on recent machines in other countries, present the
disadvantage of increasing the weight and the inertia of the arm as well as deteriorating the
arm mobility ad sensitiveness.
For optimal mobility and sensitiveness qualities, the arm must be as light as possible with a
gravity centre close to the rotation axis. The solution adopted is the realisation of an arm using
an aluminium-base alloy with improved mechanical features. The centre of gravity is adjusted
by vertical and horizontal displacement of extra weights. The arm includes a device which
controls the stability of its length by comparison against an invar ruler fixed on the frame. The
comparison is carried out using capacitative sensors. Besides, laser sensors allow the
detection of the arm angular position.
The arm is one meter long in total and it is supported in its middle by an air bearing
allowing the reduction of friction as far as possible. The air bearing is made by Dover (USA),
which is a specialist provider of high precision bearings. The internal clearance between the
rotor and the stator is situated somewhere around 10 µm. The rotor has axial thrusts, which
allow the bearing to support both axial (up to 755 N) and radial loads (maximum 530 N). Tests
made it possible to estimate mobility as being lower than 150 µN.m. An anti-vibration viscous
fluid chamber system allowed the reduction of the remaining oscillations.

Fig. 12 Arm in the integration stage

A tape is fixed at both ends of the arm to facilitate the positioning of the force and its
uncoupling. An alloy of copper and beryllium was selected for its elastic qualities. The initial
width is 0.2 mm but it will be possible to carry out test with different widths and materials if
necessary.
This tape is pressed between two plates the shape of which is particularly neat, with
gradual and symmetrical radiuses of curvature so as to reduce stress concentration
phenomena in the gripping area which can disturb the position of their resultant.

8. Operating the Torque Standard Machine

The operation mode is that of the LNE force standard machines (500, 50, and 5 kN).
For all basic functions, the machine is operated by a programmable automatic control. The
latter is operated by a computer which acts as an interface with the user. A specially designed
software makes the programming adjustable according to the type of calibration to perform.
Moreover, the automation of calibrations goes as far as allowing the recording of values for
the sensor being calibrated through the use of a camera and a character recognition system.

9. Conclusion

The machine is in the final assembly phase (fig.13). It still has to undergo metrological
qualification including interlaboratory comparisons.
 The effort put in the definition and realisation of the new torque standard machine, in
particular in terms of its geometrical properties, should make it a reference at the international
level.

Figure 13. Banc 50 N.m au cours de sa qualification

References

[1] « Guidelines on the Calibration of Static Torque Measuring Devices » - EURAMET/cg-

14/v.01 – July 2007 (Previously EA-10/14)
[2] « Nouvelle référence de force de 5 kN du LNE », P. Averlant, A. Gosset ; Congrès
international de métrologie – Toulon - France (10/2003)