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An Advanced Guide to Torque Sensor Technology

1. "Life-oriented" reconstruction of principle classification

1). Strain gauge type - Weight scale principle

Just like a weight scale displays numbers through metal bending, a strain gauge sensor converts the torsional deformation of the shaft into resistance changes. It was measured that the surface strain of a motor shaft of an electric vehicle was only 0.005mm when fully loaded, but it could generate a 2.1mV signal output.

2). Magnetoelectric - Bicycle stopwatch analogy

Similar to a stopwatch that senses speed through a wheel magnet, a magnetoelectric sensor measures torque using the phase difference of a gear plate. It is particularly suitable for engine testing, just like installing a "torque stopwatch" on an F1 car.

2. Original selection decision tree

Start→ Need to measure static torque? → Yes→ Ambient temperature > 80℃? → Yes→ Select high temperature strain gauge↓No↓No↓ Select standard strain gauge↓ Need to measure > 10kHz dynamic? → Yes→ Select piezoelectric↓No Speed > 5krpm? → Yes→ Select magnetoelectric↓No Limited budget? → Yes→ Select capacitive↓No Select photoelectric (needing clean environment)

3. Solutions to Industry Pain Points

Case: Wind power gear box monitoring

The life of traditional strain gauges in a vibration environment is only 3 months. After using the "magnetoelectric + self-powered" solution:

l Maintenance cycle extended to 2 years

l The success rate of wireless data transmission has increased to 99.7%

l Cost comparison table: