KTR DATAFLEX 42/200, 42/500, 42/1000 Torque Measuring Shaft Assembly-/Operating Instructions

KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
1
2
DATAFLEX® is a maintenance free torque measurement shaft with integrated speed measurement. In
connection with the RADEX®-N steel disc coupling it is a torsionally stiff double cardanic coupling with
integrated measuring shaft.
General Hints
Read these instructions thoroughly before operating the measurement shaft.
Please pay special attention to the safety instructions!
The assembly instructions are a part of this product. Please store them carefully close to the
measuring shaft. The copyright for these assembly instructions belongs to KTR Kupplungstechnik
GmbH.
Safety and Advise Hints
STOP
DANGER !
Danger of injury to persons.
!
CAUTION !
Damages on the machine possible.
ATTENTION !
Pointing to important items.
F
General Hints to Danger
STOP
DANGER !
With the assembly, operation, and maintenance of the measuring shaft it is
important that the entire drive train has been secured against unintentional
engagement. Please read through and observe the following safety instructions.
• All work with and to the measuring shaft must be carried out with the idea of “Safety First”.
• Secure the measuring shaft and the disengaged drive before work is carried out.
• Secure the drive system against unintentional engagement, for example place warning signs at the
switch or remove the fuse.
• Do not touch the measuring shaft when it is in operation.
• Protect the measuring shaft from unintentional contact. Use an appropriate cover or shield.
Proper Use
You are only allowed to assemble, operate, and maintain the measurement shaft if you
• have carefully read and understood the assembly instructions
• you are authorized and have the proper training
The coupling can only be used in accordance with the technical data (see sheet 11). Unauthorized
alterations to the measuring shaft are not allowed. We do not take any responsibility for any resulting
damage. In the interest of further technical development of the product we reserve the right for
modifications.
®
The DATAFLEX -measuring shaft described corresponds to the technical status at the time of
printing these assembly instructions.
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
2
2
Generally the measuring shaft is delivered in subassemblies. Before assembly the measuring shaft should be
checked for completeness.
The position of the DATAFLEX® is variable. The measurement system can be mounted horizontally as well as
vertically.
Components of DATAFLEX®-Torque Measuring Shaft
Components of
DATAFLEX®-torque measuring shaft
Component
Quantity
1
1
Components of RADEX®-N coupling
Designation
DATAFLEX®torque measuring shaft
Component
2
3
Quantity
2
2
4
2
5
2
®
Designation
flange hub
laminae package
clamping ring hub
with clamping ring
grub screw DIN 916
®
picture 1: DATAFLEX torque measuring shaft with RADEX -N
Mounting Hints
STOP
DANGER !
The maximum permissible bore diameter d1max and
®
d2max (see RADEX -N catalogue) should not be
exceeded. If these values are not followed the
coupling can break. Flying broken parts can put
lives in danger.
• When the customer manufactures the bore it is
important that the customer holds the following runout
and concentricity tolerances (see picture 2).
• The values d1max and d2max must be observed.
• Align the hubs carefully before making the finish bore.
picture 2: runout and concentricity
Displacements
The misalignment values given in table 1 provide security in order to compensate for outside influences for
example thermal expansion or foundation shifting.
!
Urheberschutz
gemäß DIN 34
CAUTION !
In order to ensure a long life of the measuring shaft the shaft ends must be precisely
aligned. The misalignment values given must be observed (see table 1). If these values are
exceeded the coupling will be damaged.
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KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
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K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
3
2
Displacements
Please note:
•
The misalignment values given in table 1 are maximum values. They cannot occur at the same time. When
radial-, axial- and angular misalignment occur simultaneously, these values must be reduced (see picture 4).
•
Please check using dial indicator, ruler or feeler gauges whether the permissible misalignment values in
table 1 are being observed.
angular displacements
radial displacements
picture 3: displacements
axial displacements
Table 1:
DATAFLEX®
size
42/200
42/500
42/1000
RADEX®-N
size
max. axial displacement
∆KA [mm]
max. radial displacement
∆KR [mm]
max. angular displacement
∆KW [degree]
60
2,0
5,2
1,3
80
2,6
5,5
1,3
picture 4: combination of
displacements
Example for the misalignment
combinations given in picture 4:
Example:
∆KR = 60%
∆KW = 20%
∆KA = 20%
Ktotal = ∆KA + ∆KR + ∆KW ≤ 100%
Assembly of Hubs
F
ATTENTION !
We recommend that the bores, shafts, keyway and feather key are checked to make sure
they are the correct dimensions before assembly.
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
4
2
Assembly of the RADEX®-Clamping Ring Hubs on the DATAFLEX®-Measuring Shaft
The force is transmitted through a frictional connection. The fit for the shaft and clamping ring hub is H7/h6.
During assembly please pay attention to the following procedures:
•
Please clean and degrease the contact surfaces of the hub bores and the shafts before assembly.
CAUTION !
Oil and grease with Molybdenum Disulfide or other hydrocarbons as well as grease
paste should not be used.
!
•
The clamping bolts must be lightly loosened, the clamping ring hub should be placed on the shaft and
adjusted to the L5 dimension.
•
The clamping bolts must be tightened evenly crosswise. The tightening torques should be increased in steps.
This procedure should be repeated until the tightening torque of all of the clamping bolts is the value given in
table 2.
picture 5: assembly of the clamping ring hubs
picture 6: adjusting to the L5 dimension
Table 2:
DATAFLEX® coupling size
RADEX®-N coupling size
clamping bolt size
number of bolts z
tightening torque TA [Nm]
1)
transmittable torque [Nm]
(frictional torque)
42/200
60
M8
6
35
42/500
42/1000
80
M10
6
69
1070
1700
1) H7/k6 shaft/hub fit
Assembly of the Driven and Driving Side Hubs
•
Assemble the hubs on the shafts of the driven and driving side (picture 7). The ends of the shafts must not
protrude through the hubs.
•
Move the units in the axial direction until the dimension L2 is achieved.
•
If the unit is fixed move the hubs on the shaft to achieve the E dimension.
F
!
Urheberschutz
gemäß DIN 34
ATTENTION !
On request the hubs can be machined for a grub screw to secure the hubs in the axial
direction. Please make this request during ordering.
CAUTION !
During assembly please make sure the correct L2 is observed (table 2). If this is not
done the measuring shaft (coupling) can be damaged.
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
5
2
Assembly of the Driven and Driving Side Hubs
picture 7: assembly of the driven and driving side hubs
picture 8: adjusting to the L2 dimension
Assembly of the Laminae Packages
CAUTION !
During assembly it is important that the laminae packages are assembled stress free in the
axial direction. If this is not done the coupling can be damaged.
!
•
Assemble the laminae packages and the DATAFLEX® on the measruing shaft (picture 9).
•
Initially only hand tighten the parts and alternate the bolts left and right.
•
Tighten the bolts with a torque wrench until the values given in table 3 are reached.
picture 9: assembly of the laminae packages
Tightening Torque of the Shoulder Bolts
The shoulder bolts should be tightened to the torque given in table 3.
Table 3:
DATAFLEX® coupling size
®
RADEX -N coupling size
bolt size
tightening torque TA [Nm]
!
Urheberschutz
gemäß DIN 34
42/200
42/500
42/1000
80
M10
65
60
M8
33
CAUTION !
After the coupling has been put into operation the tightening torque of the shoulder bolts
should be checked during normal maintenance intervals.
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
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Verteiler
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M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
6
2
Assembly Hints
•
Fix the Housing
CAUTION !
The housing must be secured against rotation. For this purpose a threaded pin is on
the underside of the housing.
!
•
Insulation
All DATAFLEX®-measuring shafts of type 42 correspond to the Protection IP50 according to DIN EN 60529.
•
Maintenance
The DATAFLEX®-measuring shaft is maintenance free.
CAUTION !
Opening the housing is not required and can lead to damage of the measurement
shaft.
!
Technical Description
1. General Description
All of the electronics are located in the fixed housing so that no additional equipment is needed to send the
signal. The measuring shaft can be wired by the connection housing DF 1 available as accessory or manually by
the 15-pole High Density Sub-D coupling (for connection diagram see table 4). The measurement system
contains three measurement outputs, from these the analog output values for torque and speed are readable.
Over two digital outputs the actual operating condition is shown and two digital inputs can be used during
calibration.
F
ATTENTION !
The measuring shaft should initially be turned on when all of the connections have been
properly connected. After it has been turned on for the first time the measuring shaft will
take around 5 minutes until this warm up phase is finished and the measurement device
will have its standard accuracy.
2. Pin assignment of the measuring shaft
Table 4: Pin assignment of the D-Sub connection
Connection
Supply Voltage +
Supply Voltage Output Voltage +
Output Voltage Output Current +
Output Current Output Speed +
Output Speed Program-LED
Fault Signal
Auto-Offset
Program
Urheberschutz
gemäß DIN 34
Sub-D-Pin
Characteristic
Input Voltage
24VIN
14
24 V DC ± 4 V / 100 mA
GND
15
Torque Output
UOUT
11
0 ... 10 V (RA = 1 kΩ)
GND
6
IOUT
1
4 ... 20 mA (RA ≤ 500 Ω)
LOUT2
Speed Output
DRZ
12
24 V / 60 impulse/revolution
GND
13
LED-Output
ULED1+
10
5 V / 5 mA prepared for LED
ULED19
ULED2+
5
24 V / 5mA prepared for LED
GND
15
Calibration Input
T1
8
activ on connection with
GND (Pin 15)
T2
3
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picture 10: plug connection
®
DATAFLEX
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
7
2
Technical Description
3. Connection housing DF1
The connection housing DF 1 has 12 screw clips where the connections of the measuring shaft can be connected
(see table 5).
Table 5: Pin assignment of the connection housing DF1
No.
Designation
10
11
24V
GND
4
5
6
U
GND
I
12
11
DRZ
GND
1
2
3
NULL
GND
SCK
13
14
15
16
L1
L2
T1
T2
TP
-
Function
Characteristic
Input Voltage
Supply Voltage +
24 V DC ± 4 V / 100 mA
Supply Voltage Torque Output
Output Voltage +
0 ... 10 V (RA = 1 kΩ)
Ground Torque Output
Output Current +
4 ... 20 mA (RA ≤ 500 Ω)
Speed Output
Speed Output +
24 V / 60 impulse/revolution.
Ground Speed Output
Digital Connections
Auto-Offset - Input
Zero Offset Alignment
Ground Digital Connections
Output Error Signal
In case of error: 24V / 50 mA
Operational Control / Indicators
Program - LED
State Indicator
Error LED
Error Indicator
Button Auto Offset
Autom. Zero Alignment
Button for Programming
New Calibration
Low-Pass Button
Filter on / off
Connection Measuring Shaft 1:1 Connecting Cable
picture 11: connection housing DF1
4. Analoguous outputs
a) Supply Voltage 24V
The supply voltage is 24V DC with a maximum current consumption of 100 mA.
b) Torque Output U, l
To control the torque there are a voltage and a current output available. Both outputs can be used at the same
time.
Table 6: Relationship between Torque - Output Values
DATAFLEX® size
42 / 200
42 / 500
42 / 1000
∆U / ∆M
2,5 V / 100 Nm
1 V / 100 Nm
0,5 V / 100 Nm
∆I / ∆M
4 mA / 100 Nm
1,6 mA / 100 Nm
0,8 mA / 100 Nm
The characteristic curves of the output are shown in pictures 12.1 and 12.2.
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
8
2
Technical Description
The characteristic curves of the output values (see pictures 12.1 and 12.2)
picture 12.1: voltage to torque relationship
picture 12.2: current to torque relationship
•
Filter voltage output
If the connection housing DF1 is used, the signal of the voltage output can be filtered.
Table 7: Low-Pass Button
Button adjustment TP
left
Low-Pass on
right
Low-Pass off
The limit frequency of the filter can be changed by
variating the DIP switches (see picture 13) inside the
connection housing:
picture 13: DIP switch (top view)
Table 8: Adjustment of the requested filter frequency
Limit frequency [Hz]
button 1
15000
OFF
1
OFF
10
OFF
100
OFF
1000
ON
A filter frequency of 1,000 Hz is preset.
Urheberschutz
gemäß DIN 34
button 2
OFF
OFF
OFF
ON
OFF
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Ersetzt durch:
button 3
OFF
OFF
ON
OFF
OFF
W
K
button 4
OFF
ON
OFF
OFF
OFF
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
9
2
Technical Description
c)
Output Speed UN
For determining the speed a square wave with a frequency of 60 impulses per revolution is available. The height
of the square wave voltage is 24 Volts.
speed (1/min) = 1 / ta(s)
speed (1/min) = f (1/s)
picture 14
5. Digital Input and Output
The general parameters for calibration of the measuring
shaft are stored electronically and can be changed by
operating the external calibration input T1 and T2. As done in
the connection box DF1 accessory the connections for the
LED output and the calibration input are wired as shown in
picture 15 (see Table 4).
picture 15
a)
LED 1 (Program)
For calibration of the measuring shaft the factors for amplification and offset can be set in steps. According to the
description of the procedure in chapter 4 (calibration) the PROGRAM-LED shows a change in the mode of
operation.
b)
LED 2 (Error) / Error Signal
The perfect function of the measuring system is permanently controlled.
An electronic defect is shown by a error signal. If an error is shown permanently, the measuring system is defect
and must be returned to KTR.
For an easy connection in control systems the error signal is accessible in the connection housing DF1
(connection pin ERROR).
Table 9:
Condition
Normal Operation
Error
c)
LED 2
OFF
ON
Fault Signal
0V
24V
Automatic Offset - Correction
If in torqueless state an incorrect value is indicated (≠ 5,0 V), an automatic offset alignment can be effected by
pressing the button T1-Auto-Offset for 2 seconds.
For this the torque is reduced to 0 and the button T1-AUTO-OFFSET must be pressed for 2 seconds. After
successful alignment the saving of the new values is confirmed by 6-fold blinking of the programme - LED and
the normal measuring operation is continued automatically.
For an easy connection in control systems the Auto-Offset-Connection is acessible in the connection housing
DF1 (connection clip NULL).
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
10
2
Technical Description
6. Calibration (Manual adjustment of amplification and offset.)
F
ATTENTION !
The measurement shaft is delivered calibrated.
We recommended checking the calibration every half year.
The amplification determines the correct relationship between
the torque and the output voltage as well as the output current.
It influences the steepness of the curves shown in picture 12.1
and 12.2. The displacement of the curves in vertical direction
depends on the offset alignment.
Both parameters can be set and saved one after the other (see
picture 16).
picture 16: flow of the manual setting
Instructions for a new calibration:
1. Press the T2-Program key for 2 seconds. The PROGRAM-LED will blink two times. An adjustment of the
amplification factor is now possible.
2. The measurement shaft should now be alternately loaded and unloaded by a defined weight. The difference
between the output values should be compared to the actual difference between the load and unload.
3. Through a quick press of the T1-AUTO-OFFSET key the amplification factor can be roughly varied. While a
fine variation of the amplification factor can be made using a quick press of the T2-PROGRAM key. One
after the other all of the types of amplification factors can be adjusted (see picture 17.1).
4. If the difference of the displayed measurement values of the loading and unloading corresponds with the
outside determined torque difference, then the adjustment of the amplification is finished.
5. Press the T2-PROGRAM key for 2 seconds. The PROGRAM-LED will blink 4 times. The manual setting of
the offset can now begin.
6. As described under point 3 the keys can be pressed quickly to set all of the values (see picture 17.2). When
no torque is present the measurement shaft should be adjusted to an output voltage of 5,0 V or rather an
output current of 12,0 mA.
7. When the offset adjustment is finished, pressing the T2-PROGRAM key for two seconds will save all of the
new parameters. The PROGRAM-LED will blink one time. The measuring shaft will once again be in its
normal operating mode.
picture 17.1
!
picture 17.2
CAUTION !
With saving all of the old data will be overwritten.
F
ATTENTION !
• The calibration can be interrupted if the measurement device is turned off for a short
time and then turned back on. The previously saved parameters will then be
reproduced.
• The safe measurement operation can be carried out after saving the new parameters
(point 7) or after interrupting the power supply.
• After saving the new parameters (point 7) the parameters will stay the same even if the
power supply is interrupted.
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
11
2
DATAFLEX® Torque Measuring Shaft
picture 18
Table 10: dimension and technical data
coupling size DATAFLEX®
42/200
Dimensions [mm]
42/500
dimension d
dimension D
dimension L1
dimension L2
dimension L3
dimension L4
dimension L5
42/1000
42
130
232
55
122
114
6,5
Electrical Data
nominal torque TKN [Nm]
limit frequency torque signal [kHz]
measuring inaccuracy [%] 1)
temperature influence [%/°K]
nominal temperature range [°C]
supply voltage [V] DC
max. current consumption [mA]
-200 .. +200 Nm
-500 .. +500 Nm
16
1
0,05
0 - 55
24 ± 4
100
-1000 .. +1000 Nm
Torque Output
output voltage torque [V]
output current torque [mA]
0 ... 10
4 ... 20
Speed Output
number of impulses / revolution
output signal [V]
60
24
Mechanical Data
static load limit TKmax. 1) [%]
1)
breaking load TK break [%]
max. bending torque [Nm]
max. radial force [N]
max. axial force [kN]
weight [kg]
torsion spring stiffness CT [Nm/rad]
torsion angle at TKN [degrees]
mass moment of inertia [kgm 2]
2)
permanent speed [1/min]
2)
peak speed [1/min]
50
280
12
4,71
40929
0,0007343
150
300
135
750
20
4,84
102321
0,28
0,0007603
7000
8500
270
1500
30
5,01
204643
0,0008048
1) referred to TKN
2) after shrinkage of the bearings
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
W
K
V
Verteiler
VA
M
KC
KTR Kupplungstechnik
GmbH
D-48407 Rheine
DATAFLEX® 42/...
Torque Measuring Shaft
Assembly-/Operating Instructions
KTR-N
sheet:
edition:
49010 E
12
2
DATAFLEX® Torque Measuring Shaft in Combination with RADEX®-N
picture 19: dimensions DATAFLEX with RADEX-N
Table 11: dimension and technical data
coupling size DATAFLEX®
coupling size RADEX®-NC
42/200
42/500
60
Dimensions [mm]
dimension d1 / d2 max.
60
dimension D1
130
dimension D2
138
dimension D3
88
dimension L1
364
dimension L2
254
dimension L3
55
dimension L4
114
dimension L5
232
dimension E
11
Clamping Screw [mm]
dimension G
M8
dimension t
20
tightening torque TA [Nm]
10
Torque of the Coupling
TKN [Nm]
690
TKmax. [Nm]
1380
Tkw [Nm]
± 230
Mechanical Data of the Combination (DATAFLEX® with RADEX®-N)
mass moment of inertia [kgm²]
0,0173
0,0174
torsion spring stiffness [Nm/rad]
29605
52304
weight [kg]
13,90
14,03
max. speed [1/min] 1)
6700
6700
42/1000
80
80
130
179
117
420
270
75
114
242
14
M10
20
17
1500
3000
± 500
0,0569
86888
24,39
5100
1) higher speeds on request
Urheberschutz
gemäß DIN 34
Gezeichnet: 19.07.02 Sha/Koe Ersatz für:
KTR-N v. 08.02.01
Geprüft:
23.07.02 Sha
Ersetzt durch:
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K
V
Verteiler
VA
M
KC
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