Design and Fabrication of a Torque meter to measure shaft torque in Newton Meter
There are various methods to develop a torque meter. Although, this torque meter is based on instantaneous currents and voltages of each phase. The data is collected in real-time and gives instantaneous torque. Current Transformers are used to measure per phase current. Whereas potential transformer
2025-06-28 16:26:20 - Adil Khan
Design and Fabrication of a Torque meter to measure shaft torque in Newton Meter
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryThere are various methods to develop a torque meter. Although, this torque meter is based on instantaneous currents and voltages of each phase. The data is collected in real-time and gives instantaneous torque. Current Transformers are used to measure per phase current. Whereas potential transformers are used to measure voltage. The process involves the calculation of magnetic flux through the real-time values of current. A microcontroller is used to code the equations of AC machine phasors (current, voltage, and stator flux). Integration and multiplication of complex numbers will also be performed through microcontroller code. The torque meter will display real-time torque value in the Newton Meter. Instantaneous current and voltages will also be displayed on the LCD screen.
All the above experiments will be performed on a 2 pole, 1.1 kW, 3 phase DeLorenzo induction machine. Upon successful completion, the torque meter will be tested on other AC motors as well.
The objective of our project is to design and implement a torque meter that measures the motor’s shaft torque and displays it on a screen. We have to establish a report about the project for both phases of the Final Year Project. After the successful hardware implementation, we have to submit a conference paper with all the details of the project and its methodologies at the time of the project submission.
This project consists of three phases.
1. Research phase
2. Market survey phase
3. Hardware implementation
In the first phase we researched on the various ways to fabricate a torque meter. We read different researches and articles available on the internet and DSU library. We came out with three different methods to design a torque meter i.e., Optical method using zebra tape, load cell method and measuring instantaneous current and voltage method. This phase lasted for about a month.
In the market survey phase, we visited different markets in the city and looked for the best available equipment and this phase took us about 1.5 months.
The last phase i.e., hardware implementation phase is being worked on by the members and we have so far tested the optical method but due to some equipment failures and unavailability of the optical sensor that we were looking for took us away from a successful result in the end. Now, the new method in which we have to calculate instantaneous currents and voltages of the motor. The process involves the calculation of magnetic flux through the real-time values of current. A microcontroller is used to code the equations of AC machine phasors (current, voltage, and stator flux).
This torque meter is specifically designed for the Electric Power System lab of DHA Suffa University. Upon successful completion of this project, students will be able to have a better and clearer understanding of AC induction machines.
The torque meter would display real-time torque in Netwon Meters as well as instantaneous currents and voltages of each phase.
Relations between instantaneous torque, speed, and power can also be observed.
The torque meter would enable students to have a deep observation of AC induction machine behavior at no-load and rated load.
This torque meter is based on the direct method and will be able to measure torque in all 3-phase AC machines irrespective of several poles and rated speed.
The deliverables of this project are:
-> hardware implementation of a torque meter which displays torque in Newton meter.
-> conference paper
Several experiments were carried out to choose the best possible method to develop a torque meter. Currently, hardware implementation of an intantaneous torque meter is under process. Currents and voltage readings are taken as input, the microcontroller processes the data to form the below mentioned formulas to calculate stator flux.
Instantaneous torque derived as output though the following formulas.
In the above mentioned formulas, the multiplication is done between complex numbers. The multiplication of imaginary parts only is a little tricky to perform. The code of All of these calculations will be programmed into the microcontroller.
This is an electromagnetic torque based on the vectors of AC machine.
The conference paper would discuss the instantaneous torque meter method based on AC machine vectors. Detailed explanation including hardware used, construction, working principle, trials and errors, limitations and abstract will be included in the conference paper.
Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Partnerships to achieve the GoalRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 51600 | |||
| CT and PT Sensors | Equipment | 10 | 1200 | 12000 |
| Microcontroller | Equipment | 5 | 1800 | 9000 |
| 3 phase module | Equipment | 1 | 15000 | 15000 |
| breadboards and veroboards | Equipment | 15 | 100 | 1500 |
| Electronic components | Equipment | 100 | 20 | 2000 |
| soldering iron | Equipment | 1 | 1500 | 1500 |
| LEDs, jumpers and others | Equipment | 10 | 200 | 2000 |
| miscellaneous | Miscellaneous | 1 | 8600 | 8600 |