Abstract:
A sensing device for detecting the amount of torque transmitted through a shaft. The device has a first and second section interconnected by a flexure arrangement to which permanent magnets are attached. Deflections of the flexures produce a repeatable and proportional change of magnetic flux which flows in a stationary annular ring that is concentrically mounted with respect to the shaft and separated from it by an air gap. The annular ring is instrumented with an array of magnetic field sensors that measure the changing magnetic flux.

Description:
[0001]    This U.S. Patent Application claims the priority of U.S. Provisional Patent Application 62/088,225, filed on Dec. 5, 2014. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure is in the field of sensors that are placed inline with a rotating shaft to determine the transmitted torque without contact and therefore without the use of slip rings, twist capsules or cable wraps. 
       BACKGROUND 
       [0003]    In the control of a shaft driven by a motor or actuator, the position, speed and torque applied to the shaft are parameters of most interest in closing the feedback loop of the system or device. There is, therefore, need for a device that can provide these measurements without contacting the shaft as these are often not very reliable, may be expensive to implement and necessarily require the use of a slip ring or twist capsule to obtain an output electronic signal for processing. One typical contact measurement method uses strain gages which are attached to the shaft of interest; when torsional stress is applied to the shaft, resistance changes in the gages are measured in a Wheatstone bridge and this correlates to a torque value. U.S. Pat. Nos. 6,553,847, 6,260,423 and 6,145,387 to Garshelis teach non-contacting methods for measuring torque on a shaft. However, each of the referenced patents utilize complex magnetic material formulations, either as permanent magnets or as members that must exhibit magnetostriction, in order to achieve the desired data. Furthermore, complex manufacturing and/or assembly processes render these devices costly for use in mass production markets. As such, there is a need for a relatively low cost, compact, rugged sensor for determining torque, speed and position of a shaft when it is placed in line with the shaft. 
       SUMMARY OF INVENTION 
       [0004]    The invention is a sensor that provides a means of measuring the torque and speed of a rotating shaft. The sensor has a first or input side and a second or output side; each side is coupled, inline, to the shaft of interest. Rotationally coupling the input and output sections of the sensor is a flexure arrangement. At least one pair of permanent magnets is attached to one end of the flexures. The flexures permit the transmission of force and therefore torque from the first (input) section to the second (output) section and vice-versa. The flexures are effectively cantilever beams that are appropriately sized for the torque to be transmitted and for low stresses and they also act as springs that maintain contact with the mating parts of the first (input) section. Hard stops may be used to prevent over loading the flexure beams. The beams may be a composite of a suitably flexible non-magnetic material to which a magnetically soft material is attached or abuts such that the assembly deflects as either one piece or such that deflections of the former produces a predictable deflection of the latter. The obvious preference is for the flexure to be of a unitary construction from a magnetic or ferromagnetic material. To further reduce stress on the flexures, an arrangement in which there are multiple paired but independent flexure beams axially spaced or offset from each other, is also possible. Depending on the strength of magnets used in the system, the additional flexures may or may not have permanent magnets attached to them. Specifically, with lower energy magnets (e.g., Alnico or Ceramic), additional magnets may be used in order to increase the amount of flux present in the magnetic circuit. 
         [0005]    Other objects, features, and advantages of the present invention will be explained in the following detailed description of the invention having reference to the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0006]      FIG. 1  is a schematic showing the key principle of the sensor. 
           [0007]      FIG. 2 a    is an exploded view of the preferred embodiment. 
           [0008]      FIG. 2 b    is a second exploded view of the preferred embodiment. 
           [0009]      FIG. 2 c    is a fully assembled view of the preferred embodiment. 
           [0010]      FIG. 3 a    is a first exploded view of a second embodiment of the invention. 
           [0011]      FIG. 3 b    is a second exploded view of a second embodiment of the invention. 
           [0012]      FIG. 3 c    is a fully assembled view of a second embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF INVENTION 
       [0013]    In the following detailed description of the invention, certain preferred embodiments are illustrated providing certain specific details of their implementation. However, it will be recognized by one skilled in the art that many other variations and modifications may be made given the disclosed principles of the invention. 
         [0014]    Referring to the schematic view shown in  FIG. 1 , the sensor  10  has two flexure beams  11 ,  12  with magnet pairs  13 ,  14  attached and configured (pole-wise), as shown. The magnets  13   a,    13   b  and  14   a,    14   b  are attached such that opposing poles are in contact with the flexure beams  11  and  12 , respectively. So, for example, if first magnet  13   a  is mounted with its North pole in contact with flexure beam  11 , at the opposite end, second magnet  13   b  will be mounted with its South pole in contact with the beam. It is necessary that the N-S arrangement, with respect to the flexure beams  11  and  12 , stay the same for both beams. The magnets  13   a,    13   b,    14   a  and  14   b  may be of any type, e.g., ceramic, alnico, neodymium iron boron or samarium cobalt. It is understood that cost-effectiveness in certain applications will determine the selection of magnet type to be used in the sensor. If a sufficiently high energy magnet is used, for example, neodymium iron boron, only two magnets  13   a  and  14   a  (rather than four), can be used in the system. This will further decrease manufacturing operations and potentially offset the cost of the more expensive rare-earth material. 
         [0015]    The magnetic fields B 1 , B 2  from the magnets want to seek a closed path, through air gaps g 1  and g 2 , via the sensing ring  15 . Sensing ring  15  has an array  16  or  16 ′ of magnetic field sensors, for example, Hall effect sensors or magnetometers, embedded in it; these sensors are capable of sensing changes in the magnetic field that flows inside the ring. The magnetic field sensors  16 ,  16 ′ may be embedded on the inner diameter, outer diameter or face of the sensing ring  15  and as noted, are in arrays with multiple sensors equally spaced around the sensing ring  15 . The more sensors used in an array, the better the resolution with which the torque, position and speed of the shaft can be determined. Because the flexure beams  11  and  12  must deflect outwardly towards the inner diameter of sensing ring  15 , the air gap g 1  may be different and larger than the air gap g 2 . The air gap g 1  is dependent on the maximum acceptable deflection of the flexure beams; the nominal configuration of the sensor is for air gap g 2  to be equal to air gap g 1 . The sensing ring  15 , made of a ferromagnetic or magnetically soft material, e.g., Hiperco® or Somaloy®, is mounted to a physical ground such that it is concentric with the shafts and flexure assembly in order to maintain the air gaps g 1  and g 2  between the outer diameter of the mounted magnets and its inner diameter. 
         [0016]    A flexure beam  11 ,  12  detects either clockwise or counter-clockwise torques. When a torque, T (in. lb), is applied to the input shaft, the derived force, F (lb), deflects the corresponding flexure beam in order to transmit the torque to the output side. The force, F (lb)=T/r, in which r is the radius, in inches, from the center of the sensor to the point of contact between the tab and the flexure beam. The related deflection, d, of the flexure beam at the point of contact with the tab is given as, d (in)=FL 3 /(3 El) in which L=r (in), E is the Young&#39;s Modulus (psi) of the material used and l is the moment of inertia (in 4 ) of the beam&#39;s cross section. The amount of deflection in the system is limited by the safe stress that can be applied for the specific material and depending on the desired life of the sensor, fatigue stresses must also be considered. However, the deflection, d, is thus proportional to the amount of torque applied and therefore to the movement of the magnets or more precisely to changes in the magnetic field. The two fields, B 1  and B 2  are nominally equal when the sensor is unloaded, that is, when there is no deflection of the flexure beams. As a flexure beam deflects under load, however, the movement shortens the air gap with respect to the sensing ring  15  inner diameter. This, in turn, increases the magnetic field in the ring and the two fields B 1  and B 2  become unequal; it is this change that is measured by the embedded magnetic field sensors. These sensors would typically be analog types. A second set of sensors, also embedded in the sensing ring, would typically be digital and their purpose would be to detect rotation and therefore speed of rotation of the shaft assembly. It is possible, with sufficient processing power, to deduce the speed of rotation of the shaft without using a digital set of sensors. A single sensor type that offers both digital and analog outputs is preferred. 
         [0017]    To practically facilitate the magnetic circuit of  FIG. 1 , the two flexure beams  11  and  12  are shown on the output sensor hub or shaft section  20  of  FIG. 2 a   ,  FIG. 2 b    and  FIG. 2 c   . The flexure beams  11  and  12  may be integrally formed on output sensor hub or shaft section  20  from a magnetically soft or ferromagnetic material; however, they may also be formed on a separate part which is then mechanically fastened to an essentially cylindrical part to form an assembly that has all the features of shaft section  20 . This arrangement provides maximum flexibility in selecting the material for the flexure beams which must be ferromagnetic or magnetically soft. Each flexure beam may be initially preloaded against tab  22  on the input sensor hub or shaft section  21 . Ideally, the tab  22  contacting the flexure beams  11  and  12  will be one or more rollers (not shown) such that friction and potentially hysteresis may be reduced in the sensor. The roller(s) can be pinned to an essentially cylindrical part such that they are free to rotate with respect to the pin with all other features common to input shaft section  21 . The roller(s) must be manufactured from a material that is not magnetic, for example, 303 stainless steel, aluminum, titanium, etc. The input sensor hub or shaft section  21  has an extension shaft  23 , beyond the tab  22 , that is inserted into and through the output sensor hub or shaft section  20 . The extension shaft  23  serves two functions: (1) to concentrically align and rotationally constrain the input sensor hub or shaft section  21  to the output sensor hub or shaft section  20  and (2) to maintain axial position of the two sections  20  and  21 , with respect to each other. In order to perform these functions, the extension shaft  23  is supported on a bearing(s) that are housed in the output sensor hub or shaft section  20  (bearings not shown in figures). Depending on the precision requirements for the sensor, the bearing arrangement may be of any type, e.g., needle roller, ball, roller, a bushing or a combination of these. The extension shaft  23  is thus supported on the inner race of the bearing(s) with axial loads reacted through the bearing by the use of a retaining ring, locknut or a flanged screw or washer and screw. The retaining ring, locknut, flanged screw or washer and screw also secures the two shaft or hub sections together to form an assembly over which the sensing ring  15  is positioned. In order to maintain the air gaps g 1  and g 2 , a thin-walled spacer or bushing or ball bearing (not shown in figures) is used to coaxially and concentrically locate the sensing ring  15  with respect to either the input sensor hub or shaft section  21  or to the output sensor hub or shaft section  20  or to both. 
         [0018]    The exploded views of  FIG. 3 a    and  FIG. 3 b    and the assembly view of  FIG. 3 c   , depict another embodiment of the sensor  30  in which there is a total of four flexure beams  34 ,  34 ′,  35 ,  35 ′ on the output sensor hub or shaft section  31 . Correspondingly, there are two radial tabs  33  and  33 ′ that are inserted in between the flexure beams, during assembly, such that rotation of the tabs with respect to the flexure beams produce deflection of the beams. Attached to the ends of the flexure beams are magnets  37 ,  37 ′,  38 ,  38 ′ with their poles arranged as in the main embodiment of the invention; the magnetic circuit and theory of operation of this configuration are also similar. However, there are still only two beams as seen by the magnetic circuit and only a single air gap is possible. In this arrangement, the flexure beams are grounded to the shaft near its center and extend outward towards the inner diameter of the sensing ring. 
         [0019]    As disclosed above, it is possible to establish the speed of rotation or position of the shaft with respect to the mechanically fixed sensing ring  15  if the device is configured as an array with multiple sensors. However, the speed of the shaft may also be measured by attaching one or more permanent magnets to the shaft and installing an array of Hall effect sensors on the sensing ring  15 . Alternatively, any standard, commercially available speed sensor (e.g., encoder, resolver, etc.) can be adapted for this purpose. 
         [0020]    It is understood that many modifications and variations may be devised given the above description of the principles of the invention. It is intended that all such modifications and variations be considered as within the spirit and scope of this invention, as defined in the following claims.