Optical Torque Transducer & Digital Twin for Rotary & Dynamic Torque

DigiDynoTorq addresses challenges in traceable torque measurement caused by torque ripples, high-frequency oscillations, and environmental factors such as temperature fluctuations and vibrations, issues conventional calibration struggles to address.

Critical across sectors

Dynamic torque measurement is critical across sectors such as automotive and transportation, energy, robotics, manufacturing e.g. CNC machining, mining, and heavy equipment, where precise control of rotating systems is vital for both performance and safety. For instance, in electric vehicles (EVs), dynamic torque measurements are essential for smooth acceleration, deceleration, and efficient regenerative braking. The variable operating conditions in EV motors make accurate dynamic torque measurements crucial for optimizing performance and energy efficiency.

Conventional calibration methods inadequate

Conventional static calibration methods are inadequate for rotary and dynamic torque, due to phenomena like torque ripples, high-frequency oscillations, and environmental influences such as temperature fluctuations and vibrations. Dynamic torque measurement faces additional challenges, including the frequency response of sensors, which can introduce significant phase and amplitude errors at certain frequencies, causing deviations between the actual and measured values. High-frequency dynamic torque or frequently occurring torque spikes can affect the mechanical behavior of the torque transducer, thereby impacting its key metrological characteristics. However, such recurring high-dynamic torque loads may remain undetected due to the filtering schemes commonly used in measurement systems. 

Optical Torque Transducer and Digital Twin 

This project responds to the identified needs by developing an Optical Torsional Rotary (OTR) torque transducer and its corresponding Digital Twin (DT), both deployed within an in-house-developed rotary torque test rig. The aim is to achieve a comprehensive physical understanding of dynamic torque measurement, enabling continuous calibration of torque transducers and active condition monitoring of rotary systems. 

Enhanced torque measurement accuracy and drivetrain efficiency modeling can minimize rotor torque control errors and optimize powertrain efficiency in EVs, thereby improving overall energy conversion and reducing both energy consumption per kilometer and total cost of ownership. By incorporating Virtual Sensors (VS), DTs enable real-time analysis and scenario testing, which enhances vehicle performance, reduces energy consumption, and extends component lifespans. Additionally, DTs facilitate predictive maintenance, which helps minimize downtime and operational costs.