Professional load analysis of rotor parts for hybrid vehicle units using sensor telemetry under extreme spatial and environmental conditions

Manner sensor telemetry: When it comes to optimizing CO2 emissions, coordination of the individual units in the vehicle is enormously important. This calls for knowledge of the dynamic mechanical power flows during driving operations, especially under a variety of operating conditions. However, the power flow must be determined accurately over a wide ambient temperature range of -40°C to +160°C. Important structural and unit design information can be obtained from these figures. In particular, weaknesses can be revealed in individual parts fitted.

High-accuracy torque meters are necessary for the high-precision detection of the dynamic mechanical power flows within the vehicle. This torque meter must possess a number of distinctive features. The mechanical behaviour of the powertrain must not be altered by the installation of the sensor and it must not take up any additional space. Furthermore, the torque meter must be reliable over a wide temperature range from -40°C to +160°C with a high resolution in time and amplitude, and operate precisely. The task is achieved by a sophisticated modification of production components in the powertrain. Production parts are, in effect, quality finished for the high value torque meter. Strain gauges serve as sensor elements.

Important measurement points include the interfaces between the internal combustion engine to the electric motor, from the electric motor to the gearbox, the gearbox output, half shafts, wheels and the crankshaft belt pulley. The values measured are of increasing importance for the optimized powertrain design and the optimization of the motor management. Torque data calculated from the engine controls have, in the past, proved unreliable. Manner has developed a special technique for refining standard modules to create high-quality torque meters with an accuracy class of 0.1. The sensor does not require lengthening of the drive train and does not influence the drive train's dynamic properties. At the heart of the sensor is a specially designed transducer with extremely low crosstalk behaviour when faced with axial, bending, and lateral force loads. In order to ensure the accuracy over a wide temperature range (-40°C to +160°C), E modulus compensation is performed. This is carried out electronically with the aid of an additional temperature measurement channel and mechanical calibration with temperature. This means that, for the first time, dynamically high-precision power flow measurements can be performed in the drive train.

The measured data of strain gauge based transducer are transmitted by a non-contact mode and with 16 bit resolution by the tried and tested digital sensor telemetry technology from Manner. Another special feature is the high temperature stability of 160°C, as well as the high fatigue resistance in on-going driving operations.