Choosing the right torque sensor: a guide for optimal performance

Selecting the right torque sensor is a critical step for achieving accurate, reliable, and efficient measurements. Whether for R&D, production, or end-of-line testing, the right sensor can be the key to unlocking innovation and ensuring quality. With over 80 years of experience, HBK offers a comprehensive portfolio of torque sensors and considerable expertise to help you find the perfect fit for your application – from automotive and e-mobility to marine, wind power, and industrial test benches.

This guide provides practical advice, technical details, and actionable steps to help you navigate the selection process and choose the best sensor for your needs.

Why precision and accuracy matter

Precision is the foundation for increasing efficiency and saving resources. In today's competitive landscape, the ability to measure with high accuracy is not a luxury, but a necessity. High-accuracy torque sensors enable engineers to detect even the smallest variations in their systems. This is crucial for optimising electric drives and gearboxes.

In R&D, high-accuracy, high-bandwidth sensors unlock development potential by revealing subtle effects and "crumbs" that drive innovation. In production and end-of-line testing, they ensure that products meet stringent quality and compliance standards. Furthermore, the ability to selectively measure small fluctuations, such as torque ripple in electric motors, allows engineers to diagnose and monitor a wider range of parameters, leading to improved performance, reduced vibration and noise, and higher efficiency.

Balancing performance and cost: the GOOD-BETTER-BEST approach

Choosing a sensor is often a balance between performance and cost. HBK simplifies this with a “GOOD-BETTER-BEST” approach, allowing you to find a sensor that fits both your application’s requirements and your budget.

GOOD: Reliable and cost-effective sensors for a wide range of standard industrial and test bench applications
BETTER: Flexible sensors that offer a great balance of performance and cost, bridging the gap between standard and high-precision models
BEST: High-precision, sensors for the most demanding applications in R&D and high-end test benches where maximum accuracy is paramount

The perfect sensor is the one that best fits your specific application, striking the right balance between performance and cost.

Step 1: Define your application and measurement goals

The first step is to understand the context of your measurement. Different applications have unique demands. Ask yourself:

What are you measuring? (for example, an engine, gearbox, or electric drive)
Is your focus on R&D, production, or end-of-line testing?
What torque range and rotational speed do you need to cover?
Are there any space or integration constraints?

HBK offers solutions for a wide spectrum of applications, from robust transducers for simple tasks to high-precision digital systems for demanding R&D.

Step 2: Determine the required accuracy and bandwidth

Based on your application, determine the level of accuracy and bandwidth you need. As mentioned, higher accuracy and bandwidth are crucial for detecting subtle effects like torque ripple and dynamic loads. Use the "GOOD," "BETTER," "BEST" framework to guide your choice based on your needs and budget (see our portfolio snapshot below).

Step 3: Consider integration and compatibility

Easy integration is crucial for reducing setup time, minimising errors, and ensuring reliable data acquisition. Consider both mechanical and electrical integration:

Mechanical integration: Check for flange size, mounting options, and the available space in your test setup. Consider maximum flexibility with the “one stator fits all” concept
Electrical integration: Ensure compatibility with your data acquisition (DAQ) system, automation software, and control systems. HBK offers digital interface modules like the TIM-PN (for PROFINET) and TIM-EC (for EtherCAT) for seamless integration with modern fieldbus systems

A well-integrated system streamlines data acquisition, reduces programming effort, and leads to faster commissioning and higher system stability.

Step 4: Assess environmental and operational conditions

Environmental factors can significantly affect measurement accuracy and sensor lifespan. Consider the following:

Temperature: Choose sensors with low temperature drift for stable results over a wide temperature range
Vibration and speed: Ensure the sensor is rated for your application’s maximum RPM
Harsh environments: For applications in marine, wind power, or aviation, select sensors specifically designed for such conditions.

HBK’s sensor designs ensure high accuracy in linearity and hysteresis, even under demanding operational conditions.

Step 5: Don’t overlook calibration and quality assurance

Professional calibration is essential for guaranteeing measurement accuracy. A calibration certificate ensures your results are traceable, verifiable, and compliant with quality management standards and technical expertise according to ISO 17025 and ISO 9001. Calibration also helps you calculate the measurement uncertainty for your specific application and reduces downtime caused by inaccurate sensors. HBK offers DAkkS-accredited calibration and working standard calibration up to 400 kNm.

Step 6: Explore customisation and special requirements

If a standard product doesn’t meet your needs, HBK can design and manufacture custom sensors to your specifications. This includes sensors with special interfaces, flexplate sensors for test drives, or high-torque transducers for marine, wind power and railway applications.

Step 7: Use HBK’s selector tools and expert support

To simplify your search, HBK offers online tools to help you find the right product:

Product selector: Available on the HBK website, this tool allows you to filter sensors by accuracy, speed, design, and other attributes
Expert advice: HBK’s team of experienced sales engineers is always available to provide personalised recommendations and support you with integration, calibration, and documentation

Step 8: Final selection and implementation

By following the steps above, you can confidently select a sensor that delivers reliable data, reduces operational risks, and supports your company’s innovation and efficiency goals. With a harmonised measurement chain from a single supplier – from the sensor to the amplifier and software – you can be sure of achieving the best possible results.

HBK torque sensor portfolio at a glance

Here is a snapshot of HBK’s versatile torque sensor portfolio:

Model	Accuracy	Torque Range	Speed (rpm)	Key Features	Typical Applications
T12HP	BEST	Up to 10 kNm	Up to 22,000	High bandwidth, digital, max precision	R&D, e-mobility, NVH, drivetrain
T110/T100	BETTER	Up to 10 kNm	Up to 25,000	Very high bandwidth, high precision Flexible, bridges the gap, digital	Drivetrain, R&D e-mobility, end-of-line, test benches, NVH
T40/T40Lite	GOOD	Up to 10 kNm	Up to 24,000	Robust, versatile, cost-effective	Industrial, end-of-line test benches production, NVH
T40MS, T40HS series	GOOD	Up to 2 kNm	Up to 45,000	Robust, versatile, high speed	Industrial, production, e-mobility.
T40FM, T40FH series	GOOD	Up to 400 kNm	Up to 8,000	Robust, high torque versatile, cost-effective	Industrial, production, test bench
T210, T22	GOOD	Up to 1 kNm	Up to 30,000	Compact, low torque, easy integration	Small motors, actuators

Real-world benefits of partnering with HBK

By choosing HBK, you get more than just a sensor. You gain a partner with:

Global support: Fast and expert assistance wherever you operate
Traceable calibration: Guaranteed measurement accuracy and compliance with quality standards
Domain expertise: Decades of experience in torque measurement and technical support to advise on everything from mechanical integration to data analysis
A comprehensive portfolio: A unique range of torque flange sensors to match any performance and cost requirement

Conclusion

Selecting the right torque sensor is a strategic decision that directly impacts the quality and reliability of your measurements. By systematically evaluating your application’s needs and leveraging the expertise and tools available from HBK, you can ensure you get the best fit for your technical, operational, and business requirements. This empowers you to accelerate product innovation and achieve reliable, high-quality results with confidence.

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Choosing the right torque sensor: a guide for optimal performance

Why precision and accuracy matter

Balancing performance and cost: the GOOD-BETTER-BEST approach

Step 1: Define your application and measurement goals

Step 2: Determine the required accuracy and bandwidth

Step 3: Consider integration and compatibility

Step 4: Assess environmental and operational conditions

Step 5: Don’t overlook calibration and quality assurance

Step 6: Explore customisation and special requirements

Step 7: Use HBK’s selector tools and expert support

Step 8: Final selection and implementation

HBK torque sensor portfolio at a glance

Real-world benefits of partnering with HBK

Conclusion

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